TDS-Maintenance Manual

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 ..................................................................... 6
3.4. Quarterly Maintenance ................................................................... 7
3.5. Semi-annually maintenance........................................................... 7
3.6. Yearly maintaining plan .................................................................. 8
4. Lubricating position ........................................................................ 9
4.1. Lubrication for carriage roller ......................................................... 9
4.2. Lubrication for Backup Tong........................................................... 9
4.3. Lubrication for main motor bearing .............................................. 10
4.4. Lubrication for lifting bail pin..........................................................11
4.5. Lubrication for balance system oil cylinder pin ............................ 12
4.6. Lubrication for link tilt device oil cylinder pin shaft ....................... 12
4.7. Lubrication for IBOP ..................................................................... 13
4.8. Lubrication for wash pipe ............................................................. 14
4.9. Lubrication for IBOP ..................................................................... 15
4.10. Lubrication for rotating head......................................................... 16
5. Maintenance for mechanical system............................................ 17
5.1 Main motor and cooling fan.......................................................... 17
5.2 Brake device................................................................................. 17
5.3 Bail................................................................................................ 19
5.4 Gooseneck ................................................................................... 19
5.5 Gearbox........................................................................................ 20
5.6 Wash pipe assembly .................................................................... 22
5.7 Link tilt device ............................................................................... 24
5.8 Upper IBOP .................................................................................. 26
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5.9 IBOP ............................................................................................. 27
5.10 IBOP locking device ..................................................................... 28
5.11 Backup Tong................................................................................. 30
5.12 Guide rail ...................................................................................... 31
5.13 Carriage........................................................................................ 32
6 Maintain for hydraulic system....................................................... 33
6.1 Accumulator.................................................................................. 33
Appendix A Bolt torque gauge .............................................................. 35
Appendix B Recommended gear oil matching table............................... 40
Appendix C Recommended grease matching table ............................... 41
Well Site Work Records .......................................................................... 42
Top Drive Failure Information Feedback List .......................................... 46

BPM Top Drive Maintenance Manual
1. 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-
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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 it’s 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.
【Warning】Releasing the pressure in accumulator before repairing the
hydraulic system.
【Warning】Please do not repair the parts which you don’t know much
better.
【Warning】Please read and learn the safety notice and warning before
maintaining.
-2-

3. Cycle and Item of Maintenance

3.1. Daily maintenance
Lubrication Item：
No. Item Lubricating Item Measure
1. wash pipe Assembly 1 grease
2. IBOP drive unit roller 2 grease
3. Backup Tong stabilizer 2 grease
Except for specify notes, filling 2 cycle grease.
Inspection Item
No. Item Inspection Item Measure
repair or replace
1. motor assembly bolt, safety lockwire, split pin etc.
as per demand
pipe handler repair or replace
2. bolt, safety lockwire, split pin etc.
device as per demand
repair or replace
3. IBOP proper operation
as per demand
wash pipe repair or replace
4. wearing and leakage
assembly as per demand
carriage and replace as per
5. guide rail pin shaft,lock pin etc.
guide rail demand
hydraulic
liquid level, pressure, add or replace as
6. system and
temperature, cleanness etc. per demand
hydraulic oil
inspect leakage status of pipe
ways
hydraulic repair or replace
7. inspect pipelines’ surface
pipelines as per demand
inspect any blistering on the
rubber tube
gearbox and liquid level, temperature, add or replace as
8.
gear oil cleanness etc. and air filter per demand
-3-


damage status
damage, wear, and point of repair or replace
9. cable
fracture as per demand
repair or replace
10. cable joint break, loose
as per demand
clamping adjust as per
11. location and lock status
device demand
oil cylinder adjust as per
12. loose
connectors demand
Note: Inspect Top Drive all fasten parts daily.
3.2. Weekly maintenance
Lubricating Item:
1. bail pin 2 grease
2. rotating head 2 grease
3. upper IBOP 1 grease
carriage
4. 18 grease
assembly
balance system
5. 2 grease
oil cylinder pin
link tilt device
6. 4 grease
cylinder pin
Except for the specify notes, filling 2 cycle grease.
-4-

Inspection Item:
guide ring and
replace as per
1. centralization damage, wear
demand
sleeve
adjust as per
2. lock device bolt torque and loose
demand
repair or replace
3. IBOP spanner torque and sealing
as per demand
IBOP drive unit repair or replace
4. wear
roller as per demand
carriage, guide
connecting piece, lockpin, repair or replace
5. rail and sway
welding seam etc. as per demand
brace
replace as per
6. Carriage roller wear
demand
main motor air louver and defence gauze repair or replace
7.
outlet breakage as per demand
loose or lose of bolt, blower
adjust or replace
8. fan assembly pressure
as per demand
air inlet radiator, brake clean
repair or replace
9. motor cable break
as per demand
replace as per
10. brake disc wear
demand
-5-

