DQ225DBZ Direct Driving Top Drive

Maintenance Manual

Contents
1 Safety cautions..................................................................................................................1
2 Periodic maintenance........................................................................................................2
2.1 Daily maintenance positions...................................................................................2
2.2 Weekly maintenance positions................................................................................3
2.3 Monthly maintenance positions..............................................................................4
2.4 Seasonal maintenance positions..............................................................................5
2.5 Semi-annual maintenance positions........................................................................5
2.6 Annual maintenance................................................................................................5
3 Lubrication........................................................................................................................6
3.1 Lubrication of pulley bearing wheel.......................................................................6
3.2 Lubrication of pulley guiding wheel.......................................................................6
3.3 Lubrication of washpipe assembly.........................................................................7
3.4 Lubrication of upper gland seal..............................................................................7
3.5 Lubrication of bail pin............................................................................................7
3.6 Pin of tilting oil cylinder.........................................................................................8
3.7 Lubrication of backup tong.....................................................................................8
3.8 Lubrication of remote control IBOP control mechanism.......................................9
3.9 Lubrication of remote control IBOP.......................................................................9
4 Check and maintenance of mechanical system...............................................................10
4.1 Main motor and air cooling motor........................................................................10
4.2 Brake device.........................................................................................................10

DQ225DBZ Direct Driving Top Drive

Maintenance Manual

4.3 Bail and bail pin....................................................................................................11

4.4 Gooseneck.............................................................................................................12
4.5 Washpipe assembly...............................................................................................13
4.6 Pipe handler..........................................................................................................14
4.7 Power rotating head..............................................................................................15
4.8 Elevator link..........................................................................................................16
4.9 Tilting mechanism.................................................................................................16
4.10 Remote control IBOP control mechanism..........................................................17
4.11 IBOP...................................................................................................................18
4.12 Thread locking device of BOP............................................................................19
4.13 Backup tong........................................................................................................20
4.14 Folding single guide rail.....................................................................................20
4.15 Guide pulley........................................................................................................21
5 Maintenance of hydraulic system...................................................................................22
5.1 Basic requirements................................................................................................22
5.2 Maintenance requirements of hydraulic source....................................................23
5.2.1 Daily check items........................................................................................23
5.2.2 Periodic spot check (once three months)....................................................23
5.2.3 General spot check (once a year)................................................................23
5.2.4 Precautions in maintenance of hydraulic source and system......................24
5.3 Maintenance of accumulator.................................................................................24
5.3.1 Check of nitrogen pressure.........................................................................24
5.3.2 Charging of nitrogen...................................................................................25
5.4 Maintenance of hydraulic pipe.............................................................................25

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Maintenance Manual

5.5 Maintenance of brake device................................................................................26

5.5.1 Check..........................................................................................................26
5.5.2 Air discharge of brake oil line.....................................................................26
5.5.3 Replacement of brake friction plate............................................................26
6 Trouble diagnosis and troubleshooting...........................................................................28
6.1 Common trouble diagnosis and troubleshooting of hydraulic elements...............28
6.1.1 Common trouble diagnosis and troubleshooting of plunger pump.............28
6.1.2 Common trouble diagnosis and troubleshooting of plunger pump.............29
6.1.3 Common trouble diagnosis and troubleshooting of pressure regulating
valve.....................................................................................................................30
6.1.4 Common trouble diagnosis and troubleshooting of check valve................31
6.1.5 Common trouble diagnosis and troubleshooting of accumulator...............31
6.1.6 Common trouble diagnosis and troubleshooting of explosion-proof
electromagnetic reversing valve..........................................................................32
6.2 Troubles for hydraulic source...............................................................................32
6.3 Troubles for hydraulic valve set............................................................................33
6.4 Troubles for IBOP hydraulic actuating mechanism..............................................34
6.5 Troubles for elevator link swinging mechanism...................................................34
6.6 Troubles for revolving head..................................................................................34
6.7 Troubles of backup tong system...........................................................................35
6.8 Troubles for balancing system..............................................................................36
6.9 Troubles of disk brake...........................................................................................36
Appendix I: Graphical symbol description of hydraulic system.......................................38
Appendix II: Lubrication and maintenance schematic diagram for DQ225DBZ direct

