Top Drive Drilling Equipment

Maintenance Manual
Model DQ70BSC
Serial No

06032

Preface
The design, manufacture and service of this product are based on the following quality
assurance system:
GB/T19001:2000 idt ISO9001:2000 Quality Management System-- Requirements
API Spec Q1 Specification for Quality Programs for the Petroleum and Natural Gas Industry
This manual contains information relating to Top Drive operation, service and maintenance.
The technical information of this product is included respectively in the following documents:
<Operation Manual>
<Electric Manual>
<Hydraulic Manual>
< Installation and Trouble Shooting Manual>
<Maintenance Manual>
<Electric House Manual>
<HSE Manual>
<Data Backup and Recovery Manual>
<Electric Drawing>
<Mechanical Drawing>
<Hydraulic Drawing>
With individualized design provided for the Top Drive based on the service operating
condition and special requirements of the customers, the technical document for this product
may not be suitable for the other products of the same type. Product type and No. shall be
checked when the technical document is used.
For information not covered by the accompanying documents and other problems arising
from the installation, operation and maintenance, contact the manufacturer if necessary:

BPM

Beijing Petroleum Machinery Factory

Ads:

No.41, Zhixin Road, Haidian District, Beijing P.R China

Postcode:

100083

Tel:

( 010) 62097381

Fax:

( 010) 62097613

E-mail:

Bpm.zhaojing@vip.163.com
-I-

Contents
1.

Introduction ..............................................................................................................1

2.

Safety Notice ............................................................................................................2

3.

Cycle and Item of Maintenance.................................................................................3

3.1.

Daily maintenance ....................................................................................................3

3.2.

Weekly maintenance .................................................................................................4

3.3.

Monthly maintenance................................................................................................5

3.4.

Quarterly Maintenance..............................................................................................6

3.5.

Semi-annually maintenance ......................................................................................6

3.6.

Yearly maintaining plan ............................................................................................6

4.

Lubricating position..................................................................................................7

4.1.

Lubrication for carriage roller ...................................................................................7

4.2.

Lubrication for Backup Tong ....................................................................................7

4.3.

Lubrication for main motor bearing ..........................................................................8

4.4.

Upper bearing cover..................................................................................................8

4.5.

Lubrication for lifting bail pin...................................................................................9

4.6.

Lubrication for balance system oil cylinder pin .......................................................10

4.7.

Lubrication for link tilt device oil cylinder pin ........................................................10

4.8.

Lubrication for IBOP .............................................................................................. 11

4.9.

Lubrication for wash pipe .......................................................................................12

4.10.

Lubrication for rotating head...................................................................................13

5.

Maintenance for mechanical system........................................................................14

5.1

Main motor and cooling fan ....................................................................................14

5.2

Brake device ...........................................................................................................14

5.3

Bail.........................................................................................................................16

5.4

Gooseneck ..............................................................................................................16

5.5

Gearbox..................................................................................................................17

PDF "pdfFactory Pro" www.fineprint.com.cn

5.6

Wash pipe assembly................................................................................................19

5.7

Link tilt device........................................................................................................21

5.8

Upper IBOP............................................................................................................23

5.9

IBOP ......................................................................................................................24

5.10

IBOP locking device ...............................................................................................25

5.11

Backup Tong...........................................................................................................26

5.12

Guide rail................................................................................................................27

5.13

Carriage ..................................................................................................................28

Maintain for hydraulic system.................................................................................29

6.1

Accumulator ...........................................................................................................29

Appendix A Bolt torque gauge...........................................................................................31

Appendix B Recommended gear oil matching table...........................................................36
Appendix C Recommended grease matching table.............................................................36
Well Site Work Records........................................................................................................37
Top Drive Failure Information Feedback List .......................................................................41

PDF "pdfFactory Pro" www.fineprint.com.cn

BPM Top Drive

1.

Maintenance Manual

Introduction

DQ70BSC Top Drive is composed of power swivel, pipe handler device, electric and
hydraulic transmission control system, driller control, single guide rail and carriage, migration
supporter. Top Drive main body:

