tesco troubleshooting

7/25/2019 Tesco Troubleshooting

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DOCUMENTNAME: 880005 REV2

Troubleshooting Guide

HCI(S) Top Drive System

500/650T HCI(S) 750/1205HP


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TROUBLESHOOTINGGUIDE COPYRIGHTANDDISCLAIMER

CONTACT:1-877-TESCO-77 500/650T HCI(S) 750/1205HP WWW.TESCOCORP.COM

INTL:713-359-7295 III WWW.TESCOPARTS.COM

Tesco Corporation ("TESCO") has made every effort to ensure that this document contains all of the

information necessary to troubleshootan HMI top drive, however, the document is intended to be

used in conjunction with a complete training program and on-site supervisionand TESCO does

not warrant or guarantee that the information contained herein is either complete or accurate in every

respect and the reader hereby protects, indemnifies and holds harmless Tesco Corporation together

with its directors, officers, employees and agents from and against all liability for personal injury,

death or property damage to any person arising directly or indirectly from the use by the reader of theinformation contained in the document.

This equipment was filled at the factory with TESCO ULTREX brand fluids and greases. To ensure

maximum performance and to avoid cross-contamination, we strongly recommend the continued

usage of TESCO ULTREX lubricants, unless otherwise specified.

TESCO ULTREX is a trademark and TESCOis a registered trademark of Tesco Corporation.

Tesco Corporation 2009

Contact Information

Corporate Head Office

3993 W. Sam Houston Parkway No., Suite 100

Houston, Texas, 77043

USA

www.tescocorp.com

www.tescoparts.com

Telephone: (713) 359-7000

Fax: (713) 359-7001

After Market Sales and Service ContactToll Free North America: 1-877-TESCO-77

International: 713-359-7295
http://www.tescocorp.com/http://www.tescocorp.com/


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REVISIONINFORMATION TROUBLESHOOTINGGUIDE


INTL:713-359-7295 IV WWW.TESCOPARTS.COM

Revision Information

Version Date Description of Changes

Rev A 2003 First release

Rev 1 2007 Updated as a result of periodic review.

Rev 2 May 2009 Added TESCO ULTREX recommendations and updated the footer to containcontact information.


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TABLEOFCONTENTS

CHAPTER1: ABOUTTHISDOCUMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

CHAPTER2: CLOSEDLOOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Preparing to Troubleshoot the Closed Loop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Mechanical Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Charge Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Saver Pumps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Low Pump Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Interpreting Pump Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Circulating Pump Case Drain Flow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Interpreting Case Drain Flow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Top Drive Shifting Manifold (Speed, Cold Climate and Torque) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Shifting Manifold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Shifting Hi/Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Torque Max/Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Loop Free Flow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Top Drive Closed Loop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Quill Will Not Rotate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Unable to Achieve Full System Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Motor Case Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Increasing Motor Case Drain Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Sundstrand Pilot Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Checking Pump Controller Function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Checking Pump Controller Electrical Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

CHAPTER3: HYDRAULICFUNCTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Checking the Auxiliary Pump and Master Relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Auxiliary Hydraulic Manifold and Integrated Reliefs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

General Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Checking the Unloader Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Checking Circulating Pressure, Hoses and Couplers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Multiple Functions Operating When One is Selected (Hydraulic Causes) . . . . . . . . . . . . . . . . . . . . . . 17

Checking for a Stuck Directional Valve Spool (Solenoid). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Checking the Rotary Seal for Port Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Grabber Lift Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Grabber Lift Down. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19


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Elevator Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

Elevator Close . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

Extend Forward . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

Extend Retract . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

Grabber Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

Grabber Close . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

Pipe Handler Unlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

Pipe Handler Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

Mud Saver Valve Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

Mud Saver Valve Close . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

Link Tilt Forward. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

Unbalanced Bail Movement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

Link Tilt Float . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

Link Tilt Reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

Unbalanced Bail Movement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

Link Tilt Float . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

Gearbox Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

CHAPTER4: COOLINGSYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

Cooling Fan (Modine). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

Hot Oil Shuttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

Adjusting the Hot Oil Shuttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32

Adjust the Hot Oil Sequence Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33

Re-Circulation Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34

Cold Climate Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35

CHAPTER5: ELECTRICCOMPONENT- HYDRAULICFUNCTIONS . . . . . . . . . . . . . . . . . . .37

Wiring Notes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37

Testing Solenoids. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37

General Electrical Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38

Conducting a Pig Tail Continuity Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38

Testing for Generalized Power Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39

Multiple Functions Operating when one is Selected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40

Checking for Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40Testing the Diode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40

Grabber Lift-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41

Grabber Lift-Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42

Pipe Handler-Unlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43

Pipe Handler-Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45

Link Tilt-Forward . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46


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Link Tilt-Back. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Link Tilt-Float . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Extend-In. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Extend-Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Elevator-Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Elevator-Close. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Elevator Close at Brake Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Grabber-Open. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Grabber-Close. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Grabber-Close Holding Contact Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Grabber/Pipe Handler Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Grabber/Drawworks Interlock Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Mud Saver Valve-Open. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Mud Saver Open Timer Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Direction Holding Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Mud Saver Valve-Close. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Mud Saver-Close Light. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Optional Current Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

CHAPTER6: POWERUNIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Write down the following: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Perform These Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Restart the System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Motor Starter Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Motor Keeps Quitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Motor Quits and Will Not Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Motor is Not Receiving Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Auxiliary Pump/Motor Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Auxiliary Pump Motor Will Not Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Auxiliary Pump Operates from Main Panel but not the Driller's Panel . . . . . . . . . . . . . . . . . . . . . . 70

Auxiliary Pump - Driller's Panel Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Engineering Sign-Off 77


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INTL:713-359-7295 1 WWW.TESCOPARTS.COM

CHAPTER1: ABOUTTHISDOCUMENT

This guide provides information on troubleshooting the HCI(S) Top Drive.

Table 1-1: Where to Find More Information

For information on Refer to

system components HCIS System Description

installing the top drive

rig up procedure commissioning

pre-operational checklists

rig out procedure

HCIS Installation Guide

setting torque and speed

drillers panel function and operating descriptions

making connections

drilling ahead

tripping

stuck pipe

HCIS Operations Guide

load path inspections

maintenance/service schedules

component assembly and disassembly

HCIS Maintenance Guide

TESCO manufactured parts and part numbers HCIS Parts List

electrical schematics

hydraulic schematics

HCIS System Schematics

available options and spares TESCO Representative


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ABOUTTHISDOCUMENT TROUBLESHOOTINGGUIDE




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CHAPTER2: CLOSEDLOOP

INTRODUCTION

TESCO closed loop systems interface a Saver Sundstrand electro-hydraulic control valve and

the motor pot board. This interface allows the operator to control the pump volume and

direction from the driller's panel. Volume and direction determine the speed and direction of

the top drive's hydraulic motors.