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DQ225DBZ Direct Driving Top Drive

Maintenance Manual

driving top drive.................................................................................................................39

IV


DQ225DBZ Direct Driving Top Drive

Maintenance Manual

1 Safety cautions
Before maintenance, carry out safety education and guidance to all workers engaged in
maintenance.
During maintenance, if original maintenance schedule is changed, revise safety
operation regulations, educate and guide all workers again, and ensure all workers know the
change of the maintenance schedule so as to guarantee the safety of workers.
Warning

a. Before maintenance (such as lubrication, check and replacement etc),

cut off main power supply.

b. Repair and maintenance are forbidden during the running of
equipment.
c. During repair and maintenance, wear protecting appliances such as
protecting glasses and gloves etc.
d. As workers are required to perform overhead work possibly for the
maintenance of top drive, pay attention to the risks of personal injury and object fall.
e. As overflowing high-pressure hydraulic oil may penetrate through skin,
use wooden plate or hard plate in checking of leakage.
f. During discharge of hydraulic oil, be careful as high-temperature
hydraulic oil can cause scald.
g. Before the repair of hydraulic system, release pressure in accumulator.
h. Do not maintain the parts that you do not know in system.
i. Before repair, read and know safety cautions and warnings.

2 Periodic maintenance
2.1 Daily maintenance positions

DQ225DBZ Direct Driving Top Drive

Maintenance Manual

Lubricating positions
Lubricating

No.

Positions

Washpipe assembly

2
3

points
1

Roller of remote control IBOP control

mechanism
Backup tong alignment wheel

Lubricant
Lubricating
grease
Lubricating
grease
Lubricating
grease

Fill lubricating grease at marked lubricating positions.

Check positions
No.

Positions

Main motor assembly

Washpipe assembly

Remote control IBOP

Manual IBOP

Pipe handler

Backup tong

7
8
9
10
11
12

Guide rail and trolley

Measures
Repair or

etc

replace
Repair or

Wear and leakage

Reliable operation and adequate

replace
Repair or

lubrication
Reliable operation and adequate

replace
Repair or

lubrication
Bolt, safety locking wire, split pin

replace
Repair or

etc

replace
Adjust or

Locking and tong die wear condition

Connecting pin, split pin and round
nut etc of guide rail

All fasteners of top

Looseness condition

drive
Hydraulic system

Contents
Bolt, safety locking wire, split pin

Liquid level, pressure, oil

Pipes of hydraulic

temperature and cleanness etc

System leakage, surface condition of

system

pipes and cables, hose joint etc

Oil cylinder joint

Looseness condition

Cables

replace
Replace
Refasten
Add or replace
Repair or
replace
Adjust or

Wear, fracture, joint looseness and

replace
Repair or

damage etc

replace

2.2 Weekly maintenance positions

DQ225DBZ Direct Driving Top Drive

Maintenance Manual

Lubricating positions
No.

Positions

Lubricating points

Bail pin

Upper gland seal

Power rotating head

Oil cylinder pin of tilting mechanism

Pulley bearing wheel assembly

16

Pulley guiding wheel assembly

Lubricant
Lubricating
grease
Lubricating
grease
Lubricating
grease
Lubricating
grease
Lubricating
grease
Lubricating
grease

Fill lubricating grease at marked lubricating positions.