Valve manifold
Air cooling
device

Lifting bail

Brake
Wash pipe
Main
motor
Gearbox assembly

Rotating head assembly

Tilt device
M

x 3

Well control system

Backup tong
Elevator link

-1-

PDF "pdfFactory Pro" www.fineprint.com.cn

BPM Top Drive

Maintenance Manual

2. Safety Notice
It is necessary to do the safety analysis and safety education work before maintaining.
Whenever changing the original plan, please revise the safe operation application in time to
ensure the safety of operators.
Warning Shut off the power before operation. Except for special notation, please shut
off the power before lubricating, Inspection or changing.
Warning Forbid to maintain and repair when the equipment is running, do not adjust the
equipment when its working.
Warning Please wear the protection tools when maintain and repair the equipment.
Wearing safety goggles to protect the eyes.
Warning Operators may do the maintenance work on high place, which may bring the
danger of bodily injury.
Warning Pay attention to the scald when evacuating the hydraulic oil. It is forbidden to
check the leakage by hands. The hydraulic oil can bring the injury to skin,
operators should use the spill or board to check and wear the safety goggles.
WarningReleasing the pressure in accumulator before repairing the hydraulic system.
WarningPlease do not repair the parts which you dont know much better.
WarningPlease read and learn the safety notice and warning before maintaining.

-2-

PDF "pdfFactory Pro" www.fineprint.com.cn

BPM Top Drive

Maintenance Manual

3. Cycle and Item of Maintenance

3.1. Daily maintenance
Lubrication Item
No.

Item

Lubricating Item

Measure

1.

wash pipe Assembly

grease

2.

IBOP drive unit roller

grease

3. Backup Tong stabilizer

grease

Item

Inspection Item

Measure

1.

motor assembly

bolt, safety lockwire, split pin etc.

2.

pipe handler device

bolt, safety lockwire, split pin etc.

3.

IBOP

proper operation

4.

wash pipe assembly

wearing and leakage

5.

carriage and guide rail

guide rail pin shaft,lock pin etc.

replace as per demand

hydraulic system and

liquid level, pressure, temperature,

add or replace as per

hydraulic oil

cleanness etc.

demand

Except for specify notes, filling 2 cycle grease.

Inspection Item
No.

6.

repair or replace as
per demand
repair or replace as
per demand
repair or replace as
per demand
repair or replace as
per demand

inspect leakage status of pipe ways

7.

hydraulic pipelines

inspect pipelines surface

repair or replace as

inspect any blistering on the rubber

per demand

tube
8.

gearbox and gear oil

9.

cable

liquid level, temperature, cleanness etc.

add or replace as per

and air filter damage status

demand

damage, wear, and point of fracture

repair or replace as

-3-

PDF "pdfFactory Pro" www.fineprint.com.cn

BPM Top Drive

No.

Maintenance Manual

Item

Inspection Item

Measure
per demand
repair or replace as

10.

cable joint

break, loose

11.

clamping device

location and lock status

adjust as per demand

loose

adjust as per demand

Item

Lubricating Item

Measure

1.

bail pin

grease

2.

rotating head

grease

3.

carriage assembly

18

grease

grease

grease

grease

12. oil cylinder connectors

per demand

Note: Inspect Top Drive all fasten parts daily.

3.2.

Weekly maintenance

Lubricating Item:
No.

4.
5.
6.

balance system oil

cylinder pin
link tilt device
cylinder pin
upper bearing cover

Except for the specify notes, filling 2 cycle grease.

Inspection Item:
No.
1.

Item
guide ring and
centralization sleeve

Inspection Item

Measure

damage, wear

replace as per demand

adjust as per demand

2.

lock device

bolt torque and loose

3.

IBOP

spanner torque and sealing

4.
5.

IBOP drive unit

roller

wear

repair or replace as per

demand
repair or replace as per
demand

carriage, guide rail

connecting piece, lockpin, welding

repair or replace as per

and sway brace

seam etc.

demand

-4-

PDF "pdfFactory Pro" www.fineprint.com.cn

BPM Top Drive

No.

Maintenance Manual

Item

Inspection Item

Measure

6.

Carriage roller

wear

replace as per demand

7.

main motor air outlet

louver and defence gauze breakage

8.

fan assembly

9.

motor cable

break

10.

brake disc

wear

replace as per demand

Item

Lubricating Item

Measure

main motor

Grease (special used)

grease

repair or replace as per

demand

loose or lose of bolt, blower pressure

adjust or replace as per

air inlet radiator, brake clean

demand
repair or replace as per
demand

3.3. Monthly maintenance

Lubricating Item:
No.
1.
2.

hydraulic pump
motor

Note: Lubrication after working for about 250 hours totally.

Check over all fasten parts monthly.

Inspection Item:
No.
1.
2.
3.

4.

Item

Inspection Item

upper mainshaft

corrosion resulting from wash pipe

bushing

leakage

link tilt device

cylinder clevis pin
crown pad and guide
rail junction block
adjustable plate,
bolts and shackle

Measure
replace as per demand

wear

replace as per demand

weld point damage or fracture

repair as per demand

safety pin or split pin lost

shackle or bolts damaged
adjustable plate eye worn

Note: Inspection after working for about 250 hours totally.

