Troubleshooting Manual

This guide was taken from the TDS9S Top Drive Service Manual (Varco
Part Number SM00001, Revision A). Please contact your local Varco
Service Center for any updates.

Select the one of the following troubleshooting areas:

Troubleshooting the AC blower motor

Troubleshooting the hydraulic system
Troubleshooting the AC drilling motor brakes
Troubleshooting the rotaing link adapter motor
Troubleshooting the IBOP actuator cylinder
Troubleshooting the shot pin cylinder
Troubleshooting the link tilt cylinders
Troubleshooting the counterbalance system
Troubleshooting the hydraulic power unit and reservoir
Troubleshooting the gearbox lubrication hydraulic system

Select the search button if you would like to search the guide for a spe-
cific topic.

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March 9, 1998
Index

Troubleshooting the AC blower motors

There are two AC blower motors, one on top of each AC drilling
motor. The following chart describes problems, probable causes
and remedies.

Table 4-5. Troubleshooting the AC blower motors

Symptom Probable cause Remedy

Mechanical noise in Loose impeller.
blower.
Faulty motor bearings.
Blower runs Faulty or loose wiring.
intermittently.
Faulty motor starter
Broken service loop
conductor.
Motor overheating, Incorrect blower rotation.
overtemp alarm stays
on with blower
running.
Broken service loop
conductor.
Reinstall impeller and hub with
threadlocking compound on screws.
Repair or replace as needed.
Locate and repair as needed.
Check for dirt or trash between
starter coil. Repair or replace as
needed.
Use spare service loop conductor.
Verify blower rotation is correct.
Use spare service loop conductor.

4-60 TDS-9S Maintenance and Troubleshooting

 Index

Troubleshooting the hydraulic system

The following hydraulic troubleshooting section provides a
schematic diagram and description for each TDS-9S hydraulic
circuit. Following each schematic is a group of troubleshooting
charts to help you quickly locate and correct hydraulic system
problems.
When performing hydraulic troubleshooting, be aware that:

❏ The electrical control system can be bypassed for

troubleshooting by manually overriding the solenoid valve for
each operational system.

n Alert all personnel near the top drive before overriding a

solenoid valve. When you override a solenoid valve, you bypass
the safety interlock and top drive components will move
possibly causing serious injury or death.

❏ Test points shown in the hydraulic schematic with a box (e.g.,

A4) can be found on the manifold under the main body
(Figure 4-27). There are also test points on the rotating link
adapter motor.
❏ The system is preadjusted. Hydraulic problems are usually
related to faulty valves, contamination, or other damage to
the system rather than misadjustments. Changes to
adjustments should be made only after all other possible
causes have been eliminated.
❏ Table 4-6 identifies the schematic symbols used in this service
manual section.

TDS-9S Maintenance and Troubleshooting 4-61

March 9, 1998
Index

Stand Jump Brake Clamp/

SV9 SV1 P1 Shot Pin Float
Link
IBOP SV5 SV8 Tilt
L4 PV PF * B8
SV4 SV6
A4 G5
CB

* SA

* P

* T1
C4
A6
SV2
C5
Rotating B6
Link B5
Adapter
B9 * These test ports are on sides
Z1 B1 or bottom of manifold.

(As Viewed From Below)

Figure 4-27. Hydraulic manifold test ports

4-62 TDS-9S Maintenance and Troubleshooting

 Index
Table 4-6. Hydraulic schematic symbols

Description Symbol Schematic Reference

Solenoid
Operated
2 Position 4 Way Valves (Single Solenoid) SV1, SV4, SV5, SV8, SV9
Valves
33-1

3 Position 4 Way Valves (Double Solenoid) SV2, SV6

33-2

Manual
Valve 3 Position 4 Way Valve MV
(Rotary)
33-3

Pumps
Fixed Displacement

33-4

Variable Displacement

33-5

Pressure
Relief
Valves Standard Valve RV2, A2R, B2R, SJR

33-6

Ventable Relief Valve RV1

33-7

Differential Unloading Valve UV1

33-8

Pressure
Reducing
Valve PC1, PC4

33-9

Pressure
Reducing/Relieving
PCC
Vavle
33-10

Chack CDF, CTF, CV2, CTR,

Valve CDR, CXCD
Prefill valve assembly
33-11
CV1, CV2

TDS-9S Maintenance and Troubleshooting 4-63

March 9, 1998
Index
Table 4-6. Hydraulic schematic symbols (continued)

Description Symbol Schematic Reference

Pilot-To-Open CKCB (Link Tilt)