Check positions
No.
1

Positions
Air outlet of main motor

Contents
Damage condition of shutter

Cable of main motor

Damage condition

Fan assembly

Floating brake

IBOP

Roller of remote control

7
8

IBOP control mechanism

Guide sheave
Guide rail

Pulley

10
11

Reverse torque beam

assembly
Fixed beam assembly

Measures
Replace
Repair or

Looseness or loss of bolt, wind

replace
Adjust or

pressure, radiator at air inlet

Wear condition of brake pad
Wrenching torque, sealing and

replace
Replace
Repair or

wear condition

replace
Repair or

Wear condition
Damage and wear conditions
Crack condition of weld joint
Wear condition of bearing wheel
and guide wheel
Looseness or loss of fastener
Looseness or loss of fastener

2.3 Monthly maintenance positions

Check positions

replace
Replace
Repair welding
Replace
Adjust or
replace
Adjust or
replace

DQ225DBZ Direct Driving Top Drive

No.

Positions

Upper main shaft liner

Maintenance Manual
Contents
Corrosion generated due to
washpipe leakage

Measures
Replace

Hydraulic cylinder pin of

2

3
4

elevator link tilting

mechanism
Hydraulic cylinder pin of
counterbalance system
Crown block padeye and

Wear

Replace

Wear

Replace

Damage or crack at weld

guide rail connecting padeye

Loss of split pin

Wear of pin
Wear of shackle and bolt
Wear of hanger plate hole

Hanging plate assembly

Repair
welding
Replace
Replace
Replace
Repair or
replace

Perform after the drilling time is 250h accumulatively.

2.4 Seasonal maintenance positions
Check positions
No.
1

Positions
Hydraulic oil of hydraulic

Contents

Oil sample analysis

system
2
Filter
Blockage
Perform after the drilling time is 750h accumulatively.

Measures
Replace
Replace

2.5 Semi-annual maintenance positions

Check positions
No.
1
2

Positions
Bail and bail pin
Main shaft

Contents
Damage
Offset

Accumulator

Nitrogen pressure

Perform after the drilling time is 1500h accumulatively.

2.6 Annual maintenance

Years

Maintenance contents
4

Measures
Replace
Adjust
Replace air bag or
accumulator

DQ225DBZ Direct Driving Top Drive

1 year

Flaw detection of main bearers (such as guide rail, trolley, bail and bail pins
etc)
Lubricating grease replacement of main motor
Equipment repair
Equipment overhaul

2 years
3 years
4 years

Notice

Maintenance Manual

All positions needing maintenance must be checked and maintained in

time as per the field practical condition of the top drive.

3 Lubrication
3.1 Lubrication of pulley bearing wheel
Positions:
8 positions on two sides of pulley
respectively (16 positions in total).
Method:
Fill lubricating grease.

3.2 Lubrication of pulley guiding wheel

Positions:
2 positions at upper and lower sides of pulley
respectively (4 positions in total).
Method:
Fill lubricating grease.
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Maintenance Manual

3.3 Lubrication of washpipe assembly

Position:
1 position on side surface of washpipe.
Method:
Fill lubricating grease.

3.4 Lubrication of upper gland seal

Position:
1 position at lower side of washpipe
assembly.
Method:
Fill lubricating grease.

3.5 Lubrication of bail pin

Positions:
1 position on two bail pin
respectively (2 positions in total).
Method:
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Maintenance Manual

Fill lubricating grease.

3.6 Pin of tilting oil cylinder

Positions:
2 positions on left and right tilting oil cylinder
positions) in total.
Method:
Fill lubricating grease.

3.7 Lubrication of backup tong

Positions:
In clamping frame, guide wheel (4
positions)
Method:
Coat butter before assembly

(4

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Maintenance Manual

3.8 Lubrication of remote control IBOP control mechanism

Positions:
1 position on rollers on left and right sides
positions in total).
Method:
Fill lubricating grease.

3.9 Lubrication of remote control IBOP

Position:
Below control handle of remote control
IBOP.
Method:
Move sliding sleeve of remote control
IBOP control device to expose lubricating
hole. Disassemble conical plug, assemble
grease nozzle, and fill lubricating grease.
Disassemble grease nozzle after filling of
lubricating

grease

is

completed,

and

assemble conical plug.