Pump control redundancy equipment is provided in case of electrical interface failure. A smallcontrol lever on the face of the Sundstrand valve (the manual control) can also be used to

control pump speed and direction during troubleshooting. Redundancy equipment includes:

joystick pressure reducing valve four 150 ft hoses

PREPARINGTOTROUBLESHOOTTHECLOSEDLOOP

Before you begin troubleshooting, you should become familiar with your closed loop systemby determining the following:

charge circuit pump arrangement pump control (pot board or joy stick) top drive shift (speed control) torque relief filtration hot oil shuttle location of all gauges

TESCO has incorporated pressure and temperature gauges that monitor all critical loop

components. These include flow meters for the following:

forward loop flow hot oil shuttle flow motor case drain

Test gauge ports are also provided on the filter manifold and top drive switching manifold.

Caution: All manifold test ports are straight-thread ORB. Do not

attempt to screw tapered thread fittings into these ports.

!


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CLOSEDLOOP TROUBLESHOOTINGGUIDE



MECHANICALINSPECTION

This is a list of general checks that can be performed as part of preliminary troubleshooting for

the closed loop system:

1. Before troubleshooting the hydraulic system, visually inspect equipment. Look

for the following: mechanical damage to shafts or couplings (prime mover and pump drive) kinked or ruptured hoses in the service loop proper valve position adequate oil reservoir level (site glass valve open)

2. If possible, listen for peculiar noises from the motors, pumps, and transmission.

3. Ensure that the flow rate is adequate to produce the desired pressure.

4. If the system is not functioning properly, check to see if the same problem occursin both forward and reverse.

5. Pressure test the motors in various quill positions as follows: close the grabber pressure test the first position rotate the quill 20 repeat the pressure test continue moving and testing the quill in 20increments until each position hasbeen tested

6. Pressure test the pumps against closed valves at the power unit using the controllever on the face of the Sundstrand valve.

CHARGEPRESSURE

IMPORTANT: This equipment was filled at the factory with TESCOULTREX brand fluids and greases. To ensure maximum performance

and to avoid cross-contamination, we strongly recommend the continued


The charge pump is a fixed displacement gear pump. On four pump prime mover

configurations, each saver pump has a small gear pump attached to the back side of the main

pump. On six pump prime mover configurations, a gang of gear pumps is located opposite the

input shaft, at the center of the pump drive.

Charge pump flow rate varies with the rpm of the prime mover but remains proportionally

constant with the maximum available loop flow. The ratio of charge flow to maximum

available loop flow is .25:1.

The charge pumps maintain a pressurized closed loop, provide control pressure, cool and

lubricate the piston pumps, allow loop oil exchange through the hot oil shuttle and make up for

loop leakage.

If fluid losses in the closed loop exceed the charge pump output, the charge pressure will drop.

Pressure drop below normal operating range (minimum 333 psi) will cause damage to the

main closed loop pumps. Pressure loss points are indicated in the illustration below.


13/86

TROUBLESHOOTINGGUIDE CLOSEDLOOP



Figure 2-1: Pressure Losses that Effect Charge Pressure

Note: A drop in charge pressure does not always signify a problem with thecharge pump. Other factors must be considered.

Perform the following checks:

1. Ensure that the charge pump has adequate oil supply.

2. Check the pressure differential across the charge pump filter.Note: If the differential is higher than 100 psi, change or service the charge pumpfilter.

3. Check the case drain from the top drive.Note: With the auxiliary pump turned off, the case drain flow should be between2-6 gpm at low operating pressure. If the case drain flow is higher than this, theremay be excessive system fluid losses in one or both motors.

4. Check the saver pumps.Note: Check the output of all saver pumps using the main flow meters If pumpsare operating normally, output from all pumps should be nearly equal (+/- 5%).

Check the case drain temperature from all pumps. Elevated case drain temperatureindicates possible fluid loss over the pump relief.

Warning! Important: Elevated case drain temperature orimproper pump outputs indicate that a problemmay exist. Either condition will effect chargepressure. Investigate immediately.

5. Check the hot oil shuttle setting.Note: The hot oil shuttle should be set to 35-50 gpm. If the hot oil shuttle is sethigher than this, charge pressure may be adversely effected.

Closed LoopPump

Hydraulic

Motor

Cooler

Tank

FilterManifold

Case

Drain

Hot Oil Shuttle

Pump Case

Drain to Tank

Charge

Pump

Charge

Filter

Indicates flow that may effect charge pressure.

Closed LoopPump

Hydraulic

Motor

CoolerCooler

Tank

FilterManifold

Case

Drain

Hot Oil Shuttle

Pump Case

Drain to Tank

Charge

Pump

Charge

Filter

Indicates flow that may effect charge pressure.

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14/86




6. If all other checks have been performed, and no significant problem is uncovered,you can increase charge pressure by reducing the hot oil shuttle setting.

Warning! If you reduce the hot oil shuttle setting, carefullymonitor system temperature to ensure thatadequate cooling is taking place. A fine balancemust be maintained to ensure adequate chargepressure and adequate cooling.

7. If the checks above do not reveal the source of the problem, investigate chargepump or pumps for possible causes.

SAVERPUMPS

Saver pumps operate very reliably. If a problem arises it will usually be indicated by one or

more of the following:

reduced pump flow (according to main flowmeters)

elevated case drain temperature unable to achieve full system pressure

Low Pump Flow

If the flowmeter indicates that pump output is low, check the pump history to confirm that the

pump is operating outside of normal range. Also, ensure that the flowmeter is operating

properly. This can be done by switching flowmeters and confirming low pump output.

Interpreting Pump Flow

Pump flow is metered at the filter manifold forward header. To check the ratio of total pumpflow produced to useful work performed (rpm), refer to the flow rate efficiency chart (see HCI

Torque and Flow Charts). If the actual flow rate: rpm ratio does not correspond to the chart

ratio (+/- 10%), cross port leakage may be occurring at the motor vanes, relief or directional

logic poppit or a shuttle valve.

Note: Shuttle valves are located in the shifting manifold and filter manifold.

Circulating Pump Case Drain Flow

Pump case drain is the combined flow of internal pump leakage and charge pressure relief

valve discharge. Charge flow rate varies with engine rpm. For specific flow information, refer

to the flow chart for your system.Note: The charge pressure relief valve setting is 23 bar (350 psi).

In a normally operating system, the maximum pump case drain flow should not exceed the

theoretical charge flow rate. A minimum flow rate of 3 gpm/per pump should be maintained.

This will ensure adequate case flush and pump temperature control.

Note: There is no flowmeter that monitors pump case drain. If required, aflowmeter can be teed into the case drain line, ahead of the collector manifold.

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15/86




Case drain temperature for each pump is monitored using gauges provided. All pumps receive

the same work command and are subjected to identical load. Therefore, case drain temperature

should not vary from pump to pump.