Check 33-12
Valves

CA6, CB6, CV3, CV4

Pilot-To-Close
(Clamp Body)
33-13

1
Cavity 3
Plug PC5
2
33-14

Internal
Plug
33-15

Non Adjustable
Flow Control CV1
Valves
33-16

Non Adjustable
Orifice Diameter in inches
33-17

3 Port (Internal Drain) CBCA (Link Tilt Circuit)

Counter- 33-18
balance
Valves

4 Port (External Drain) CWCK (Link Tilt Circuit)

33-19

Standard Cartridge LA^, LB6, LC5, LODC

Logic 33-20
Cartridge

With Metering See Prefill Assembly

33-21

Quick
Disconnect
Coupling
33-22

4-64 TDS-9S Maintenance and Troubleshooting

 Index
Table 4-6. Hydraulic schematic symbols (continued)

Description Symbol Schematic Reference

Non Bypass
Filter See Lube Oil Circuit
33-23

Filter
with Bypass See Return Circuit

33-24

Manual
Shutoff
Valve
33-25

Termostat Lube Oil Circuit

33-26

Pressure
Switch Lube Oil Circuit
33-27

Heat Hydraulic Circuit

Exchanger (Inside Brake Housing)
33-28

Pressure
Compensator Part of the Pump
Control
33-29

Hydro-
Pneumatic
Accumulator 33-30

Hydraulic
Motor
(Bi-Directional)
33-31

Hydraulic
Cylinder
33-32

Tank
(Reservoir) 33-33

Test
Point
33-34

TDS-9S Maintenance and Troubleshooting 4-65

March 9, 1998
Index

Troubleshooting the AC drilling

motor brakes
The AC drilling motor brakes are spring released and hydraulic
pressure applied at 1,400 psi. The pressure reducing valve
regulates the pressure to 1,400 psi. The solenoid valve operates to
apply pressure, setting the brakes, or stop pressure to release the
brakes.

Table 4-7. Troubleshooting the AC drilling motor brakes

Symptom Probable cause Remedy

Brake does not Directional valve is stuck. Test the valve and replace if
release. necessary.
Brake releases but still Check valve is blocked or Replace the check valve or tube as
drags. tube is pinched. required.
Mechanical problems with Repair brake mechanism.
brakes.
Brakes do not engage Hydraulic oil on brake pads. Check for hydraulic leaks and repair.
or slip.
Pressure is not 1,400 psi or Reducing valve is plugged or needs
does not rise crisply to 1,400 to be adjusted or replaced.
psi.
Directional valve is stuck Replace valve or check electrical
(check pressure at B1). signal.
Delay in brakes Hydraulic oil is Replace hydraulic oil.
actuating after console contaminated.
switch is turned on.
Pressured reducing valve is Replace valve.
faulty.

Figure 4-28 shows the hydraulic circuit schematic for the AC

drilling motor brakes. To test the system, turn the auto brakes
switch on the driller’s console to the ON position. Attach a
pressure gauge to B1 in the manifold. The pressure reading
should be 1,400 psi. If the reading is not 1,400 psi, adjust the
pressure control reducing valve PC 1 to 1,400. Turn the auto
brakes switch to the OFF position. The pressure reading should
be very low. If the pressure is high, the solenoid valve might be
sticking.

4-66 TDS-9S Maintenance and Troubleshooting

 Index
Brake Calipers

2 Position
Solenoid Valve
Brakes On

Cable ID
Number A B
b
C01
P T -4

SV1 B1
.055ø
D03
Non-Adjustable
Orifice Test Point

1400 PSI

PC1 1 T-11A

Reducing
Valve
2 3

System Drain
Pressure
Tank

Figure 4-28. Hydraulic circuit for AC drilling motor brakes

TDS-9S Maintenance and Troubleshooting 4-67

March 9, 1998
Index

Troubleshooting the rotating link adapter

(rotating head) motor

Operation
The three position directional valve controls the direction of the
rotating head to the left or right. The pressure is applied to the A
or B port of the hydraulic motor, depending on the selected
direction. The auto return function is controlled by the processor
and returns the tool to the home position.

System test
The hydraulic circuit schematic for the rotating link adapter
(rotating head) is shown in Figure 4-29. To test the system,
operate the link adapter switch on the control panel. Verify both
directions of rotation. The rotation speed is limited by the
nonadjustable orifice. The torque is limited by the two relief
valves.

z The 1,600 psi test pressure at ports A and B is maximum load

pressure. If the rotating link adapter is free to rotate, the load
pressure will be less than maximum. The shot pin must be
engaged to achieve full load pressure.