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Maintenance Manual

4 Check and maintenance of mechanical system

4.1 Main motor and air cooling motor
Check:
1. Looseness or loss of bolt and locking
steel wire.
2. damage to outlet end of motor cable.
3. Damage to shutter at air outlet of motor.
4. Annual detection of insulation resistance.
4. Normality of wind pressure of fan and
radiator at air inlet.
Maintenance:
1. Keep air intake of fan dry and prevent
rainwater from entering.
2. Insulation resistance of motor shall be
more than 1M , bake motor when the
insulation resistance is less than 0.8 M , and
then start motor.
3. As heater has an automatic heating function, close the heater circuit when the heater is
not used for a long time.
4.2 Brake device
Check:
1. Leakage of brake hydraulic pipe.
2. Wear of brake friction block.
Maintenance:
1. Air exhaust
Apply pressure to oil line of brake
device, open air bleeder carefully, and
close the air bleeder after the air is
exhausted completely. Repeat above
process on brake oil cylinder until air
is exhausted completely.
2. Replacement of friction block
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Maintenance Manual

When the thickness of brake friction block is less than 4mm, replace friction block.
During replacement of friction block, release pressure of brake oil line, and then
open brake guard, withdraw friction block, replace with new friction block, and
finally install the brake guard.
Note

Friction block loses braking capacity after being polluted by oil or

grease. Replace friction block which absorbs excessive grease.
Replaced new friction block can reach rated torque after a period time

of running-in.
Notice

Keep friction block clean and does not attach oil or grease at ordinary

time.
3. Replacement of brake disk
When the thickness of brake disk is less than 10mm, replace the brake disk in time.
4.3 Bail and bail pin
Check:
1. Wear of bail and bail pin.
2. Adequate lubrication of bail pin.
3. Looseness of baffle and screw of bail pin.
Maintenance:
1. Fill lubricating grease in lubricating grease
nozzle in bail pin periodically.
2. Periodically check wear conditions of bail and
bail pin, and decrease bearing weight when
wearing capacity is more than 2mm. Replace
when the wearing capacity exceeds 4mm.

4.4 Gooseneck
Check:
1. Periodically check the wear and
corrosion of gooseneck.

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Maintenance Manual

2. Periodically check fixing bolt and

locking steel wire of gooseneck.
3. Periodically carry out bulge test on
gooseneck.
Maintenance:
1.

In

movement

and

check

of

gooseneck, disassemble bolt for fixing

gooseneck and bolt for fixing clamp.
2. Clean inner hole of gooseneck,
visually inspect depression, wear
and corrosion, and carry out flaw
detection if any.
3. Coat thread grease at threads
before reinstallation.

4.5 Washpipe assembly

Check:
Leakage of washpipe.
Maintenance:
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Maintenance Manual

1. Assembly
1) Put upper end of lower packing box downwards, install lower sealing pressure
sleeve, packing, distance ring and lower bushing ring in lower packing box, align
upper and lower distance ring grooves during installation, and install flat holding
screw and lubricating grease oil cup.
2) Manually coat all seals with universal lithium base or high-temperature
molybdenum base lubricating grease, and prevent lubricating grease from being in
contact with external surface of distance ring.
3) Install mud pipe in lower packing box assembly (grooved end is upward), and
make tail end of washpipe be flush with lower packing box.
4) Install lower packing box gland and upper packing box gland on washpipe.
5) Install packing and bushing ring in upper packing box.
6) Manually coat all seals with universal lithium base or high-temperature
molybdenum base lubricating grease, and prevent lubricating grease from being in
contact with external surface of distance ring.
7) Install upper sealing pressure sleeve, packing and upper bushing ring in grooved
end of mud pipe.
8) Install spring ring.
9) Install upper O-ring and lower O-ring and keep them at proper positions with
lubricating grease.
2 Installation
2) Coat thread oil at threads, install washpipe assembly on top drive, manually
tighten upper and lower packing box glands.
2) Manually rotate main shaft for 1-2 turns, and centralize packing box of mud pipe.
3) Start brake of top drive.
4) Hammer each flange until the packing box is tightened.
5) Release brake, rotate main shaft, and hammer each flange (release brake for each
hammering) until packing box does not rotate.
6) Slightly hammer flange to tighten packing box gland. Mud leakage cannot be
caused by hammering.
7) Fill universal lithium base or high-temperature molybdenum base lubricating
grease at grease nozzle.
8) Do not open mud pump, rotate main shaft of top drive at rotation speed of about
50r/min for 1 minute, and then open mud pump and check leakage. If leakage
occurs, disassemble, check and repeat the assembly and the installation of washpipe
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Maintenance Manual