If the closed loop system is operating correctly, the sum of the motor case drain, pump case

drain, and the hot oil shuttle flow should equal the theoretical charge flow. Therefore, pump

case drain can be calculated using this formula:

theoretical charge flow (hot oil shuttle + motor case drain flow) = pump case drain flow

INTERPRETINGCASEDRAINFLOW

If the sum of the hot oil shuttle and motor case drain becomes equal to or greater than the

theoretical charge flow the following can occur:

charge pressure falls below the relief setting (350 psi) the saver pumps do not receive sufficient suction pressure (resulting in cavitation) lack of oil at the charge reliefs causes inadequate case flush and case drain temperature

rises rapidlyNote: If this condition occurs, the case drain temperature for one pump may beginto rise. This is because relief setting may vary +/- 5 psi from one pump to another.The pump with the greatest relief setting will show a temperature increase becausethe pump case is not being flushed.

Standby operations can cause pump case drain temperature to rise. This occurs because all

charge oil is forced over the charge reliefs when the motors are not rotating and the shuttle is

not activated.

Excessive pump case drain flow or temperature increase may be caused by pump damage. If

case drain flow increases suddenly when the pumps are shifted out of neutral (using themanual joystick control), serious pump damage is likely.

TOPDRIVESHIFTINGMANIFOLD(SPEED, COLDCLIMATEAND

TORQUE)

Shifting Manifold

The function of the shifting manifold is to direct or prevent flow to the top motor. This makes

it possible to control forward torque and allow free flow through the loop during stand-byoperations in cold weather.

The shifting manifold contains two high-flow poppits and a shuttle valve. Poppit control

components include two directional valves (3F speed and 1A Max Torque) and two Bosch

pilot relief valves (Max and Set).


16/86




Shifting Hi/Low

The shifting manifold shuttle valve directs loop high pressure to the 3F valve. The 3F valve

directs control pressure to the appropriate high-flow poppit as selected at the driller's Panel

range Hi/Low switch. Range Hi/Low determines one or two motor operation.

Torque Max/Set

Control interface and valve design allows the two high flow poppits to function

simultaneously as pressure reliefs and directional control valves.

The Bosch pilot reliefs Max and Set are configured in a way that allows the user two torque

limits to be applied to the drill string. When energized, the 1A directional valve isolates Set

torque, and Max torque becomes the active torque relief.

Loop Free Flow

When the cold climate button is pushed, the power that energizes the speed control isinterrupted. This allows loop free flow through the shifting manifold during cold weather

stand-by operations.

TOPDRIVECLOSEDLOOP

Quill Will Not Rotate

The shifting manifold operates very reliably. If the power unit is functioning properly and the

quill will not rotate, check the shifting manifold control components.1. Ensure that the pipe handler is notlocked.

2. Ensure that the cold climate switch has notbeen activated.

3. Ensure that the hi/low speed control 3F directional valve is energized and shifting.

4. Ensure that the Bosch pilot relief valves are properly set.

5. Ensure the shuttle valves (located in the shifting manifold and filter manifold) aresound.Note: Remove and inspect.

6. If pressure in the loop rises and the quill will not rotate check the loop lines forblockage (s) or closed valve(s).

7. If all valves are open and the quill will not rotate, ensure that the quill is notobstructed.


17/86




UNABLETOACHIEVEFULLSYSTEMPRESSURE

If only partial pressure is obtained on the loop header gauges when you select forward or

reverse, switch the manual control to determine whether the problem is electric or hydraulic.

1. Ensure that the mechanical transmission items (engine speed, pump drive, engine)in the power train are operating properly.

2. Ensure charge pressure is adequate (330 375 psi).

3. Check the pressure differential at the pump servo control ports.

4. Ensure the flow rate is adequate to produce the desired pressure.Note: A minimum flow rate of 75 gpm is required to achieve full system pressure.

5. Ensure the pipe handler is locked and the cold climate switchis notengaged.

6. Ensure the shuttle valves (located in the shifting manifold and filter manifold) aresound.Note: Remove and inspect.

7. Observe auxiliary system circulating pressure.Note: Blockage in the case drain hose will effect poppet function and systempressure.

Note: If all these checks do not reveal a problem and you are unable to achievefull system pressure, perform the following steps:

8. Isolate the power unit by closing the high-pressure valves at the hose reel.

9. Install an override cap on the reverse torque relief directional valves.Note: Reverse torque is located at the filter manifold.

10. Function the pumps using the manual control lever and redundancy equipment(joystick).

Warning! The active pressure relief (located at the saver

pump) is now 4,500 psi. Oil flow over this reliefwill cause a dramatic temperature increase.Pump failure can occur very quickly whenoperating in this condition. Carefully monitorpump case drain temperature.

If you are unable to achieve full pressure at the isolated power unit then considerthe following:

a. One of the combination high-pressure relief/ charge make-up valves may bedamaged, sticking or leaking.Note: If pressure will not build up in one direction, inspect these valves. Heatmay be present at the faulty valve. If a faulty valve is found, change out thevalve.

b. If pressure will not build up in both forward and reverse a faulty valve is notthe likely cause (unless, by coincidence, both a forward and reverse valve arefaulty).

c. If pressure will not build in both forward and reverse, and flow is lagging orabsent at one flow meter, the problem is likely a faulty pump spline or pumpcoupling. Replace pump or repair pump drive, as required.

d. If there is no pressure build up when operating in reverse only, the reversetorque relief may be faulty.

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18/86




e. If full system pressure can be developedwhen the pumps are deadheaded atthe power unit valves, but cannot be developedwith the grabber closed tostall the quill, one of the following may apply:

f. If the fault occurs in specific quill positions in forward and reverse, theproblem may be a stuck vane. The faulty motor can be determined by testingin both high and low range.

g. If the fault occurs regardless of quill position or fluid direction, the problem islikely the top drive shift (3F directional valve speed control). Troubleshoot forelectrical causes, or change out the 3F valve. Ensure that the pipe handler isin the locked position and check the cold climate button and shuttle valve.

h. If the fault exists only in forward, check the pilot relief valve and forwardtorque relief system (motor manifold).

MOTORCASEDRAIN

Rineer motors require case drain to lubricate moving parts. The case drain flows between therotors and timing plates, and between the vanes and timing plates. As it leaves the motor, the

case drain flushes the motor shaft bearings.

IMPORTANT: This equipment was filled at the factory with TESCO

ULTREX brand fluids and greases. To ensure maximum performance

and to avoid cross-contamination, we strongly recommend the continued


Increasing Motor Case Drain Flow

Caution: The case drain flowmeter is located at the power unit(electrical panel side). It displays the case drain flow from the

motors plus the return auxiliary hydraulic oil flow. When calculating

motor case drain, always turn off the auxiliary pump to get an accu-

rate motor case drain reading. If it is not possible to turn off the

auxiliary pump, subtract seven gpm from the flowmeter reading to

get an approximate case drain value.

Note: The pilot to open check valve in the 11-station manifold blocks looppressure when drilling ahead. If this valve fails to check:

You will observe high flow at the motor case drain flow meter You may observe lack of torque at the quill

These observations may lead you to assume high motor case drain and a fauly motor. Always

check the CP-458-2-B valve when high case drain is observed.

During normal operations, motor case drain flow ranges from 0.5 to 1.5 gpm.

This figure may vary depending on the operation being performed and the condition of the

motors. Operations that are more demanding result in higher case drain flow. Worn motors

also tend to have higher case drain flow.