-5-

PDF "pdfFactory Pro" www.fineprint.com.cn

replace as per demand

replace as per demand
repair or replace as per
demand

BPM Top Drive

Maintenance Manual

3.4. Quarterly Maintenance

Inspection Item:
No.

Item

Inspection Item

Measure

1.

gearbox oil

sample oil analysis

replace

2.

hydraulic system oil

sample oil analysis

replace

jam

replace

3.

oil take tube filter

sieve

Note: Inspect after working for about 750 hours totally.

3.5. Semi-annually maintenance

Inspection Item:
No.

Item

Inspection Item
mechanical pitting, wear and

Measure

1.

gear teeth

2.

gearbox lube pump

wear or damage

3.

mainshaft

axial direction excursion

adjust as per demand

4.

bail, bail pin

wear or damage

replace as per demand

5.

accumulator

nitrogen gas pressure

backlash

replace as per demand

repair or replace as per
demand

replace capsule or
accumulator

Note: Inspect after working for about 1500 hours totally.

3.6. Yearly maintaining plan

One yearNondestructive evaluation (NDE) for guide rail and main bearing parts
Three yearsEquipment maintenance (please contact the service department for details)
Five yearsEquipment thorough repair (please contact the service department for details)
Above all items must be checked and maintained according to practical usage.

-6-

PDF "pdfFactory Pro" www.fineprint.com.cn

BPM Top Drive

4.

Maintenance Manual

Lubricating position

4.1. Lubrication for carriage roller

Lubricating position:
a

2 points at upper carriage

2 points at lower carriage

14 points at two sides of carriage

(Totally 14 points, one side has 7 points)

Lubricating method:
Filling choke with grease by grease gun.

4.2. Lubrication for Backup Tong

Lubricating position:
a

2 chokes on stabilizer

Lubricating method:
Filling choke with grease by grease gun.

-7-

PDF "pdfFactory Pro" www.fineprint.com.cn

BPM Top Drive

Maintenance Manual

4.3. Lubrication for main motor bearing

Lubricating position:
a

1 point at upper main motor

1 point at lower main motor

Lubricating method:
Filling choke with grease by grease gun.
Filling motors with lubricating grease: fill
choke at front side of main motor with special
used lubricating grease, till the lubricating
grease spill over from the screw plug at back
side of main motor.
The lubricating grease used for main motor is
special used, which is recommended to use
Aeroshell No.7 or better ones.

4.4. Upper bearing cover

Lubricating position:
Side face of upper bearing cover
Lubricating method:
Filling choke with grease by grease gun.

-8-

PDF "pdfFactory Pro" www.fineprint.com.cn

BPM Top Drive

Maintenance Manual

4.5. Lubrication for lifting bail pin

Lubricating position:
a

2 points at two sides of gearbox (Totally 2 points, one side has 1 point)

Lubricating method:
Filling choke with grease by grease gun.

-9-

PDF "pdfFactory Pro" www.fineprint.com.cn

BPM Top Drive

Maintenance Manual

4.6. Lubrication for balance system oil cylinder pin

Lubricating position:
a

front side of balance system oil cylinder pin

Lubricating method:
Filling choke with grease by grease gun.

4.7. Lubrication for link tilt device oil cylinder pin

Lubricating position:
a

out side of link tilt cylinder pin (Totally 4 points)

Lubricating method:
Filling choke with grease by grease gun.

- 10 -

PDF "pdfFactory Pro" www.fineprint.com.cn

BPM Top Drive

Maintenance Manual

4.8. Lubrication for IBOP

Lubricating position:
a

2 roller shaft chokes on both sides (fill up grease)

Lubricating method:
Filling choke with grease by grease gun.

- 11 -

PDF "pdfFactory Pro" www.fineprint.com.cn

BPM Top Drive

4.9.

Maintenance Manual

Lubrication for wash pipe

Lubricating position:
a

choke on wash pipe side face

Lubricating method :
Filling choke with grease by grease gun.

Note: Please refer to appendix C about the selection of grease.

- 12 -

PDF "pdfFactory Pro" www.fineprint.com.cn

BPM Top Drive

Maintenance Manual

4.10.Lubrication for rotating head

Lubricating position:
2 points at front of rotating head
Lubricating method
Filling choke with grease by grease gun.