assembly.
4.6 Pipe handler
Check:
1. Check the rotation flexibility of rotating head.
2. Check the conformity of forward tilting
angle and backward tilting angle of elevator link
with requirement.
3. Check the oil leakage of oil line of tilting oil
cylinder.
4. Check the movement flexibility of tong jaw
block.
Maintenance:
1. Periodically fill lubricating grease in 2
grease nozzle of rotating head.
2. Periodically fill lubricating grease in grease
nozzles (4 positions) of left and right tilting oil
cylinders.
3. Periodically fill lubricating grease in guide
wheel and clamping frame of backup tong.
4. Visually inspect depression or wear of
elevator link, and if any, carry out flaw detection
with ultrasonic wave. Replace elevator link if
necessary.
5. Visually inspect wear condition of tong dies,
and replace with new tong dies if wear is
excessive.

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Maintenance Manual

4.7 Power rotating head

Check:
Adequate lubrication of motor drive gear of
rotating head.
Maintenance:
When 11 rotary seals of rotating head need
replaced, assemble new rotary seals with
specially made assembly tool and guide sleeve.

4.8 Elevator link

Check:
1. Lubrication and wear of elevator link
hole.
2. Position of elevator link clamp.
3. Tightness of U-shaped screw bolt of
elevator link clamp.
Maintenance:
1. Periodically lubricate elevator link
hole.
2. Disassembly and installation
1) Take down elevator from lower end of elevator link.
2) Take down locking screw rod from elevator link clamp.
3) Take down locking rods at lifting lugs on two sides of
rotating head.
4) Lift elevator link away from pipe handler with crane.
5) Repeat above steps to take down the other elevator link.
6) Install elevator links as per steps reverse to above steps.
4.9 Tilting mechanism
Check:
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DQ225DBZ Direct Driving Top Drive

Maintenance Manual

1. Lubrication and wear of pin of elevator tilting oil cylinder.

2. Oil leakage of oil line of tilting oil cylinder.
Maintenance:
1. Periodically fill lubricating grease in all grease nozzles.
2. If oil line of tilting oil cylinder leaks oil, repair
or replace hydraulic component and oil pipe in
time.
3. Disassembly and installation
1) Turn off power supply, release pressure of hydraulic system, and close master
valve of hydraulic system.
2) Disassemble hydraulic pipes on tilting oil cylinder, and cover all joints with
protecting covers.
3) Take down pin of tilting oil cylinder, and disassemble tilting oil cylinder.
4) Install tilting mechanism as per steps reverse to above steps.
4.10 Remote control IBOP control mechanism
Check:
1. Looseness of bolt and screw, and loss or damage of locking steel wire and oil cup.
2. Leakage of remote IBOP oil cylinder.
3. Rotation flexibility of crank.
4. Lubrication and wear of driving device oil cylinder.
Maintenance:
Periodically lubricate crank, driving device oil cylinder and roller.
Warning

The flexible action of remote control IBOP is the premise for safe drilling,

and check the remote control IBOP every day.