!


19/86




If there is a sudden significant rise in motor case drain volume, damage to internal motor

components, or debris in the motor vanes is the likely cause.

Any immediate surge in motor case drain flow should be investigated immediately, as high

case drain increases the flow demand on the charge pumps.

Note: Excess case drain results in loss of rpm and mechanical efficiency. It may

be a symptom of a cracked timing plate.

If excess case drain combined with hot oil shuttle flow exceeds the theoretical charge flow, the

loop pumps may cavitate and pump failure may occur.

SUNDSTRANDPILOTVALVE

If you are unable to get full flow from the pumps, or if the pumps are not stroking (no output/

flow, no rotation), there may be problem with the Sundstrand Pilot Valve or the electrical

connections required to operate it.

Checking Pump Controller Function

1. Ensure the power unit is running.

2. Ensure it is safe to rotate the quill.

Caution: If it is not safe to rotate the quill, you can perform the fol-

lowing test with the system in Cold Climate mode. Cold Climate

mode allows you to circulate closed loop oil without rotating the

quill. The Cold Climate switch is located on the side of the driller's

panel. It is interfaced with the speed control and interrupts power

flow to the speed control when pushed in.

3. Locate the pump controller manual control toggle.Note: This is located at the power unit, on the front of the pump controller.

4. Idle the power unit.

5. Manually operate the pump controller toggle.

6. Observe the pump flowmeters. If pump flow is evident when the toggle is manually operated, there is likely aproblem with the control electronics.

If no pump flow is evident, there may be problem with the controller itself, orwith a pump actuator.

7. To determine if there is a pump controller problem, do the following:

Watch the control gauges on top of the first pump. At zero strokes, both gaugeswill read the same. To create stroke, the controller changes the differentialbetween the forward and reverse lines.

When the controller is manually actuated, the gauges should respondaccordingly.

If the differential is not changing, there is a controller problem.Note: Actual pressure values are not as important as the differential change.

!


20/86




Checking Pump Controller Electrical Connections

The Sundstrand Pilot Valve is operated by a current signal from the motor pot board. To check

output from the motor pot board to the controller, you must check the following:

Check the motor pot board output as follows:

1. Ensure your digital multi-meter is set to 10A- DC Amp mode.

2. At the motor pot board, remove wire 239 from terminal 9.

3. Attach the negative lead of the DMM to terminal 9.

4. Attach the positive lead to wire 239.

5. At the drillers panel, select Pump Direction-Forward.Note: The power unit (prime mover) does not need to be running.

6. Using the Pumps Speedswitch, increaseand decreasepump speed.

7. Observe the DMM. It should rise and fall when pump speed is increased anddecreased.

If the meter does not read at all there is likely a break in the electrical controllines. Connect the DMM directly across terminals 9 and 10 (with the wiresremoved). If there is no power, it is likely that the problem resides with themotor pot board. Using the appropriate electrical schematics, check all inputs tothe motor pot board.

If proper current is observed, the motor pot board is operating correctly. Thisindicates there may be a problem with the pump controller. Using the correctelectrical schematics, troubleshoot the circuit as required.


21/86




CHAPTER3: HYDRAULICFUNCTIONS

Many hydraulic system problems exhibit similar symptoms. To pinpoint the exact cause of any

difficulty you must follow an organized testiUse the following procedure to confirm that the

auxiliary pump and master relief valve are functioning properly.

Confirm proper operation of the following hydraulic system components before performing

more detailed hydraulic system checks:

auxiliary pump master relief valve

hoses and couplers auxiliary manifold unloader valve

If any one of these primary system components is faulty, repair or replace as required. If these

components are functioning correctly, troubleshoot specific functions as defined in the

following sections.

CHECKINGTHEAUXILIARYPUMPANDMASTERRELIEF

Use the following procedure to confirm that the auxiliary pump and master relief valve arefunctioning properly.

1. Disconnect the auxiliary pump discharge and return at the power unit.Note: This will isolate the pump and master relief valve from the remainder of thehydraulic circuit. The auxiliary pump will be deadheaded into the master reliefvalve.

2. Start the auxiliary pump.

3. Observe the pressure gauge located at the front of the auxiliary oil tank, left of theauxiliary pump.Note: Pressure should build to 2,100 psi (+/- 50).

Caution: Operating in this mode causes hydraulic oil heat build-up.Do not allow the system to operate for extended periods.

4. If pressure does not build to 2,100 psi (+/- 50), ensure that: the motor is running at full rpm the auxiliary pump suction is not restricted or drawing air the suction lines are properly connected to the pump the valve on the suction line is open

!


22/86

HYDRAULICFUNCTIONS TROUBLESHOOTINGGUIDE



5. If the checks above do not reveal a problem, check the relief valve for heat build-up.Note: Heat build up indicates that there is flow over the relief valve. If full auxil-iary pressure cannot be developed and flow is evident at the master relief valve,the master relief valve may be faulty. Repair or replace as required.

6. If auxiliary pump pressure is adequate and the master relief is functioning prop-

erly, go to testing the Auxiliary Hydraulic Manifold and Integrated Reliefs.Note: Low circulating pressure (


23/86

TROUBLESHOOTINGGUIDE HYDRAULICFUNCTIONS



3. Are there any significant leaks in the hydraulic system? If yes, inspect and repair leaks as required, then check hydraulic function. If no, go to the next step.

4. Is the circulating pressure adequate (375 psi +/- 50)? If yes, go to the next step. If circulating pressure is high, see Checking Circulating Pressure, Hoses and

Couplers on page 16. If circulating pressure is low, check the auxiliary pump for internal wear.

5. Are solenoids receiving power? If no, refer to the Electrical troubleshooting section. If yes, manually function the solenoid valve(s) for any function that is not

working.

6. Do the solenoids travel freely when manually operated (without electrical power)? If no, replace the solenoid (s). If yes, go to the next step.Note: Some resistance is expected when operating with hydraulic pressure.

7. Does the function(s) work after the solenoid has been manually cycled?

If no, check internal hosing for leaks. If no leaks are found, refer to thetroubleshooting section for the specific function(s) that are not working.

Checking the Unloader Valve

If one or more hydraulic functions are not working correctly, and the general system checks

have turned up nothing, the problem may be the unloader valve. This valve is located on the

auxiliary hydraulic manifold and functions as follows.

When anyhydraulic function (except Link Tilt Float) is commanded, the unloader valve

energizes. This dead heads the pressure line from the auxiliary pump. The line pressure rises

and flows across the relief for the selected function, or across the main system relief.

Note: If no function is selected, the oil is allowed to circulate at system pressure(375 psi +/- 50).

If the unloader valve is manually closed and pressure is less than 2,100 psi, the performance of

all hydraulic functions may be compromised. To overcome this problem you may have to

troubleshoot the pump and main relief.

System pressure can be monitored using the pressure gauge at the power unit.