- 13 -

PDF "pdfFactory Pro" www.fineprint.com.cn

BPM Top Drive

Maintenance Manual

5. Maintenance for mechanical system

5.1 Main motor and cooling fan
Inspection item:
a Inspect whether the coil out cable is
damaged or not.
b Inspect the blot and lockwire to prevent
them from loosening or damage.
c Inspect whether the louver and filter gauze
in air outlet are damaged or not.
d Making yearly inspection of insulation
resistance with megohmmeter.
Maintain item:
a Preventing the rain from coming into the air suction opening.
b Inspect the motor preliminarily: 1. Whether the motor has been damaged during the
transportation; 2. Whether there are sundries in the sprue runner of motor; 3. Whether
the jigger can rotate well and there is the voice of scuffing.

5.2 Brake device

Inspection item:
a

Wear degree of brake friction disc.

If the brake friction disc wears symmetrically.

If the brake pipeline leakages.

d Inspect the fix screws of brake assembly.

Maintain item
1.

Exhaust Process
a

Give pressure to the hydraulic circuit of brake device.

- 14 -

PDF "pdfFactory Pro" www.fineprint.com.cn

BPM Top Drive

Maintenance Manual

Equipped with a hose on the air discharge, then open it carefully, close it when the
air has been drained off.

Close the air discharge shoe.

Repeat the process of a to c on two brake oil cylinders.

IllustrationThe brake disc will lose the friction force if it is polluted by oil or grease.
The brake disc should be replaced if the friction material sucks the oil or
grease.
Replace the brake friction disc.
Replace the brake friction disc when the friction material
is 6mm left. Note: the new brake friction disc can reach
the rated torque after running in period.
a Discharge the system oil pressure of brake
device.
b Remove the shot pin and return spring screw.
c Sliding the brake disc upward and outward.
d Slip in the new brake friction disc
e Install the shot pin and r return spring screw.
f Tighten up the screw
Note: keep the friction materials clean; dont touch any of oil or grease.
Replace the brake disc.
Replace brake disc when it remains 10mm.

- 15 -

PDF "pdfFactory Pro" www.fineprint.com.cn

BPM Top Drive

Maintenance Manual

5.3 Bail
Inspection item:
a The lubrication condition of bail pin.
b The wear condition of bail and bail pin.
c Bail pin baffle and screw.
Maintain item:
a Fill choke in the bail pin with grease regularly.
b Inspect the wear degree of lifting bail and bail pin
regularly; replace when necessary.

5.4 Gooseneck
Inspection item:
a Inspect the fixed bolt and safety lockwire of
gooseneck and wash pipe support regularly.
b Inspect the gooseneck regularly (if there are
concave, wear or corrosion)
c Regularly bulge test for the gooseneck.
Maintain item:
a Dismount the bolts used to fasten the
gooseneck and fix device, in order to fix and
move the gooseneck.
b Clean the inner hole of gooseneck; visually measure and ensure no concave, wear and
corrosionIf exists, please use ultrasonic flaw detection.
c Paint the thread grease to the thread before reinstalling.

- 16 -

PDF "pdfFactory Pro" www.fineprint.com.cn

BPM Top Drive

Maintenance Manual

5.5 Gearbox
Inspection item
a
b
c
d

Gear oil filter.

Oil level of gear (lubrication).
Flowing status of gear oil (when pump is running).
Gearbox lubricating pump.

Maintain item:
IlluminationBPM Top Drive could work in the condition of widely changeable
ambient temperature. Before changing the oil, select the oil according to the
prognostic circumstance temperature.
NoteIt is recommended to replace oil every six (6) months or replace according to
practical inclement situation.
warning

Using oil viscosity degree over than environment requires will lead to
damage of gears and bearings.

Using oil viscosity degree lower than environment requires could not create
effective oil film, and finally lead to wear and tear.

Make sure that the lubrication oil is clear enough before filling into the
gearbox. Prevent contaminants, such as mud or grains of sand from going
- 17 -

PDF "pdfFactory Pro" www.fineprint.com.cn

BPM Top Drive

Maintenance Manual

into the gearbox, and finally result in blocking up of lubrication oil way or
damaging the bearing and gear, etc.
a The oil level of gearbox should keep a certain height. Charging the oil when the level
is over low to prevent the bearing gear from wearing.
NoteOil level of gearbox should between the lowest and highest scale. The oil level
is over low, which will lead to less of lubrication cooling. The oil level is
over high, which will lead to leakage of lubrication oil.
b Clear up mud after replacing wash pipe. Keep gearboxs cover, wash pipe bracket,
and mud umbrella clean all the time. Inspect oil pointer once a day at least, if colour
of lubricating oil is unusual, check in time by below items:

Open ball valve and take oil sample.