4-68 TDS-9S Maintenance and Troubleshooting

 Index
Rotating Head Motor

A B

Fixed
Displacement
Motor

1 2

Pressure
T-10A 1600 PSI Relief
Valves
1600 PSI T-10A

2 1

A B

Rotate Left Rotating Head

Solenoid Rotate
Right
Cable Solenoid
ID Number Cable ID
A B Number
b a
C03 C02
Left P T Right
-6

-6

A2 SV2 B2
.055ø
D03

Non-Adjustable 3 Position
Orifice Pressure Tank Solenoid Valve

Figure 4-29. Hydraulic circuit for the rotating link adapter motor

TDS-9S Maintenance and Troubleshooting 4-69

March 9, 1998
Index
Table 4-8. Troubleshooting the rotating link adapter motor

Problem Probable cause Remedy

Tool does not rotate. Direct control valve or relief Inspect, repair or replace the
valve is sticking. valve. Look for pressure changes
when solenoid is energized. If
there is no pressure change, try
the manual overide on the valve.

n When you override a directional

valve, you bypass the safety
interlock and top drive
components move, possibly causing
serious injury or death.
Solenoid valve is not Check electrical connections and
electrically operating. valve functions.
Motor is worn out or gear Replace the motor.
teeth are broken.
Shot pin is engaged. Adjust the relief valve.
Mechanical interference. Inspect and repair.
Directional valve does not Test pressure left and right.
shift. Replace the valve.
Fixed valve orifice is Clear orifice or replace the valve.
plugged.
Hydraulic lines are Replace hydraulic lines.
damaged.
Tool does not return to Valve is sticking or relief Test pressures and inspect valves.
home position. valve is out of adjustment. Adjust the relief valve as
required.
Sensor is broken. Replace sensor.
If the motor will drive Checkout control system.
normally, but not drive to
the home position, the cause
could be the control system.
Links are not Counterbalance valves are Adjust valves together-pressure is
synchronized. out of adjustment. the same for all four valves.

4-70 TDS-9S Maintenance and Troubleshooting

 Index

Troubleshooting the IBOP actuator cylinder

Operation
The IBOP is in the open position under low hydraulic pressure,
A4 = 500 psi, B4 and C4 = less than 100 psi. When you close the
IBOP, high pressure is applied to the cylinder. A4 is less than 100
psi; B4 and C4 are 2000 psi. When the solenoid is de-energized,
for opening the IBOP, A4 goes to 500 psi after a small time delay.
B4 is less than 100 psi and C4 reaches 2000 psi after a small time
delay. The time delay is operated by the time delay accumulator.

Table 4-9. Troubleshooting the IBOP actuator cylinder

Problem Probable cause Remedy

Safety valve leaks. Internal parts worn out.
Actuator not functioning
properly.
Excessive vibration or Yoke bushings or actuator
wobble while rotating. bushings worn out.
Worn cam rollers.
Cylinder does not actuate. Pressure reducing valve
plugged orifice.
Accumulator not charged.
No system pressure.
Check for washouts or
defective parts and repair or
replace as needed.
Check mechanical operation
of actuator. Check reducing
valves.
Replace bushings.
Repair or replace rollers and
roller brackets.
Test pressures and adjust or
replace the pressure reducing
valve.
Test accumulator pressure
and charge as required.
Check hydraulic system
operation.

TDS-9S Maintenance and Troubleshooting 4-71

March 9, 1998
Index
System test
Figure 4-30 shows the hydraulic circuit schematic for the IBOP
actuator cylinder. The IBOP is normally open.

n Alert all personnel near the shot pin, clamp, and link adapter
before overriding a directional valve. When you override a
directional valve, you bypass the safety interlock and top drive
components move, possibly causing serious injury or death.

To test the system, engage the IBOP and measure the pressure at
B4 at 2,000 psi. The pressure at A4 drops to 500 psi. Open the
IBOP and test the pressure at A4, which increases to 2,000 psi.
The pressure at B4 and C4 drops to 500 psi.

4-72 TDS-9S Maintenance and Troubleshooting

 Index
IBOP Actuator Cylinder

2.500" Dia. Bore X 4.00" Stroke

1.750" Dia. Rod Test Point
Typical
Open
Close Hydraulic
Cylinder

CR

LODC 30 PSI
2 CXCD 1
1 T-13A
Logic Gas Charged
Cartridge 3 2 Accumulator
50 PSI (Small)
CP T-11A VR