24/86




CHECKINGCIRCULATINGPRESSURE, HOSESANDCOUPLERS

Frequent shifting of the unloader valve results in pressure build up/unload in hydraulic oil

supply hoses. This may eventually cause internal hose rupture, it may loosen screw on type

connectors, or it may damage quick couplers. Any of these problems will result in increased

circulating pressure, reduced flow rate, and slow cylinder movement.

Normal standby circulating pressure at 20C is 375 psi (+/- 50). Note that pressure varies with

oil temperature.

If high circulating pressure is encountered perform the following tests. Recheck the

circulating pressure after each step.

1. Inspect the circuit for damaged, kinked, or misshapen hoses.Note: Replace damaged hoses immediately and check circulating pressure.

2. 2.Inspect all quick couplers and tighten all screw on connectors.Note: Check circulating pressure.

3. Check the K-10 return filters for hose particles and debris.Note: These filters are located on the auxiliary oil return to tank. Important:If thefilters are clogged, they should be changed.

Warning! If hose particles are present, check all hoses forvisible damage. If metal flakes are present,inspect the auxiliary pump for cylinder wear ordamage.

4. If internal hose rupture is suspected (hose lining is found in the oil filter, or oil isweeping from a hose jacket), remove the 3/4" x 225' auxiliary pressure hose fromthe top drive at the JIC fitting, before the coupler.Note: This coupler tends to screen debris from the hydraulic oil.

5. Start the auxiliary pump.

6. Displace the hydraulic oil between the hose saddle and JIC (approximately twogallons)Note: This will flush accumulated debris from the hydraulic line.

7. If circulating pressure is still high, remove the unloader directional valve.

8. Inspect the pressure passage through the unloader valve and auxiliary manifoldfor partial blockage or debris.

Caution: When servicing the auxiliary manifold, remove auxiliary

pressure and return hoses at the top drive. This will block hydro-

static pressure exerted from the height of the hose saddle.

9. Check hoses and couplers at the mechanical section for blockage.

10. If the circulating pressure problem is not solved using these procedures, andelectrical causes have been ruled out, contact a qualified TESCO representative.

!

!


25/86




MULTIPLEFUNCTIONSOPERATINGWHENONEISSELECTED

(HYDRAULICCAUSES)

When more than one hydraulic function operates, when only one is selected, the likely causes

are: one of the directional valve spools (solenoids) is stuck the rotary seal is damaged and is allowing hydraulic oil flow from one port to another

If the Grabber Lift and Grabber Open/Close are operating together when only one is selected,

the problem may be related to damage in the star valve located in the pipe handler manifold.

Checking for a Stuck Directional Valve Spool (Solenoid)

1. Ensure that the auxiliary pump, master relief, and system plumbing are alloperating correctly.

2.Start the auxiliary pump.

3. Ensure that circulating pressure is in the normal range.

4. Ensure no function valves are energized (no switches are on).

5. Install an override cap on the unloader valve.

6. Allow system pressure to build to 2,100 psi (+/-50).

7. If any hydraulic function operates, the solenoid for that function is faulty.

8. Repair or replace the solenoid as required.

Caution: When replacing solenoids, always ensure the correct

replacement model is used.

Checking the Rotary Seal for Port Communication

Port communication refers to the flow of hydraulic oil past ruptured or damaged seals within

the rotary seal. This flow may activate unrequested hydraulic functions.

1. Remove the hoses from the inner and outer sleeve of port where seal damage issuspected.Note: All ports have two hydraulic connections. They are located above the loadcollar, between the pipe handler and main frame.

2. Cap the hoses.Note: Leave the rotary seal ports open to atmosphere.

3. Function the auxiliary hydraulic circuits on either side of the suspect port.

!


26/86




4. Observe the open rotary seal port for hydraulic oil leaks.Note: Leakage from the open port indicates that the rotary seal is damaged.

Caution: If the rotary seal is damaged, it should be changed as

soon as operations allow. As a temporary measure you may do the

following:

Cap the rotary seal port when the damage was noted. Use a jumper hose to bypass the damaged seal.

Warning! If a bypass hose is installed, you will not be ableto rotate the pipe handler.

GRABBERLIFTUP

Before using this troubleshooting procedure:

Refer toGeneral Testingfor a more general list of checks to perform.

Using the Grabber Liftswitch, select Down. This will confirm that the leg is not at thetop if its stroke.

Ensure the Grabber is open.

1. Is the grabber lift needle valve closed?Note: This valve is located above the kidney manifold on the off-driller side.

If no, close the valve and check the function again. If yes, remove the hydraulic line from the rotary seal area. Install a 3,000 psi pressure gauge at the end of the line. Function grabber up and monitor the gauge.

2. Is the pressure adequate (2,050 psi main relief)? If yes, go to the next step.

If no, manually cycle the solenoid.3. Is pressure observed?

If no, check the auxiliary system pump relief and reset as required. If yes, reconnect the hydraulic line with gauge teed in. Install a 3,000 psi gauge into the Grabber down line. Function the grabber up. If the pressure rises on the return line, there may be leak from the pressure side

to the tank side.

4. Did the grabber lift? If no, check for mechanical binding.

5. Is there a mechanical obstruction?

If yes, repair as required. If no, check pressure on the Grabber Down circuit. If pressure is less than 400 psi, remove the Grabber lift cylinder and inspect for

integrity.

!

!


27/86




GRABBERLIFTDOWN

Before using this troubleshooting procedure:

Refer toGeneral Testing on page 14for a more general list of checks toperform.

Using the Grabber Liftswitch, select Up. This will confirm that the leg is not atthe bottom if its stroke.

1. Operate the grabber lift down function.

2. Observe the pressure on the grabber accumulator manifold gauge.

3. Is pressure adequate (600 psi)? If yes, go to the next step. If no, set pressure reducing valve to 600 psi. Check the function again.

4. Does the function work? If no, check for mechanical binding.

5. Is there an obstruction? If yes, repair as required. If no, remove the grabber cylinder and inspect for integrity.

ELEVATOROPEN

Before using this troubleshooting procedure, refer to General Testing on page 14for a more

general list of checks to perform.

The following procedures should be performed when it is determined that auxiliary line

pressure is building up, but the elevators will not open.

Warning! Elevators are extremely powerful and can causeserious injury. Never place hands, arms, or toolsinto the elevators when they are operatingunpredictably.

Warning! Unexpected closing of elevators may result inserious injury.

1. Check the quick couplers at the elevators.

2. Are the open and close lines connected properly? If no, reconnect lines and check the function. If yes, install a 3,000 psi pressure gauge into the open line and cycle the Open

function.

3. Is there adequate pressure (1,800 psi) in the open line? If no, check the relief setting and reset as required. If yes, crack the Closeside fitting on manifold and check for pressure lock.

!

!


28/86




4. Do the elevators open slightly when the fitting is cracked? Is the close side overpressured? If yes, this indicates that there is a blockage on the Closeside. If no, proceed to the next step.

5. Crack the fittings on the Openside of the main body cylinder, and the elevatorlatch cylinder.

Caution: Exercise caution. The hydraulic oil pressure is 1,800 psi.

6. Do the cylinders move? If yes, it is likely that the main hinge of the latch or body hinge are seized.

Repair as required.