3.3. Monthly maintenance
Lubricating Item:
Grease (special
1. main motor 4
used)
hydraulic pump
2. 2 grease
motor
Note: Lubrication after working for about 250 hours totally.
Check over all fasten parts monthly.
Inspection Item:
upper mainshaft corrosion resulting from replace as per
1.
bushing wash pipe leakage demand
elevator link tilt
replace as per
2. device cylinder wear
demand
clevis pin
crown pad and
weld point damage or repair as per
3. guide rail
fracture demand
junction block
replace as per
demand
adjustable safety pin or split pin lost
replace as per
4. plate, bolts shackle or bolts damaged
demand
and shackle adjustable plate eye worn
repair or replace
as per demand
Note: Inspection after working for about 250 hours totally.
-6-

3.4. Quarterly Maintenance
Inspection Item:

1. gearbox oil sample oil analysis replace
hydraulic
2. sample oil analysis replace
system oil
oil take tube
3. jam replace
filter sieve
Note: Inspect after working for about 750 hours totally.
3.5. Semi-annually maintenance
Inspection Item:

mechanical pitting, wear and replace as per
1. gear teeth
backlash demand
gearbox lube repair or replace
2. wear or damage
pump as per demand
adjust as per
3. mainshaft axial direction excursion
demand
replace as per
4. bail, bail pin wear or damage
demand
replace capsule or
5. accumulator nitrogen gas pressure
accumulator
Note: Inspect after working for about 1500 hours totally.
-7-

3.6. Yearly maintaining plan

One year—Nondestructive evaluation (NDE) for guide rail and main
bearing parts
Three years—Equipment maintenance (please contact the service
department for details)
Five years—Equipment thorough repair (please contact the service
department for details)
Above all items must be checked and maintained according to
practical usage.
-8-

4. Lubricating position
4.1. Lubrication for carriage roller
Lubricating position:
a） 2 points at upper carriage
b） 2 points at lower carriage
c） 12 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
a） 2 chokes on stabilizer
Lubricating method:
-9-

4.3. Lubrication for main motor bearing
a） 1 point at upper main motor
b） 1 point at lower main motor
Lubricating method:
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.
- 10 -

4.4. Lubrication for lifting bail pin
a） 2 points at two sides of gearbox (Totally 2 points, one side has 1
point)
Lubricating method:
- 11 -

4.5. Lubrication for balance system oil cylinder pin
a） front side of balance system oil cylinder pin
Lubricating method:
4.6. Lubrication for link tilt device oil cylinder pin shaft
a） out side of link tilt cylinder pin (Totally
4 points)
Lubricating method:
- 12 -

4.7. Lubrication for IBOP
a） 2 roller shaft chokes on both sides (fill up grease)
Lubricating method:
- 13 -

4.8. Lubrication for wash pipe
a） choke on wash pipe side face
Lubricating method :
Note: Please refer to appendix C about the selection of grease.
- 14 -

4.9. Lubrication for IBOP
þ Lower of Upper IBOP operating handle
Lubricating method：
Move up sliding sleeve of IBOP control device, dismount tapered bore
plug, mount the chock and fill choke with grease by grease gun. After
finishing, dismount chock and mount the tapered bore plug.
- 15 -

4.10. Lubrication for rotating head
þ 2 points at front of rotating head
Lubricating method：
- 16 -

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.
b） If the brake friction disc wears
symmetrically.
c） If the brake pipeline leakages.
- 17 -

d） Inspect the fix screws of brake assembly.

Maintain item
1. Exhaust Process
a） Give pressure to the hydraulic circuit of brake device.
b） Equipped with a hose on the air discharge, then open it carefully,
close it when the air has been drained off.
c） Close the air discharge shoe.
d） Repeat the process of “a” to “c” on two brake oil cylinders.
【Illustration】The 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; don’t touch any of oil or grease.
Replace the brake disc.
Replace brake disc when it remains 10mm.
- 18 -

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 corrosion：If exists, please use ultrasonic flaw
detection.
c） Paint the thread grease to the thread before reinstalling.
- 19 -