Time-Delay
Accumulator
-6

-6
A4 B4 30 Cubic Inches
800 PSI Precharge
A4 B4
-6

-6

IBOP Close Solenoid

(Solenoid Valve 4) IBOP Close
Double Solenoid Valve

Cable ID
A B
Number
b
C04
P T
-6

-6
-6

A4 SV4 B4 C4
.031ø
D03

500 PSI CV4

D4
1 T-11A Flow Control
3 1 2 Valve
T-11A .010ø
2 3
PC4

System
Tank
Pressure

Figure 4-30. Hydraulic circuit for the IBOP actuator cylinder

TDS-9S Maintenance and Troubleshooting 4-73

March 9, 1998
Index

Troubleshooting the shot pin cylinder and

clamp cylinder

Operation
The shot pin cylinder and clamp cylinder operation are
interrelated and complex. The shot pin cylinder is different in
that it has an extra port called the barrel port. The barrel port is
back from the end of stroke which creates a valving effect. When
the shot pin and clamp cylinders are not activated, the shot pin is
fully retracted with full pressure and the clamp cylinder is
retracted with 500 psi.
When you energize the clamp cylinder, the shot pin cylinder is
actuated against the rotating gear and it may miss one of the 24
holes. The control system starts pulsing the link adapter to move
slowly until the shot pin engages a hole on the rotating gear. The
shot pin cylinder pressure is limited by the relief valve until the
cylinder passes through one of the holes. Once the pin engages
the hole, full system pressure is applied to C5 which opens valve
CV5, applying full pressure to the clamp cylinder to close.
When the clamp cylinder is de-energized, the clamp releases and
the shot pin pulls out.

System test
Figure 4-31 shows the hydraulic circuit schematic for the shot pin
cylinder and clamp cylinder. At rest the pressure at C5 is 2,000
psi, B5 is less than 100 psi, CP is less than 100 psi, and CR is
500 psi.

4-74 TDS-9S Maintenance and Troubleshooting

 Index
Clamp Cylinder
10.000" Dia. Bore, 8.000" Dia. Rod X 2.0" Stroke

Hydraulic
Cylinder

Cavity Plug CP CR

1 3
CKEB
T-2A
Pilot-to-Close 2
Check Valve
30 PSID
2 1
Shot-Pin Cylinder Relief CNEC
3 T-2A 1
2.000" Dia. Bore X 2.31" Stroke Valve T-5A
COFA
1.500" Dia. Rod
.047ø

2 2
Shot Pin .094ø 200 PSI 30 PSID

Cylinder 2
VP VR

2 Position 1
Solenoid 1 T-10A Non-Adjustable
Valve 5 1 2 Flow Control

-8

-8
Clamp/ Clamp
Shot Pin E5 G5

Cable ID A B
Number E5 G5
C05 -8

-8
P T
-6

-6

Pressure
A5 SV5 B5 C5 E5 G5
Reducing
.031ø
D03 Valve

.159ø .031ø T-11A 1

50 PSI .031ø
.031
3 AR5
3
1 2
LC5 2
Logic .031ø
.031 500 PSI
T-11A
Cartridge Externally-
Drained Pilot-
to-Open Valve
3 2
T-21A
4 75 PSI
CV5 1
P5
Drain 1
3
T-11A
System Pressure
PC5 2
Tank Drain

System Pressure

Tank
T1 T1 D5
Manifold Manifold

Figure 4-31. Hydraulic circuit for the shot pin cylinder and clamp cylinder

TDS-9S Maintenance and Troubleshooting 4-75

March 9, 1998
Index

n Alert all personnel near the shot pin, clamp, and link adapter
before overriding a directional valve. When you override a
directional valve, you bypass the safety interlock and top drive
components move, possibly causing serious injury or death.

When you energize solenoid valve SV5, using the manual

override, pressure increases to the barrel of the shot pin cylinder.
The pressure is controlled by a .031 pressure reducing valve that
prevents the shot pin from putting full force on the link adapter
surface until the pin engages in one of the holes.
Pressure at B5 is 200 psi (limited by the relief valve), C5 is less
than 100 psi, G5 is less than 100 psi, CP is less than 100 psi, and
CR is less than 100 psi.
Once the shot pin engages the hole, full pressure is applied in C5
to control valve CV5 open for clamp. Pressure at B5 is 2,000 psi,
C5 is 2,000 psi (forces valve CV5 open for clamp), G5 is less than
100 psi, CP is 2,000 psi, and CR is less than 100 psi.
When solenoid valve SV5 is de-energized, the shot pin cylinder
withdraws the shot pin, and the clamp disengages at the same
time. The circuit returns to rest conditions.