Check lubricating oil.

If mud leakage exists, discharge all lubricating oil.

Clean gearbox by gasoline. To avoid blocking oil circuits, do not use cotton
kinds of things to erase.

Check oil sealing sleeve wearing status, replace when necessary.

Replace sealing, ring, and V water sealing nearby the mud umbrella. Smear
flange sealant on K-face when assembling.

- 18 -

PDF "pdfFactory Pro" www.fineprint.com.cn

BPM Top Drive

Maintenance Manual

c Please contact the BPM Top Drive centre when dismounting the gearbox lubricating
pump.
d Please contact the BPM Top Drive centre when dismounting the gearbox.
e Please select the proper gear oil refers to appendix B.

5.6 Wash pipe assembly

Wash pipe assembly (metric)

- 19 -

PDF "pdfFactory Pro" www.fineprint.com.cn

BPM Top Drive

Maintenance Manual

Wash pipe assembly (inch size)

- 20 -

PDF "pdfFactory Pro" www.fineprint.com.cn

BPM Top Drive

Maintenance Manual

5.7 Link tilt device

Inspection item
a Elevator link eye lubrication.
b Elevator link eye wear.
c Wear status of elevator link tilt cylinder
pin.
d The position of clamping device and the
clamp status.

x 3

Maintenance Item:
a Lubricate the elevator link eye with pipe
lubricant of threads.
b Lubricate the lubricating points.
c The installation and
elevator link.

disassemble of

Dismount elevator from elevator link.

Dismount U-bolt, which is used to elevator link and link tilt cylinder.
Dismount protective shield.
Remove the elevator link from the pipe handler device with crane. Repeat the above
steps to put down another elevator link.
d installation and disassemble of tilt oil cylinder
Shut off the power and discharge the pressure of hydraulic system; close the main
valve gate of hydraulic system.
Dismount the hydraulic pipeline on tilt oil cylinder and cover all joints with guard
cover.
Dismount the pin shaft and tilt oil cylinder.

- 21 -

PDF "pdfFactory Pro" www.fineprint.com.cn

BPM Top Drive

Maintenance Manual

Elevator link wear table

For the worn elevator link, operator could measure the hoist capacity by measuring the wear
extent of ear.
Lifting bail
specification

3 1/2, 350 ton

Upper lifting ear

Lower lifting ear

inch

inch

2 3/4

350

4 13/16

2 9/16

300

4 5/8

2 3/8

225

4 7/16

2 3/16

175

Note: hoist capability is the lowest value of two elevator links.

- 22 -

PDF "pdfFactory Pro" www.fineprint.com.cn

Hoist capability
ton

BPM Top Drive

Maintenance Manual

5.8 Upper IBOP

Inspection item:
a If the bolts are loosened; if the accessories, safety lockwire, pin and split pin are lost
or damaged.
b If the upper IBOP works normally; and if it is leaked out.
c The lubrication and wear status of drive system crank. If there is logy happens.
d Lubrication and wear status of drive system cylinder.
e Lubrication, deflection, and wear status of drive system roller.
Oil cylinder supporter
Oil cylinder

Baffle

Rotating pin

Roller

Axle

Support

Bolt

Sleeve
Crank
Cover plate

Upper IBOP Control Device

WarningInspect it everyday.
- 23 -

PDF "pdfFactory Pro" www.fineprint.com.cn

BPM Top Drive

Maintenance Manual

5.9 IBOP
Inspection Item
a Inspect the lubricating position everyday.
b Ensure working normally and no leakage.
c Inspect the wear status of IBOP weekly.
Illuminationit is important to inspect the wear status of IBOP weekly.
Maintain item:
Two IBOP (upper and lower) should be
sealed well; test pressure should be
70MPa; open or close totally when
operating.

retaining
ring

upper
matching

Its easy to generate wear fatigue crack

owing to the existence of fluting and
shoulder, which will lead to the raise of
bend and drawing stress.

ring
support
ring
upper
valve seat

It is recommended to do magnaflux
handle
seat

inspection for the outer surface of valve taper

knob
body yearly. If there is crack or damage,
it might be necessary to replace; as for
the crater pit or rust corrosion larger

operation
handle
than 1.6mm, it is necessary to replace at
once.

lower
matching ring

ball

float

lower
valve seat

valve
body

- 24 -

PDF "pdfFactory Pro" www.fineprint.com.cn

BPM Top Drive

5.10

Maintenance Manual

IBOP locking device

Inspection item
a If the bolts loose or not.
b Inspect the safety lockwire
Noteplease replace the loosened bolts as soon as possible.
Disassemble the IBOP locking device
a Dismantle the lockwire.
upper lock
ring

b Dismount all lock bolts.