ELEVATORCLOSE



The following procedures should be performed when it is determined that line pressure is

building up, but the elevators will not close.

Warning! Elevators are extremely powerful and can causeserious injury. Never place hands, arms, or toolsinto the elevators when they are operatingunpredictably.

Warning! Unexpected closing of elevators may result inserious injury.

1. Check the quick couplers at the elevators.2. Are the open and close lines connected properly?

If no, reconnect lines and check the function. If yes, install a 3,000 psi pressure gauge into the close line and cycle the Close

function.

3. Is there is adequate pressure (1,800 psi) in the close line? If no, check the relief setting and reset as required. If yes, crack the Openside fitting on manifold and check for pressure lock.

4. Do the elevators close slightly when the fitting is cracked? Is the open side overpressured? If yes, this indicates that there is a blockage on the Openside. If no, install two 3,000 psi pressure gauges, one on the close side of the mainbody cylinder and one on the close side of the latch cylinder.

Ensure the sequence valve is set to 1,500 psi. Function the elevator close and watch gauges. The gauge on the main body cylinder should rise to 1,500 psi, then the latch

cylinder should rise to 1,500 psi.

5. Is the pressure up sequence correct? If no, check for obstruction in hoses. If yes, check for mechanical obstruction of the elevators latch.

!

!

!


29/86




EXTENDFORWARD



The following procedures should be performed when it is determined that line pressure isbuilding up, but the extend forward function will not operate.

1. Are the extend quick couplers properly connected? If no, reconnect and try the function again. If yes, go to the next step.

2. Is the speed control valve located in-line properly set? If no, reset and try the function again. If yes, install a pressure gauge in the forward side line, as close as possible to the

cylinder. Try the function again, and monitor the pressure.

3. Does the pressure build to 1,800 psi? If no, there is likely a line blockage on the forward side.

If yes, the problem may be a mechanical bind in the extend mechanism, or ablockage on the Retract side.

4. Crack the fitting on the retract side.

5. Is there a build up of pressure on the retract side? If yes, there is likely a blockage on the retract side. Investigate and repair as

required. If no, there is likely a mechanical bind in the extend mechanism. Investigate and

repair as required.

EXTENDRETRACT




building up, but the extend retract function will not operate.

1. Are the extend quick couplers properly connected? If no, reconnect and try the function again. If yes, go to the next step.

2. Is the flow control valve located in-line properly set? If no, reset and try the function again. If yes, install a pressure gauge in the retract side line, as close as possible to the

cylinder. Try the function again, and monitor the pressure.

3. Does the pressure build to 1,800 psi? If no, there is likely a line blockage on the retract side. If yes, the problem may be a mechanical bind in the extend mechanism, or ablockage on the forward side.

4. Crack the fitting on the forward side.


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5. Is there a build up of pressure on the forward side? If yes, there is likely a blockage on the forward side. Investigate and repair as

required. If no, there is likely a mechanical bind in the extend mechanism. Investigate and

repair as required.

GRABBEROPEN

Before using this troubleshooting procedure, refer toGeneral Testing on page 14for a more


The following procedures should be performed when it is determined that auxiliary line

pressure is building up, but the grabber open function will not operate.

1. Install the following pressure gauges at the grabber cylinder port extensions: one 5,000 psi pressure gauge on the close side one 3,000 psi gauge on the open side

2. Function the grabber open and observe the gauges.

3. Does the pressure gauge on the open side reach 2,000 psi? If no, check the internal needle valve on the kidney manifold and ensure it is

closed.Note: If this valve is open, the grabber will attempt to lift whenever open isselected.

If yes, proceed to the next step.

4. Are any of the following conditions true? There is pressure at the grabber open solenoid and at the auxiliary manifold, but

not at the grabber cylinder. This indicates there is likely a line blockage betweenthese two points. Inspect and repair as required.

There is pressure at the open piston, but not on the close side. This indicatesthere is likely a mechanical bind in the grabber mechanism. Inspect and repair asrequired.

The pressure gauge on the close side rises when the open function is requested.One of two conditions may exist: there may be a blockage in the grabber closeline or there may be a faulty pilot operated check valve (on pipe handlermanifold). Inspect and repair as required.


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GRABBERCLOSE

Before using this troubleshooting procedure.If no solution is found, refer to General Testing

on page 14for a more general list of checks to perform.

The HCI grabber is operated using auxiliary system hydraulic power. An intensifier poweredby the closed loop system provides additional clamping pressure when making and breaking

connections. Full auxiliary system pressure is critical to intensifier function and must be

achieved before loop pressure is applied.


building up, but the grabber close function will not operate.

1. Locate the following gauges: Pipe handler manifold gauge (port M) Loop pressure gauge next to the Bosch relief valves (top drive main frame)

2. Install the following pressure gauges at the grabber cylinder port extensions:

one 5,000 psi pressure gauge on the close side one 3,000 psi gauge on the open side

3. Function the grabber closed and observe the gauges.

4. Does the gauge on the close side rise to auxiliary closing pressure (2,000 psi)? If there is 2,000 psi on both the Close side and the Open side, there may be a lineblockage or there may be a problem with the "pilot to open" check valve in the11 station manifold (CP-45B-2-B).

If there is 2,000 psi at the Close side piston, and the Open side has returnauxiliary line pressure, there may be a mechanical bind in the grabber box orpiston. Inspect and repair as required.

If there is no pressure at the cylinder, check the pressure gauge at the pipehandler manifold (port M).

Remove the hose from port 2 of the rotary seal. Install a 2,000 psi pressure gauge.

Function Grabber-Close and monitor the pressure. If there is nopressure,there may be a problem between the rotary seal and the auxiliary manifold.The problem may be a line blockage, or a faulty solenoid.

If the Close side shows partial pressure, ensure that all checks described inGeneral Testing have been performed then:

Test the rotary seal ports 3 and 4 for communication from port 2.

Test the "pilot to close" check valve for possible leakage to the loop.

Ensure no other functions are energized (e.g. Elevaor-Close)

Test the pipe handler lock cylinder for leakage.Note: The lock is energized when the grabber is closed and may effect the

Grabber-Close function.


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PIPEHANDLERUNLOCK



The following procedures should be performed when it is determined that line pressure isbuilding up, but the pipe handler unlock function will not operate.

1. Crack the fitting on the pipe handler lockfunction.

2. Is there is pressure build-up on the lockside? If yes, there may be blockage on the lockside of the hydraulic system. If no pressure build up, go to the next step.

3. Crack the fitting on the unlockside. If there is pressure on the unlockside, there may be mechanical bind in the lock

mechanism or in the piston.

PIPEHANDLERLOCK




building up, but the pipe handler lock function will not operate.

1. Crack the fitting on the pipe handler unlockfunction.

2. Is there is pressure build-up on the unlockside? If yes, there may be blockage on the unlockside of the hydraulic system.

If no pressure build up, go to the next step.

3. Crack the fitting on the lockside. If there is pressure on the lockside, there may be mechanical bind in the lock

mechanism or in the piston.