4-76 TDS-9S Maintenance and Troubleshooting


Table 4-10. Troubleshooting the shot pin cylinder and clamp cylinder
Problem
Shot pin does not engage.
Shot pin applies excessive
force to rotating head gear.
Clamp cylinder does not
actuate.
Shot pin engages but clamp
cylinder does not activate.
Index
Probable cause Remedy
Solenoid valve is not Check electrical actuation
operating or relief valve is not and test pressure. Adjust as
adjusted. required.
Abnormal pressure change at Replace directional control
B5 and C5 indicates valve valve.
problem.
Normal pressure change Repair plumbing or shot pin
indicates plumbing or shot cylinder.
pin cylinder are faulty.
Relief valve is not operating Test pressures and adjust as
or out of adjustment. required.
No pressure or reduced Test pressures and adjust and
pressure at the cylinder. repair as required.
Cylinder is damaged. Inspect cylinder and repair or
replace.
Note: To provide high Repair plumbing, rotating
pressure to the clamp circuit, head, or clamp cylinder.
pressure at C5 must be 2,000
psi and G5 must be less than
100 psi. If this condition is
met, pressure at CP should
increase from less than 100
psi to higher than 2,000 psi.
If not, check the plumbing,
rotating link adapter, and
clamp cylinder.
While clamping, pressure at Clean or repair CNEC valve.
CR should be 2.7 times the
pressure at CP. When the
dies contact the pipe,
pressure at CR should be less
than 100 psi. If the pressure
does not fade, check valve
CNEC for contamination.
Control valve not operating. Check pressure at C5.
Replace valve CV5 if
required or the regenerate
manifold.
TDS-9S Maintenance and Troubleshooting 4-77
March 9, 1998
Index

Troubleshooting the link tilt cylinders

Operation
Figure 4-32 shows the hydraulic circuit schematic for the link tilt
cylinders. The solenoid valve SV6 operates two cylinders with
load holding manifolds.
When the solenoid valve SV6 is actuated to the mousehole
position, full pressure is applied through E6 to the link tilt
cylinder to move the links to the mousehole position. When
solenoid valve SV6 is actuated to the drill down position, full
pressure is applied through G6 to move the cylinder to the drill
down position.
The link tilt float solenoid valve SV8 releases pressure from the
cylinder to allow the link tilt to move to the well center position.

System test
For the link tilt circuit, there is nothing to adjust on the
manifold. The four load-holding valves are adjusted in pairs, two
for the rod end and two for the piston end. Adjusting the valves
at the same time assures the link tilt operation is synchronized.

n Alert all personnel near the shot pin, clamp, and link adapter
before overriding a directional valve. When you override a
directional valve, you bypass the safety interlock and top drive
components move, possibly causing serious injury or death.

4-78 TDS-9S Maintenance and Troubleshooting

 Index
Link Tilt Cylinder
TP 4.000" Dia. Bore X 22.0" Stroke
3:1 CKCB 2.500" Dia. Rod
3 30 PSI .126ø

2 1
T-11A 1:1 1500 PSI
IP TP
3
VP .031ø
1500 PSI 2 1 CWCK
T-11A VP .075ø

4
2 30 1
T-21A PSI
1 CBCA T-11A 3
3 2
PP PP .031ø 3:1
3:1 CKCB
.159ø
FL VP FL FL VR

Mousehole
TP
3:1 CKCB Drill Down
3 30 PSI .126ø

2 1
T-11A 1:1 1500 PSI
IP TP
3
VP .031ø
1500 PSI 2 1 CWCK
T-11A VP .075ø

4
2 30 1
T-21A PSI
1 CBCA T-11A 3
3 2
PP PP .031ø 3:1
3:1 CKCB
.159ø
FL VP FL FL VR

Quick-Disconnect
Coupling, Typical
-8

-8

-8

-8

-8

-8
B8 B8 E6 E6 G6 G6

B8 E6 G6
Link Tilt
-8

-8

-8
Link Tilt Link Tilt "Drill Down" Solenoid
"Float" Solenoid (Solenoid Valve 6) "Tilt" Solenoid
Cable ID
(Solenoid Valve 8)
Link-Tilt Float
Number Link Tilt
(Solenoid Valve 6)
Cable ID
Cable ID Number
Number A B A B

C08
b
C07
b a
C06
Logic
P T Drill Down P T M'hole Cartridge
-6

-8

-8

SV8 D03 B8 E6 .031ø .031ø SV6 D03 .031ø G6

Logic
Cartridge
.031ø
LA6 T-11A .071ø
75 PSI B6
1
50 PSI 2
2 3 T-11A
4 3
CA6 1
T-21A
3 1
.071ø
.031ø 50 PSI 2
A6
LB6 2
4 3