c Wipe off the rust and soil in
the IBOP locking device;
take down the IBOP locking
devices in the mainshaft,
IBOP and saver sub.

tooth plate

bolt

lower lock ring

Noteloosen all bolts gradually

and synchronically, every bolt should be rotated about 1/4 cycle to prevent the flange from
getting lopsided or being stuck. Forbidden to loosen all bolts, otherwise, the flange will drop
off.
NoteIt is forbidden to reuse the replaced lock bolts
Installation of IBOP locking device
a Paint the supramoly grease under the thread surface, bolt cover
and conical surface of inner ring.
b Ensure no culmination on the saver sub, IBOP and outer
surface of mainshaft; wipe them off with file or fine stone
wheel.
c Clean the IBOP, mainshaft and the surface of saver sub to
ensure them clean enough and no grease.
d Put the IBOP locking device in pairs on joint position.
e Put the tong tooth into the flange groove.
f Homogeneously tighten the bolts in the IBOP locking device
- 25 -

PDF "pdfFactory Pro" www.fineprint.com.cn

BPM Top Drive

Maintenance Manual

flange plate, and make sure that the flange interspaces are equal.
g Tighten the bolts with torque wrench clockwise or counterclockwise till all tighten
torque of bolts reach to 200Nm.
h Fix all bolts with steel wire.
Illustrationthe IBOP locking device should be put in the connection position between
two parts of upward and downward in equidistance. The tooth plate should
be distributed in the connection position between two parts of upward and
downward in equidistance.
Noteplease do not tighten the lock bolts before the IBOP locking device is put
correctly.
NoteIt is forbidden to tighten the lock bolts on diagonal direction.
NoteEnsure all bolts to be tightened correctly; The interspaces between IBOP
locking device flange plates should be consistency.

5.11

Backup Tong

Inspection item
Inspect the fastener of bolts timely to make sure
they have fasten-locked and no damage happens.
Replacing is needed when they are broken, and
please avoids the fastener parts loose or drop off.
Maintain item
a Clean the oil contamination and sundries in the
tooth plate groove and surface in time.
b Fill grease to choke every day.(refer to the
picture)
c Paint enough grease on the tong tooth seat
when replacing it.
Disassemble and installation of Backup Tong
When disassemble and install the Backup Tong, firstly, please dismount the hanging pin
which connecting the Backup Tong bracket and supporter connection. Then, dismount the
Backup Tong bracket, put the Backup Tong down onto the ground or workbench, disassemble
- 26 -

PDF "pdfFactory Pro" www.fineprint.com.cn

BPM Top Drive

Maintenance Manual

the two pins and front Backup Tong and the back tooth seat which connecting on the piston.
Because the front and back covers are all fixed by three semiannular rings, operator could
take out the piston at backside when disassemble the semiannular rings stop collar and
semiannular rings itself. Please take care of avoiding breaking the seal parts when take out the
piston and covers.
Replace tong tooth
a Dismount the pin which connecting the front tong with hydraulic cylinder
(disassemble one is enough), then, rotate to pull apart the front tong 90.
b Dismount the tong tooth fixing plate, and replace the tooth plate, then, install the
fixing plate and pins.
c Replace the tong tooth seat does the same first step as changing the tong tooth. You
must open the front tong firstly, then dismount the front and back tooth seat, and
replace the relevant tooth seat.

5.12

Guide rail

Inspection item
a Inspect the guide rail joint pin, lock pin and split pin.
b Inspect the welding spot damage and fracture status
of adjustable plate and guide rail junction block.
c Inspect the loose status of fix bolts of guide rail
reactive torque supporter.
Maintain item
a Inspect the guide rail connecting pin shaft, lock pin
and split pin.

- 27 -

PDF "pdfFactory Pro" www.fineprint.com.cn

BPM Top Drive

5.13

Maintenance Manual

Carriage

Inspection item
a Inspect the loose status of roller nut.
b Inspect the wear status of roller surface.
Maintain item
a Fill grease to the choke of two-side roller shaft and carriage up/down face.
Replace the roller
It is forbidden to dismantle the roller when the carriage is on the slide position (the normal
working position) of guide rail; to replace roller, operator must slide Top Drive body and
carriage out from guide rail.
a Fix the body and the first guide rail under the guide rail with pins.
b Dismantle the joint pin of the first guide rail, and then dismantle this guide rail from
Top Drive body.
c Separate the first guide rail from the body and pull it out from the carriage.
d Dismantle the old roller and install a new one.
e Install the body onto the guide rail as per contrary processes.