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Maintenance Manual

4.11 IBOP
Check:
1. Check the adequate lubrication of positions
needing lubrication.
2. Check leakage.
3. Check the wear condition of IBOP.
The weekly check of the wear condition
Notice

of the IBOP is very import and must be

executed strictly.

Maintenance:
Ensure the reliable sealing of two IBOPs (a

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DQ225DBZ Direct Driving Top Drive

Maintenance Manual

manual IBOP and a remote control IBOP). When test

pressure reaches 35MPa, the operation of the BOP
must be reliable absolutely, and ensure the complete
opening or closing of the BOP.
Groove and shoulder exist in valve body of BOP,
valve body easily has wear and endurance crack due to
the repeated use of BOP and the erosion of solid
particles in mud. The stress is increased sharply due to
the defects in valve body. Carry out magnetic powder
inspection on external surface of valve body of BOP
annually or the drilling time is 3000h accumulatively
so as to check its damage and crack condition, and
replace the valve body as per its wear extent.

4.12 Thread locking device of BOP

Check:
Check the looseness of bolt and locking
steel wire. Immediately replace bolt loosening.
Maintenance:
1. Disassembly
1) Disassemble locking steel wire of
thread locking device, and disassemble
all locking bolts.
2) Remove iron rust and dirt on thread
locking device, and then take down
lower flange, taper sleeve and upper
flange.
Gradually loosen all bolts in bolt disassembly, unscrew each bolt for 1/4
Notice

turn, avoid deflection and blockage of flange, and then gradually loosen
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Maintenance Manual

the bolts uniformly.

Notice

Replaced locking bolts cannot be used again.

2. Installation
1) Coat molybdenum disulfide lubricating grease on
thread surface of locking bolt and internal surface of
taper sleeve.
2) Clean surfaces of main shaft, IBOP and protecting
joint, and remove grease and dirt on surfaces.
3) Install thread locking device as per the sequence of
upper flange, upper taper sleeve, lower taper sleeve and
lower flange, and complete the installation of the thread
locking devices of main shaft, BOP and protecting joint.
Notice

After the thread locking device is placed properly,

screw up locking bolt and install locking steel wire.

4.13 Backup tong

Check:
Frequently check fastener on backup tong for looseness or
damage, replace the fastener which loosens or is damaged in
time, and prevent fastener from loosening or falling.
Maintenance:
1. Ensure adequate lubrication in clamping frame and of
guide wheel (4 positions in total) of backup tong.
2. Before normal drilling, remove grease and dirt of tooth
groove and surface of tong die plate in time.
3. When tong dies are worn excessively or cannot clamp
drill pipe any more, replace with new tong dies.
4. Steps of replacing tong dies
1) Disassemble connecting bolt between guide
centralizing

device

and

clamping

device,

and

disassemble guide centralizing device.

2) Disassemble connecting pins between tong jaw
bodies, and disassemble the tong jaw bodies from
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Maintenance Manual

lower tong body.

3) Take out worn tong dies from tong jaw bodies and
replace with new tong dies.
4) Install clamping device and guide centralizing
device as per the steps reverse to above steps.
4.14 Folding single guide rail
Check:
1. Check guide rail connecting pin and spit pin.
2. Check crown block padeye, hanger plate and guide rail connecting padeye for weld
crack.
3. Check mounting bolt of reverse torque beam of guide rail for looseness.
4. Check mounting bolt of guide rail fixing beam for looseness.
Maintenance:
1. Replace guide rail connecting pin and split pin as per wear condition.
2. If check crown block padeye, hanger plate and guide rail connecting padeye have weld
cracks, carry out repair welding in time.
3. If the mounting bolt of reverse torque beam and fixing beam of guide rail loosen,
readjust and fix the installation positions of the reverse torque beam and the fixing beam,
and screw up mounting bolts.