1
Pressure CB6 75 PSI
T-21A
Tank
A8 D1

Figure 4-32. Hydraulic circuit for the link tilt

TDS-9S Maintenance and Troubleshooting 4-79

March 9, 1998
Index
Use the following procedures to test the link tilt cylinder:
1. From the drillers console, set the link tilt to the mousehole
position, which energizes the solenoid valve SV6 and drives
the link tilt cylinder to full extension.
2. The cylinder goes to full extension and the pressure at test
port TP is 2000 psi.
3. Set the system to a neutral position and observe the pressure
drop. Adjust the pressure at relief valve CBCA to approach
1,500 psi.

z This is an iterative process. Continue to set the driller’s console

control to mousehole and neutral, taking present and delayed
pressure readings.

e Turning the relief valve counterclockwise increases the pressure.

4. Both system rod and piston relief valve pressures at TP and

FL are 1,500 psi for balanced hydraulic system operation.
Adjust relief control valves CBCA and CWCK for rod and
piston pressure at 1,500 psi. The piston relief valves are set at
the pistons fully extended and the rod relief valves are set at
the pistons fully retracted.

4-80 TDS-9S Maintenance and Troubleshooting


Table 4-11. Troubleshooting the link tilt
Problem
Drill pipe elevator does
not reach mouse
hole/derrickman position.
Links drift when valve is
released.
Drill pipe elevator does
not float back to center
position.
Link tilt does not tilt.
Links do not move
together.
Index
Probable cause Remedy
Link clamp incorrectly Readjust.
adjusted.
Pressure at B8 does not decay Replace pilot to open check
to less than 100 psi. valve.
Pilot to open check valve is Replace pilot to open check
stuck open or contaminated. valve.
Faulty cylinder seal. Replace seal.
Load holding relief valves are Adjust or replace load
out of adjustment, stuck holding relief valve.
open, or contaminated.
Use manual override – if link Test solenoid and
tilts, the problem is electrical. connectors.
If links do not tilt, the Test hydraulic system.
problem is hydraulic.
Solenoid valve is not shifting. Check electrical continuity.
Load holding valves are out Adjust pressure for all four
of adjustment. valves to 1,500 psi.
TDS-9S Maintenance and Troubleshooting 4-81
March 9, 1998
Index

Troubleshooting the counterbalance system

Figure 4-33 shows the hydraulic circuit schematic for the
counterbalance system. The accumulator, with precharge pressure
of 900 psi, along with check valve CV3, maintains a hydraulic
pressure. Refer to the vendor documentation material located in
the Vendor Documentation Package, for the gas charging procedure
for the accumulator.
A three-position manually operated valve controls counterbalance
operation for rig-up, run, and shut down modes. In the rig-up
mode, system pressure is applied to XC and the prefill valve,
causing both cylinders to extend. When the cylinders extend, you
make up the mechanical connection to the bail. In the run mode,
for counterbalance operation, approximately 1,600 psi is needed
at the counterbalance cylinders to lift the TDS-9S off the hook.
The optional stand jump feature is controlled by solenoid valve
SV9. With the counterbalance in the run mode and the stand
jump switch on, additional pressure of approximately 300 psi is
applied to over the normal counterbalance pressure to lift the
TDS-9S and drill string off the hook.
In the shutdown mode, the hydraulic system bleeds down the
system accumulator and the counterbalance accumulator pressure.

Counterbalance testing
For the counterbalance operation, a lift of approximately 30,000
lb is achieved with a pressure of 1600 psi at CB. Perform the
following steps to adjust the force:
1. Set the counterbalance mode valve to the RUN mode. Set the
pressure control valve PCC to the minimum setting (fully
counterclockwise).
2. Test the pressure at port B9. There should be a 0 psi reading.
3. Test the pressure at port CB. Observe the position of the top
drive on the hook.
4. Adjust the pressure at pressure control valve PCC clockwise,
observing pressure at CB, until the top drive just lifts off the
hook. Back off the pressure 25 psi, as the top drive rests on
the hook.

4-82 TDS-9S Maintenance and Troubleshooting

 Index
Counterbalance Cylinders
4.000" Dia. Bore X 8.50" Stroke Counterbalance
2.000" Dia. Rod
Pressure Cylinders
2500 PSI
Relief
T-3A 1
Valve

-4
2
ZC CP
OR1 OR2
CP -12
.075ø .075ø Counterbalance
75 PSI 75 PSI
Accumulator
1 2 1 2 CP -12
728 Cubic Inches
T-13A T-13A 900 PSI Precharge
CV1 CV2 -12 Counterbalance
T
Accumulator
-12 Normally-Open (Large)
.010ø
T
Logic Cartridge
T -16
Metering
5 PSI
-6
90 PSI
Stand - Jump Solenoid
XC
25mm
(Solenoid Valve 9)
Prefill Valve Cable ID
.047ø
Number
Counterbalance Mode
Stand Jump
RIG-UP SHUT-DOWN
RUN 2 Position
A B A B Valve
C09
P T P T
-6