Round nut
Stop ring
Wheel body

Loaded wheel

- 28 -

PDF "pdfFactory Pro" www.fineprint.com.cn

BPM Top Drive

Maintenance Manual

6 Maintain for hydraulic system

Inspection item
Daily inspect the hydraulic power unit (HPU):
a Observe the hydraulic tank gauge; the level should be higher than limited point or
middle position of the lower oil pointer.
b Observe the hydraulic temperature. The temperature of hydraulic oil can not be higher
than 70.
c Observe filter plugging state with filter indicator light.
d Visually inspect the leakage status of hydraulic system pipeline
e Visually inspect the surface condition of hydraulic cable.

6.1 Accumulator
The accumulator of counterbalance cylinder and HPU is a pre-filled nitrogen pressure
container. Long time use will lead to capsule break so that the nitrogen will out. Therefore, it
is necessary to inspect the pressure of pre-filled nitrogen and refill the nitrogen or replace the
capsule.
NoteClose the stop valve between oil mouth and pressure oil tube, keep the
accumulator oil pressure higher than the gas filling pressure.
Inspection item
If accumulator is error, inspect the following items:
a If the gas valve is leak out; refill nitrogen if necessary.
b If there is no nitrogen in the capsule, while the gas valve position is leaking oil, please
inspect the capsule.
c Please shoulder up the connecting parts if the accumulator is leak out. If it still can
not work, please replace the relevant parts.
Inspect the nitrogen pressure
Inspect the gas filling pressure with filling tools.
Fill nitrogen with charging tools when the pressure is lower than the preset pressure.

- 29 -

PDF "pdfFactory Pro" www.fineprint.com.cn

BPM Top Drive

Maintenance Manual

Replace the accumulator capsule

a Disassemble/install the capsule at upper big opening when repairing.
b Pay attention that firstly you must install the support ring onto the gas filling valve
seat of capsule in shell.
c Chip off both sides of support ring in order to put it into the shell. Put down support
ring horizontally, and then align the big opening of shell to install/disassemble.
NoteDrain off the pressure oil when repairing. Discharge the nitrogen in the capsule
with gas filling tool first, and then dismount the components.

- 30 -

PDF "pdfFactory Pro" www.fineprint.com.cn

BPM Top Drive

Maintenance Manual

Appendix A Bolt torque gauge

Bolt torque lubricated with light machine oil (coarse thread, UNC)

Diameter

Thread per inch

Min. torque
(ft-lb)

Max. torque
(ft-lb)

Holding force (lb)

1/4

20

7.6

8.4

2020

5/16

18

16

18

3340

3/8

16

29

32

4940

7/16

14

48

53

6800

1/2

13

71

79

9050

9/16

12

105

116

11600

5/8

11

143

158

14400

3/4

10

247

273

21300

7/8

409

452

29400

608

672

38600

1-1/8

760

840

42300

1-1/4

1064

1176

53800

1-3/8

1387

1533

64100

1-1/2

1843

2037

78000

- 31 -

PDF "pdfFactory Pro" www.fineprint.com.cn

BPM Top Drive

Maintenance Manual

Bolt torque painted with antiblocking agent (coarse thread, UNC)

Diameter

Thread per inch

Min. torque
(ft-lb)

Max. torque
(ft-lb)

Holding force (lb)

1/4

20

5.7

6.3

2020

5/16

18

12.1

13.4

3340

3/8

16

21.4

23.6

4940

7/16

14

36

39

6800

1/2

13

53

59

9050

9/16

12

78

87

11600

5/8

11

107

118

14400

3/4

10

185

205

21300

7/8

306

339

29400

456

504

38600

1-1/8

570

630

42300

1-1/4

798

882

53800

1-3/8

1040

1150

64100

1-1/2

1382

1582

78000

- 32 -

PDF "pdfFactory Pro" www.fineprint.com.cn

BPM Top Drive

Maintenance Manual

Bolt torque lubricated with light machine oilfine thread, UNC

Diameter

Thread per inch

Min. torque
(ft-lb)

Max. torque
(ft-lb)

Holding force (lb)