5.5 Gearbox
Inspection item
a） Gear oil filter.
b） Oil level of gear (lubrication).
c） Flowing status of gear oil (when pump is running).
d） Gearbox lubricating pump.
Maintain item:
【Illumination】BPM Top Drive could work in the condition of widely
changeable ambient temperature. Before changing the oil,
select the oil according to the prognostic lowest
temperature.
【Note】It is recommended to replace oil every six (6) months or
replace according to practical inclement situation.
【warning】：
① Using oil viscosity degree over than environment requires
will lead to damage of gears and bearings.
- 20 -

② Using oil viscosity degree lower than environment requires

could not create effective oil film, and finally lead to wear
and tear.
③ 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 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.
【Note】：Oil 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） Please contact the BPM Top Drive centre when dismounting the
gearbox lubricating pump.
c） Please contact the BPM Top Drive centre when dismounting the
gearbox.
d） Please select the proper gear oil refers to appendix B.
- 21 -

5.6 Wash pipe assembly
Wash pipe assembly (metric)
- 22 -

Wash pipe assembly (inch size)
- 23 -

5.7 Link tilt device
Inspection item
a） Elevator link eye lubrication.
b） Elevator link eye wear.
c） Wear status of elevator tilt oil
cylinder clevis pin.
d） The position of clamping device
and the clamp status.
M x 3
Maintenance Item:
a） Lubricate the elevator link eye
with pipe lubricant of threads.
b） Lubricate the lubricating points.
c） The installation and disassemble
of elevator link.
① Dismount elevator from elevator link.
② Dismount U-bolt, which is used to elevator link and link tilt cylinder.
③ Dismount protective shield.
④ 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
① Shut off the power and discharge the pressure of hydraulic system;
close the main valve gate of hydraulic system.
② Dismount the hydraulic pipeline on tilt oil cylinder and cover all
joints with guard cover.
③ Dismount the pin shaft and tilt oil cylinder.
- 24 -

Elevator link wear table

For the worn elevator link, operator could measure the hoist capacity by
measuring the wear extent of ear.
Upper lifting ear Lower lifting ear
Lifting bail Hoist
（inch）（inch）
specification capability（ton）
（ F ）（ E ）
5 2 3/4 350
4 13/16 2 9/16 300
3 1/2”, 350 ton
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.
- 25 -

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.
【Warning】Inspect it everyday.
- 26 -

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.
【Illumination】it is important to inspect the wear status of IBOP weekly.
Maintain item:
Two IBOP (upper and lower)
should be sealed well; test
retaining
卡环 ring
pressure should be 70MPa;
open or close totally when upper
上拼合扣环matching
operating.
ring
support
支撑环 ring
It’s easy to generate wear
fatigue crack owing to the upper
上阀座 valve seat
existence of fluting and
shoulder, which will lead to the lower
下拼合扣环matching ring
handle
手柄座
seat
raise of bend and drawing
stress. taper手柄套
knob ball float
浮球
It is recommended to do
magnaflux inspection for the 操作手柄
operation handle
lower
下阀座 valve seat
outer surface of valve body
yearly. If there is crack or
damage, it might be necessary
to replace; as for the crater pit valve
阀体 body
or rust corrosion larger than
1.6mm, it is necessary to
replace at once.
- 27 -

5.10 IBOP locking device

Inspection item
a） If the bolts loose or not.
b） Inspect the safety lockwire
【Note】please replace the loosened bolts as soon as possible.
Disassemble the IBOP locking device
a） Dismantle the
lockwire. upper lock上牙嵌体
ring
b） Dismount all lock 牙板
bolts. tooth plate
螺栓
c） Wipe off the rust and bolt
soil in the IBOP 下牙嵌体
lower lock ring
locking device; take
down the IBOP locking
devices in the mainshaft, IBOP and saver sub.
【Note】loosen 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.
【Note】It 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.
- 28 -

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 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 200N•m.
h） Fix all bolts with steel wire.
【 Illustration 】 the 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.
【Note】please do not tighten the lock bolts before the IBOP locking
device is put correctly.
【Note】It is forbidden to tighten the lock bolts on diagonal direction.
【Note】Ensure all bolts to be tightened correctly; The interspaces
between IBOP locking device flange plates should be
consistency.
- 29 -

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 calcium soap base grease to the
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 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.
- 30 -

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 crown pad
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.
- 31 -

5.13 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
- 32 -

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.
【Note】Close 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.
- 33 -

Fill nitrogen with charging tools when the pressure is lower than the
preset pressure.
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.
【Note】Drain off the pressure oil when repairing. Discharge the
nitrogen in the capsule with gas filling tool first, and then
dismount the components.
- 34 -