3 Position D03 MV .055ø CB SV9

Valve with XC
D03
Detent CV3
B9
75 PSI 1 Test Port B9
T-21A 4
CB
3
CDF 2 Pressure
4 PSI 1
T-10A Relief
DF 2 1 1
1600 PSI
SJR
Valve
PCC 4
T-13A 2 100 PSI
T-21A
DF 2 3
System
Accumulator
126 Cubic Inches 2 1
800 PSI Precharge System Pressure
TF CTF
T-5A
30 PSI

SA To Tank

Figure 4-33. Hydraulic circuit for the counterbalance system

TDS-9S Maintenance and Troubleshooting 4-83

March 9, 1998
Index
Stand jump testing
For the optional stand jump feature, a lift of about 33,000 lb is
achieved with a pressure of approximately 1800 psi at CB. The
additional 300 psi pressure over the normal counterbalance
pressure is provided by energizing the stand jump solenoid valve
SV9. Perform the following steps to adjust the pressure:
1. Set the counterbalance mode switch to RUN and engage the
stand jump switch. Test the pressure at port CB and B9.
Adjust relief valve SJR fully counterclockwise to the
minimum setting.
2. Slowly increase the pressure at CB by adjusting relief valve
SJR clockwise until the bail lifts off the hook with a stand of
pipe in the elevator.

z Adjust relief valve SJR slowly to allow pressure at CB to stabilize.

4-84 TDS-9S Maintenance and Troubleshooting

 Index
Table 4-12. Troubleshooting the counterbalance system

Problem Probable cause Remedy

Counterbalance does Cylinder damaged. Seal leaks.
not function.
No hydraulic pressure.
Solenoid valve SV9 is
not operating.
PCC is not operating.
Relief valve is not operating.
Precharge on accumulator
is low.
Stand jump does not Cylinder damaged. Seal leaks.
function.
No hydraulic pressure.
Solenoid valve SV9 is
not operating.
PCC is not operating.
Relief valve is not operating.
Precharge on accumulator
is low.
Inspect cylinder and repair or
replace seal.
Test pressure and adjust pressure
reducing valve.
Test electrical and hydraulic
operation. Replace or repair as
applicable.
Replace the valve.
Replace the valve.
Charge accumulator.
Inspect cylinder and repair or
replace seal.
Test pressure and adjust pressure
reducing valve.
Test electrical and hydraulic
operation. Replace or repair as
applicable.
Replace the valve.
Replace the valve.
Charge accumulator.

TDS-9S Maintenance and Troubleshooting 4-85

March 9, 1998
Index

Troubleshooting the hydraulic power unit

and reservoir

Operation
Figure 4-34 shows the onboard hydraulic power unit schematic. A
10 HP electric motor drives the variable displacement pump and
the fixed displacement pump. A pressure compensator controls
the variable displacement pump.
The fixed displacement pump provides hydraulic power to
operate the lubrication pump motor. Pressure can be tested at
port PF. Relief valve RV2 limits the driving pressure of the lube
oil circuit.
The variable displacement pump provides hydraulic power to the
counterbalance cylinders, drilling motor brakes, rotating link tilt
motor, IBOP actuator cylinder, shot pin cylinder, and link tilt
cylinders.

System test
Test the circuit pressure at port PV. Relief valves RV1 and UV1
are a part of the circuit. UV1 is a differential unloading valve,
which can be pressure checked at port Z1.
RV2 is set at 400 psi and can be tested at PF. Test the pressure at
PV to confirm the relief valve RV1 is set at 800 psi. The
differential unloading valve UV1 is tested at Z1 to confirm the
pressure is 2,000 psi.