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MUDSAVERVALVEOPEN



The following procedures should be performed when it is determined that line pressure isbuilding up, but the mud saver valve open function will not operate.

Caution: Do not service the mud saver valve unless the top drive is

disconnected form the drill string. Never service the mud saver

valve while pumping fluid through the quill.

Caution: The piston racks have a vent between the open and close

piston seals. A ruptured seal will vent to atmosphere.

1. Install a 2,000 psi pressure gauge on the open and close side lines.

2. Function open and monitor the pressure gauges.

3. Is there pressure in the open line? If no, check the pressure relief on the mud saver for proper setting (1,500 psi). If yes, there may be a ruptured seal in the mud saver valve. Check the seals as

follows:

Remove the close hose from the valve actuator.

Leave the test gauge on the close port.

Function the mud saver open.

If both gauges read 1,500 psi, then the seals are bypassing.

Service seals as required. If the seals are good, put close hose on, functionopen and monitor pressure gauges, then go to next step.

4. Is there pressure in close line?

If yes, there may be a problem with the shuttle valve. Inspect and repair asrequired. If no, there may be a mechanical bind in the actuator or mud saver valve. Inspect

and repair as required.Note: The actuator drive keys can be removed to determine whether the actuatoris working. Actuator function can be confirmed without operating the mud savervalve.

MUDSAVERVALVECLOSE




building up, but the mud saver valve close function will not operate.

1. Install a 2,000 psi pressure gauge on the open and close side lines.

2. Function close and monitor the pressure gauges.

!

!


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3. Is there pressure in the closeline? If no, check the pressure relief on the mud saver for proper setting (1,500 psi). If yes, there may be a ruptured seal in the mud saver valve. Check the seals as

follows:

Remove the open hose from the valve actuator.

Leave the test gauge on the open port.

Function the mud saver open. If both gauges read 1,500 psi, then the seals are bypassing.

Service seals as required. If the seals are good, put open hose back on,function close and monitor pressure gauges, then go to next step.

4. Is there pressure in close line? If yes, there may be a problem with the shuttle valve. Inspect and repair as

required. If no, there may be a mechanical bind in the actuator or mud saver valve. Inspect

and repair as required.Note: The actuator drive keys can be removed to determine whether the actuatoris working.

LINKTILTFORWARD


general list of checks to perform. Also, ensure there is no electrical signal at the float solenoid.


building up, but the link tilt forward function will not operate.

1. Function link tilt forward.

2. Observe the flow control valve.

3. Is the forward side of the control valve closed? If yes, open and retry the function. If no, proceed to the next step.

4. Install a 3,000 psi pressure gauge on the forward line.

5. Retry the function and observe pressure.

6. Is pressure adequate? If yes, check for mechanical binding, or look for factors that may impede bail

movement. If no, proceed to the next step.

7. Install a pressure gauge on the link tilt reverse line.

8. Try the link tilt forward function.

9. Is there pressure on the reverse line? If yes, the problem may be a blockage between the cylinder and the auxiliary

manifold.Note: Both forward and reverse have a relief valve in the auxiliary manifold.These reliefs should be set to 1,800 psi. If there is pressure at the link tilt cylinder,but it is less than required, check for proper relief settings.


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Unbalanced Bail Movement

The link tilt forward line has a flow divider valve that equalizes flow to each side of the bails.

This equalizes the movement of the left and right bails. If one bail is moving more than the

other, there may be a problem with the flow divider valve. Inspect and repair as required.

Also, if air has entered the system, the flow divider will operate incorrectly and may causeunbalanced bail movement.

Link Tilt Float

Using the Float function opens the flow path between the forward and reverse link tilt lines.

When pressure on the forward and reverse side is mixed, the bails float to the vertical (neutral)

position.

If pressure on either the forward or reverse link tilt will not build to required pressure, the float

valve may be stuck. If this valve is partially open, it may result in reduced pressure to the link

tilt forward or reverse functions.

Caution: Using the float function allows the bails to move in any

direction that will relieve force on the cylinders. If the bails are sub-

ject to external stresses when the float function is used, the bails

may move in an unanticipated direction. See the illustration below

for an example.

!


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LINKTILTREVERSE


general list of checks to perform. Also, ensure there is no electrical signal at the float solenoid.


building up, but the link tilt reverse function will not operate.

1. Function link tilt reverse.

2. Observe the flow control valve.

3. Is the reverse side of the control valve closed?

If yes, open and retry the function. If no, proceed to the next step.

4. Install a 3,000 psi pressure gauge on the reverse line.

5. Retry the function and observe pressure.

6. Is pressure adequate? If yes, check for mechanical binding, or look for factors that may impede bail

movement. If no, proceed to the next step.

Figure 3-1: Unanticipated Bail Movement


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7. Install a pressure gauge on the link tilt forward line.

8. Try the link tilt reverse function.

9. Is there pressure on the forward line? If yes, the problem may be a blockage between the cylinder and the auxiliary

manifold.

Note: Both forward and reverse have a relief valve in the auxiliary manifold.These reliefs should be set to 1,800 psi. If there is pressure at the link tilt cylinder,but it is less than required, check for proper relief settings.

Unbalanced Bail Movement

The link tilt forward line has a flow divider valve that equalizes flow to each side of the bails.

This equalizes the movement of the left and right bails. If one bail is moving more than the

other, there may be a problem with the flow divider valve. Inspect and repair as required.

Link Tilt Float

Using the Float function opens the flow path between the forward and reverse link tilt lines.When pressure on the forward and reverse side is mixed, the bails float to the vertical (neutral)

position.

If pressure on either the forward or reverse link tilt will not build to required pressure, the float

valve may be stuck. If this valve is partially open, it may result in reduced pressure to the link

tilt forward or reverse functions.

Caution: Using the float function allows the bails to move in any

direction that will relieve force on the cylinders. If the bails are sub-

ject to external stresses when the float function is used, the bails

may move in an unanticipated direction.

GEARBOXLUBRICATION

The HCI gearbox incorporates flood design lubrication. Oil level is maintained above the top

bearing. Gear train movement causes the oil to circulate throughout the gearbox.

!


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CHAPTER4: COOLINGSYSTEM

COOLINGFAN(MODINE)

The Modine cooling fan can be used to cool system hydraulic oil to slightly above ambient

temperature. The cooling fan operates more efficiently in humid environments than in dry

ones.

If ambient temperatures are above the desired operating temperature, then additional cooling

will be required. Most units are equipped with a Trane fluid-to-fluid plate exchanger forsupplemental cooling.

If the Modine cooling fan motor will not start, check for physical obstructions in the cooler

and fan. If none are present, consult the section called Motor Starter Problems on page 68.

HOTOILSHUTTLE

The purpose of the hot oil shuttle is to divert hydraulic oil from the low pressure side of the

loop to the Modine cooler and Tranter plate exchangers.

The hot oil shuttle is pressure relief operated.