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DQ225DBZ Direct Driving Top Drive

In

Maintenance Manual

the

drawing, =Hanger plate assembly

4.15 Guide pulley
Check:
1. Check locking nuts of bearing wheel and guide wheel for looseness.
2. Check external surfaces of bearing wheel and guide wheel for wear condition.
Maintenance:
1) Periodically fill lubricating grease at grease nozzles of bearing wheel shaft and guide
wheel shaft.
2. Replacement of roller (bearing wheel or guide wheel)
1) Lower top drive device onto drill floor.
2) Disassemble connecting bolts between pulley plate and gear box of top drive, and
disassemble left or right pulley plate.
2) Disassemble locking nuts, take down wheel shaft and roller, and replace with new
roller.
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DQ225DBZ Direct Driving Top Drive

Maintenance Manual

4) Install the left or right pulley plate on gear box as per the steps reverse to above
steps, and embed guide plate on guide rail between two rows of bearing wheels
during installation.

5 Maintenance of hydraulic system

5.1 Basic requirements
1) Liquid level in oil tank cannot be lower than 100mm, and the oil temperature cannot be
higher than 70.
2) Check filtering plug device of filter for blockage, and clean or replace filter element if
blockage occurs.
3) Hydraulic oil must be clean and shall be replaced after being used for 3-6 months.
4) Before pump startup, open valve at oil suction port, and connect pipe at oil outlet with
system.
5) Pipe connection must be reliable.
6) Disconnect electric control part, and hanging warning board.
7) Slowly release all system pressure by using load release valve in system, and make sure
no pressure in pipe.
8) Before pipe disassembly, mark all connection positions so as to ensure correct
reconnection.
9) Take effective measures to prevent hydraulic oil from leaking and entering other
electric or mechanical components.
Before disassembly of hydraulic pipe, close valves in system, prepare
Note

proper containers, oil plugs, cotton silks etc, and prevent residual
hydraulic fluid in pipe from flowing out to pollute equipment and
environment around when the pipe is opened.

Notic
e

The temperature of hydraulic equipment and hydraulic oil may be

quite high, and the approachable temperature can be reached after a
period of time of cooling.

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5.2 Maintenance requirements of hydraulic source

5.2.1 Daily check items
Check the hydraulic source daily, and the check items comprise:
1) Check liquid level meters of oil tank, and the liquid level cannot be lower than the
central line of the lower liquid level meter.
2) Observe hydraulic liquid temperature which cannot be higher than 70.
3) Whether the valve locations of cut-off valve and ball valve are proper or not.
4) Obverse cleanness indication of filter and judge the blockage condition of filter.
5) Whether working pumps have abnormal vibration, noise and heating or not.
6) Visually check leakage condition of pipes of hydraulic system.
Visually check the surface condition of hydraulic pipes and cables.
5.2.2 Periodic spot check (once three months)
1) Sample and assay oil liquid in oil tank, and determine the cleanness grade of oil liquid.
2) Verify pressure gauge to avoid incorrect measurement.
3) Tighten motor bolts.
4) Check the air pressure of accumulator.
5) Check the heat exchange capacity of air cooler, and inlet oil temperature is higher than
outlet oil temperature.
6) Check and clean air filter.
Check hose joint for air bubbles.
5.2.3 General spot check (once a year)
1) Sample and assay oil liquid, partially or completely replace with new oil if necessary,
and circularly clean pipe for 24h.
2) Readjust system.
3) Replace relative elements and parts as per circumstances.
4) Check electric wiring, signaling and interlocking functions.
5) Check sealing of hydraulic cylinder, and replace ineffective sealing ring.
Sample and assay oil liquid in oil tank, and determine the cleanness grade of oil
liquid.
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5.2.4 Precautions in maintenance of hydraulic source and system

1) When HPU goes wrong, analyze and judge faulted positions and reasons.
2)