4-86 TDS-9S Maintenance and Troubleshooting

 Index

System
Pressure
Pressure
800 PSIG Compensator
Control

1.00 In^ 3/Rev. Filter

L
(Strainer)
M 1.10 In^ 3/Rev. Max.
.50 In^ 3/Rev. Min.
10 HP
1800 RPM

L1
S

Variable Fixed
Displacement Displacement
Pump Pump
Manual Filter with
Shut-Off Bypass Valve
Valves
6

50 PSID

Prefill Valve

-12
T

T -16

-6
XC

Figure 4-34. Hydraulic circuit for the hydraulic power unit and reservoir

TDS-9S Maintenance and Troubleshooting 4-87

March 9, 1998
Table 4-13. Troubleshooting the hydraulic power unit and reservoir
Problem Probable cause
Hydraulic system Relief valves out of
overheating. adjustment.
Unloading valve is not
working.
Counterbalance mode
valve left in shut down
position too long and
pressure bleeds down.
No precharge in system
accumulator.
Hydraulic components System pressure is down.
do not operate.
Piston pump is not working. Replace the pump.
Flexible coupling is
damaged.
Lubrication pump is not
working.
Pressure at UV1 is too low.
Pumps are rotating in the
wrong direction.
Suction valve closed.
Low oil level in reservoir.
4-88 TDS-9S Maintenance and Troubleshooting
Index
Remedy
Test pressures and adjust relief
valves.
Test and adjust UV1 or replace
unloading valve.
Check system pressure.
Charge system accumulator.
Test pumps and motors. Test
relief valve pressures. Adjust as
required. Check for leaks, loose
fittings, loose cylinders, worn
hoses, fluid levels and seals.
Replace the flexible coupling.
Replace the lubrication pump.
Adjust pressure at UV1.
Inspect hydraulic connections
and correct rotation.
Open suction valve.
Fill hydraulic reservoir.
 Index

Troubleshooting the gearbox lubrication

hydraulic system

Operation
Figure 4-35 shows the gearbox lubrication hydraulic system
schematic. Hydraulic power drives the lubrication pump motor
which drives a fixed displacement lube pump inside the gearbox
housing. Test the hydraulic pressure to the lube pump motor at
port PF. The pressure should not exceed 400 psi, and is limited by
relief valve RV2. A heat exchanger lowers the temperature of the
hydraulic fluid after it flows through the lube pump motor.

System test
The lube pump delivers lube oil to the transmission gears and
bearings. Lube oil pressure can be tested at port L4. Oil pressure is
normally between 80 and 100 psi.

TDS-9S Maintenance and Troubleshooting 4-89

March 9, 1998
Index
Pressure
Switch

S05 30 PSI
Decreasing
Spray
Nozzles (4) Orifices (6)
L4
1.0 1.5
.205ø .059ø .047ø
System
GPM GPM
Ea. Ea. Pressure
.071ø .059ø .047ø -16 -16
Upper Lower L4 L3
Compound Compound
Gear Gear
Upper Mainshaft Bearing
Lower Radial/Main Thrust Bearings
Upper Compound Bearing
Lower Compound Bearing -16
L2
60µm
Lube Pump 5.10 In.^ 3/Rev.

L1 -16
Lube-Oil Pump
Lube-Oil
75 PSID
-10 Filter
A B

3.0 In.^ 3/Rev.

-10 Lube Pump Motor

Hydraulic
Hydraulic Motor
Heat Exchanger

Figure 4-35. Hydraulic circuit for the gearbox lubrication system

4-90 TDS-9S Maintenance and Troubleshooting

 Index
Table 4-14. Troubleshooting the gearbox lubrication and hydraulic system

Problem Probable cause Remedy

Oil leaking from lower seal. Worn oil seals.
Oil leaking from upper Worn oil seals.
bearing retainer.
Gearbox oil temperature Oil level too low or too high. Adjust oil level to middle of
(less than 230˚F).
Incorrect lubricant used.
Damaged gears or bearings. Repair or replace as needed.
Oil pump loss alarm is on. Oil level is too low.
Oil overheated.
Gear spray nozzle missing.
Excessive oil viscosity.
Faulty motor. Intermittent
operation.
Oil pump hydraulic motor
failure.
Broken lube pump adapter
plate spline.
Faulty fixed displacement
pump.
Low hydraulic fluid in
reservoir.
Suction valve closed on fixed Open suction valve.
displacement pump.
Water/mud in oil. Missing inspection plugs.
Upper gearbox seals worn.
Excessive foaming. Water in oil.
Excessively viscous oil.
Cold oil.
Metal in oil. Worn gears or damaged
bearings.
Damaged oil pump.
Restricted oil flow. Foreign particles blocking
orifice or nozzle.
Replace seals.
Replace seals.
sight glass.
Check recommended
lubricants chart and replace
as needed.
Add oil.
Replace spray nozzel.
Lower oil viscosity.
Replace motor.
Replace motor.
Replace adapter plate spline.
Check pressure at PF.
Replace pump if pressure is
low.
Add hydraulic fluid.
Replace inspection plugs.
Replace seals.
Replace oil.
Lower oil viscosity.
Replace gears or bearings.
Replace oil pump.
Clean orifice or nozzle.

TDS-9S Maintenance and Troubleshooting 4-91