Figure 4-1: Hot Oil Shuttle


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COOLINGSYSTEM TROUBLESHOOTINGGUIDE



During normal operations, the hot oil shuttle should be set between 35-70 gpm. Shuttle flow

into the top side of the Modine cooler can be monitored using a gauge mounted opposite the

power unit's main electrical panel.

If loop temperature is rising beyond acceptable levels, you may need to increase the hot oil

shuttle volume.

Caution: Increasing the hot oil shuttle results in a closed loop flow

loss. The charge pump must compensate for this flow loss. If the

demands on the charge pump become too great, the system may

actually start to increase temperature rather than decrease.

Caution: If you are performing high flow/pressure operations and

pump case drain temperatures are rising above acceptable levels,

increasing the hot oil shuttle may actually make the problem worse.

Adjusting the Hot Oil Shuttle

To adjust the hot oil shuttle, the unit should be operating and the oil warmed to operating range(approximately 120F, depending on ambient temperatures and oil blend).

Warning! Charge pressure should always be monitoredwhen the hot oil shuttle is adjusted. Never allowthe charge pressure to fall below 350 psi.

1. At the drillers panel, use the Pump Directionswitch, select Forward.

2. Using the Increase/Decreaseswitch, increase pump speed.Note: 1000 psi is required to activate the shuttle.

3. Unlock the shuttle control knob (aft side of the filter manifold).

Caution: If sequence is set too low, shuttle will occur in reverse and

reverse pressure will relieve over the shuttle.

4. Observe the flow meter on the right side of the Modine cooler (opposite the mainelectrical panel).

Figure 4-2: Adjusting Hot Oil Shuttle

!

!

!

!


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TROUBLESHOOTINGGUIDE COOLINGSYSTEM



5. Adjust the shuttle flow by rotating the shuttle control knob.Note: For six pump power units, the hot oil should be set to 50 gpm. For fourpump power units, the hot oil shuttle should be set 30 gpm.

6. Monitor charge pressure to ensure it does drop below acceptable levels.

7. Lock the shuttle control knob in place.

8. Monitor system temperature to ensure adequate cooling.

9. Adjust hot oil shuttle flow, if required.Note: Only the flow control should be adjusted. The sequence control settingshould not require adjustment.

Adjust the Hot Oil Sequence Control

If the sequence control is not operating properly, it can be reset as follows. Sequence control is

factory set and should require no further adjustment.

1. Increase the hot oil shuttle control (bottom control) to an elevated level.Note: Do this by rotating the control knob counter-clockwise past the normal

operating position. This will allow you to perform a visual check when setting thesequence control.

2. Increase sequence control by rotating the control knob clockwise as far as it willgo.

3. Ensure the quill is not rotating.

4. Close the grabber on the saver sub.

5. Ensure that the pipe handler is locked.

6. Ensure pump speed is at zero.

7. At the driller's panel, select Mode Drill, Direction- Forward.

8. Gradually increase pump speed until there is a differential pressure between theforward and reverse loop.Note: Increase until there is 1,000 psi forward pressure.

9. Slowly decrease the sequence control (turn knob slowly in the counter-clockwisedirection) until flow is registered on the hot oil shuttle flowmeter (right side of theModine).

10. At the driller's panel, select Direction Neutral.

11. Key lock the sequence control (if lock is present).

12. Refer to Adjusting the Hot Oil Shuttle on page 32for information on resettingthe oil flow to 35 50 gpm.


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RE-CIRCULATIONPUMP

The re-circulation pump moves oil from the storage tank through the Modine cooler and back

to tank. The re-circulation pump provides supplemental cooling of tank oil during demanding

operations.

If the re-circulation pump will not start, see Motor Starter Problems on page 68.

Caution: There is no gauge to monitor flow from the re-circulation

pump. You can confirm pump operation by listening for pump

noise. Alternately, you can place a current meter on the pump's 480

V leads (in the electrical junction panel). Proper operating current is

approximately eight amps.

Always ensure that the pump's suction valveis openbefore starting the re-circulation pump.

Figure 4-3: Re-circulation pump

!


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TROUBLESHOOTINGGUIDE COOLINGSYSTEM



COLDCLIMATESWITCH

When operating in cold climates (-20C or lower) the Cold Climate switch can be used to

circulate and warm hydraulic oil before operating, or when the top drive is not in use.

Activating the Cold Climate button (pulling out the red mushroom button on the side of thedriller's panel) opens a relief poppit and the high/low poppit in the top drive manifold. Closed

loop oil crosses directly to the return line without going to the top drive motors. This allows

you to circulate oil through the closed loop system without rotating the quill.

If the power unit is operational, but you are unable to achieve quill rotation, check the Cold

Climate switch to ensure it has not been accidentally activated.

If the Cold Climate switch does not function refer to Chapter 5: Electric Component -

Hydraulic Functions.


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CHAPTER5: ELECTRICCOMPONENT-HYDRAULICFUNCTIONS

Warning! All electrical troubleshooting must be conductedby a qualified TESCO representative orelectrician. All electric troubleshootingprocedures should be used in conjunction withthe wiring schematics provided as part of theHCI(S) System Schematics document set.

WIRINGNOTES

The 37 conductor cable that runs from the top drive to the drillers panel and from the driller's

panel to the power module contains 37 colour coded wires.

Each colour-coded wire corresponds to a single terminal number. For example, conductor wire

5 (solid yellow wire) will be connected to terminal number 5 at the top drive, drillers panel

and power module.

For additional information, refer to theHCI System Schematics.

TESTINGSOLENOIDS

You can confirm whether solenoids are receiving power using a simple magnetism test.

Hold any ferrous tool close to the solenoid. If magnetism is detected, the solenoid is receiving

power.

When testing for power, always test both sides of the solenoid. If both sides are receiving

power, the associated function may not work properly. This is because power supplied to both

sides simultaneously will tend to hold the function in the neutral position.

!


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ELECTRICCOMPONENT- HYDRAULICFUNCTIONS TROUBLESHOOTINGGUIDE



GENERALELECTRICALTESTING

If one or more hydraulic functions are not operating correctly, perform these checks to

determine if the problem is mechanical or electrical.

If these general checks do not resolve the problem, refer to the troubleshooting topic for thespecific function(s) not working.

1. Is the hydraulic oil level adequate? If not adequate, fill oil and check hydraulic function.

2. Is the auxiliary pump on and operating properly? If no, inspect and repair the auxiliary pump as required, then check hydraulic

function. If pump motor was replaced, check for proper rotation. If yes, go to the next step.

3. Are there any significant leaks in the hydraulic system? If yes, repair leaks as required, then check hydraulic function. If no, go to the next step.

4. Are solenoids receiving power?Note: You can easily check this using any ferrous tool. Hold the tool close to thesolenoid. If magnetism is detected, the solenoid is receiving power. This does notrule out electrical problems but provides a good indication that the problem isrelated to hydraulics.

If yes, manually function the solenoid valve(s) for any function that is notworking.

If no, go the to the next step.

5. Are the operating switches (contact blocks) at the drillers panel receiving power? If yes, check the contact block and switch actuator. If no, check the B conductor power terminals DPB 17/1

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