Appendix A Bolt torque gauge

Bolt torque lubricated with light machine oil (coarse thread, UNC)
Thread per Min. torque Max. torque Holding force

Diameter
inch (ft-lb) (ft-lb) (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 9 409 452 29400
1 8 608 672 38600
1-1/8 7 760 840 42300
1-1/4 7 1064 1176 53800
1-3/8 6 1387 1533 64100
1-1/2 6 1843 2037 78000
- 35 -

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

Diameter
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 9 306 339 29400
1 8 456 504 38600
1-1/8 7 570 630 42300
1-1/4 7 798 882 53800
1-3/8 6 1040 1150 64100
1-1/2 6 1382 1582 78000
- 36 -

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

Diameter
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
1 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
- 37 -

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

Diameter
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
1 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
- 38 -

Thread tighten torque
thread Recommended torque Recommended torque Recommended torque
spec （N.m）8.8 grade （N.m）10.9 grade （N.m）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
Note：M20 tighten torque on IBOP locking device is 200N.m
- 39 -

Appendix B Recommended gear oil

matching table
Gear oil
Temperature range
Manufacture
Winter 7℃--30℃ Summer
AGMA viscosity
(USA gear manufacture 2EP 4EP 6EP
institute)
ISO viscosity
(international standard 68 150 320
organization )
Castrol Alpha LS-68 Alpha LS-150 Alpha LS-320
Chevron NL Gear 68 NL Gear 150 NL Gear 320
Spartan Spartan Spartan
Exxon
EP68 EP150 EP320
EP Lube EP Lube EP Lube
Gulf
HD68 HD150 HD320
Mobil Gear Mobil Gear Mobil Gear
Mobil
626 629 632
Shell Omala 68 Omala 150 Omala 320
Loadway Loadway Loadway
Statoil
EP68 EP150 EP320
Texaco Meropa 68 Meropa 150 Meropa 320
Carter EP 68 Carter EP Carter EP320
Total
150
Extra Duty Extra Duty Extra Duty
Union
NL2EP NL2EP NL2EP
- 40 -

Appendix C Recommended grease

matching table
Extreme pressure Precision
Synthesis lithium base
Name lithium lubricating instrument
grease
grease grease
Model 0 1 2 3 ZL-1H ZL-2H ZL-3H ZL-4H ZT-53-7
Be used in
Remarks GB7323-87
winter
- 41 -

Well Site Work Records
Service personnel： recorder：

Date Detail Work Remark
- 42 -

- 43 -

- 44 -

- 45 -

Top Drive Failure Information Feedback List
Client: Group number:
Contact person: Well number:
Phone: Mobile phone:

Contact
Fax: Email:
Well location:
Top Drive model/serial no: Installation time:
Present task:
Hole configuration
Next task:
Planned well depth: Maximum speed:
Latest drill depth: Maximum torque:

Drilling
Mud density: Cumulative drilling time:
parameter
Hook weight（average）: Cumulative failure time:
Failure
description
- 46 -

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
- 47 -

TDS-Maintenance Manual

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Top Drive Drilling Equipment

Serial No： 06032

GB/T19001:2000 idt ISO9001:2000 « Quality Management System-- Requirements»

< Installation and Trouble Shooting Manual>

<Electric House Manual>

<Data Backup and Recovery Manual>

BPM Beijing Petroleum Machinery Factory

Tel: ( 010) 62097381

Fax: ( 010) 62097613

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Rotating head assembly

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3. Cycle and Item of Maintenance

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No. Item Inspection Item Measure

3.2. Weekly maintenance

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3.3. Monthly maintenance

Check over all fasten parts monthly.

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3.4. Quarterly Maintenance

No. Item Inspection Item Measure

3.5. Semi-annually maintenance

No. Item Inspection Item Measure

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3.6. Yearly maintaining plan

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4.2. Lubrication for Backup Tong

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4.3. Lubrication for main motor bearing

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4.4. Lubrication for lifting bail pin

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4.5. Lubrication for balance system oil cylinder pin

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4.7. Lubrication for IBOP

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4.8. Lubrication for wash pipe

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

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4.9. Lubrication for IBOP

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4.10. Lubrication for rotating head

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5. Maintenance for mechanical system

5.1 Main motor and cooling fan

5.2 Brake device

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d） Inspect the fix screws of brake assembly.

Replace the brake friction disc.

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② Using oil viscosity degree lower than environment requires

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5.6 Wash pipe assembly

Wash pipe assembly (metric)

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Wash pipe assembly (inch size)

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