1/4

28

9.5

10.5

2320

5/16

24

18

20

3700

3/8

24

33

37

5600

7/16

20

52

58

7550

1/2

20

86

95

10700

9/16

18

114

126

12950

5/8

18

162

179

16300

3/4

16

285

315

23800

7/8

14

447

494

32400

14

665

735

42200

1-1/8

12

836

924

47500

1-1/4

12

1178

1302

59600

1-3/8

12

1596

1764

73000

1-1/2

12

2090

2310

87700

- 33 -

PDF "pdfFactory Pro" www.fineprint.com.cn

BPM Top Drive

Maintenance Manual

Bolt torque painted with antiblocking agent (fine thread, UNC)

Diameter

Thread per inch

Min. torque
(ft-lb)

Max. torque
(ft-lb)

Holding force (lb)

1/4

28

7.1

7.9

2320

5/16

24

13.5

15.0

3700

3/8

24

25

28

5600

7/16

20

39

43

7550

1/2

20

64

71

10700

9/16

18

86

95

12950

5/8

18

121

134

16300

3/4

16

214

236

23800

7/8

14

335

370

32400

14

499

551

42200

1-1/8

12

627

693

47500

1-1/4

12

884

977

59600

1-3/8

12

1197

1323

73000

1-1/2

12

1568

1733

87700

- 34 -

PDF "pdfFactory Pro" www.fineprint.com.cn

BPM Top Drive

Maintenance Manual

Thread tighten torque

thread spec

Recommended torqueN.mRecommended torqueN.mRecommended torqueN.m

8.8 grade

10.9 grade

12.9 grade

M8

22

30

37

M10

45

63

75

M12

78

109

131

M16

193

271

325

M20

328

531

637

M24

653

906

1101

M30

1300

1828

2193

NoteM20 tighten torque on IBOP locking device is 200N.m

- 35 -

PDF "pdfFactory Pro" www.fineprint.com.cn

BPM Top Drive

Maintenance Manual

Appendix B Recommended gear oil matching table

Gear oil
Temperature range
Manufacture
AGMA viscosity
(USA gear manufacture institute)
ISO viscosity
(international standard organization )

Winter

7--30

Summer

2EP

4EP

6EP

68

150

320

Castrol

Alpha LS-68

Alpha LS-150

Alpha LS-320

Chevron

NL Gear 68

NL Gear 150

NL Gear 320

Exxon

Spartan EP68

Spartan EP150

Spartan EP320

Gulf

EP Lube HD68

EP Lube HD150

EP Lube HD320

Mobil

Mobil Gear 626

Mobil Gear 629

Mobil Gear 632

Shell

Omala 68

Omala 150

Omala 320

Statoil

Loadway EP68

Loadway EP150

Loadway EP320

Texaco

Meropa 68

Meropa 150

Meropa 320

Total

Carter EP 68

Carter EP 150

Carter EP320

Union

Extra Duty NL2EP

Extra Duty NL2EP

Extra Duty NL2EP

Appendix C Recommended grease matching table

Name
Model
Remarks

Extreme pressure lithium

lubricating grease
0

Synthesis lithium base grease

ZL-1H ZL-2H ZL-3H ZL-4H

GB7323-87

Precision
instrument grease
ZT-53-7
Be used in winter

- 36 -

PDF "pdfFactory Pro" www.fineprint.com.cn

BPM Top Drive

Maintenance Manual

Well Site Work Records

recorder

Service personnel
Date

Detail Work

- 37 -

PDF "pdfFactory Pro" www.fineprint.com.cn

Remark

BPM Top Drive

Date

Maintenance Manual

Detail Work

- 38 -

PDF "pdfFactory Pro" www.fineprint.com.cn

Remark

BPM Top Drive

Date

Maintenance Manual

Detail Work

- 39 -

PDF "pdfFactory Pro" www.fineprint.com.cn

Remark

BPM Top Drive

Date

Maintenance Manual

Detail Work

- 40 -

PDF "pdfFactory Pro" www.fineprint.com.cn

Remark

BPM Top Drive

Maintenance Manual

Top Drive Failure Information Feedback List

Client:

Group number:

Contact person:
Contact

Well number:
Phone:

Mobile phone:

Fax:

Email:

Well location:
Top Drive model/serial no:

Installation time:

Present task:
Hole configuration
Next task:

Drilling
parameter

Planned well depth:

Maximum speed:

Latest drill depth:

Maximum torque:

Mud density:

Cumulative drilling time:

Hook weightaverage:

Cumulative failure time:

Failure
description

Signature:

Date:

Note Please fax this list to: Beijing Petroleum Machinery Factory Top Drive Center
Tel.:0086-10-62097381 Fax: 0086-10-62097613 Email: bpm.zhaojing@vip.163.com

- 41 -

PDF "pdfFactory Pro" www.fineprint.com.cn