When faulted element on hydraulic system is disassembled, first judge the medium

connection between the faulted element and high-pressure oil line, judge whether the
element to be disassembled has pressure before disassembly, and if the element has pressure,
try to release pressure, and then disassemble faulted element.
3) When faulted element is repaired, plug exposed oil port outside hydraulic system with
special part or clear object to prevent impurities from entering hydraulic system.
When element is worn or aged seriously, replace in time to ensure the working
performance and reliability of hydraulic system.
5.3 Maintenance of accumulator
Accumulator of balancing oil cylinder is a nitrogen-precharged pressure container, the
nitrogen leaks to influence usage performance as the piston is worn after the accumulator is
used for a long time. Therefore, periodically check the pressure of precharged nitrogen,
supplement nitrogen if necessary, or replace and reinstall seals.
5.3.1 Check of nitrogen pressure
Check period: check every month or check for each well, and take the shortest period.
1) Check of air leakage
a) Check charging pressure with charging tool. As air is released a little for the check
each time, the method is not suitable for the accumulator with small capacity.
b) Install pressure gauge near oil port of accumulator, fill oil liquid in accumulator fully
with pump, stop the pump, and flow the pressure oil slowly from accumulator through valve
connected with the accumulator. In the oil discharge process, observe charging pressure
gauge, the pointer of pressure gauge descends slowly, close the lift valve of accumulator
when the charging pressure valve of the accumulator reaches, and the pointer of the
pressure gauge reaches zero quickly. The read value on the pressure gauge before the
pressure gauge descends quickly is the charging pressure of the accumulator.
2) When the device is not used for a long time, close cut-off valve between oil port and
pressure oil pipe, and keep the oil pressure in accumulator above charging pressure.
3) If accumulator does not play a role in the device, please check the reason of air leakage
of the air valve, and supplement nitrogen if necessary. If no nitrogen is the air cavity of the
accumulator, oil pours from the air valve, please disassemble and check the piston for
23

DQ225DBZ Direct Driving Top Drive

Maintenance Manual

damage. If Oil leaks outside the accumulator, please screw up connection part. If oil leakage
occurs still, please disassemble and replace relevant parts.
4) In disassembly, discharge pressure oil, release nitrogen in air cavity with charging tool,
and then disassemble all parts.
5) As per the characteristics of accumulator, assemble the oil inlet valve in the following
way of first putting oil inlet valve, rubber support and supporting ring in shell, installing
rubber support and supporting ring on the valve in the shell in sequence, and then pull outlet
end of valve out of large opening of shell, finally assemble in sequence.
6) Supporting ring is designed so that it can be put in the shell, cut off two sides of the
supporting ring. In assembly and disassembly, flatwise put the cut position of the supporting
ring, and align it with large opening of shell for assembly and disassembly.
5.3.2 Charging of nitrogen
Notic
e

Charge inert gases such as nitrogen etc only.

The charging tool is provided along with the top drive, and the safety connection
between the air valve and the nitrogen source shall be ensured. Ensure whether the nitrogen
source is closed before charging, and then connect charging pipe on nitrogen bottle.
5.4 Maintenance of hydraulic pipe
Visually check hose and joint, stop and replace hose assembly when any one of the
following conditions appears:
1) Joint slides on hose.
2) Outer coating is damaged, scratched or corroded.
3) Hose hardens, thermally cracks or carbonizes.
4) Joint is broken, damaged or seriously corroded.
5) Joint or hose leaks.
6) Hose is bent and pressed flatly or twisted.
Outer coating is foamed, softened, corroded or delaminated.
5.5 Maintenance of brake device
5.5.1 Check
1) Wear degree of brake friction block.
2) Symmetrical wear of brake friction block.
24

DQ225DBZ Direct Driving Top Drive

Maintenance Manual

3) Leakage of hydraulic brake pipe.

Notic
e

It is forbidden to check the leakage of hydraulic pipe with bare hands.

It is difficult for naked eyes to discover the high pressure oil leaking
from small hole, and the high pressure oil possibly seeps into skin to
cause serious damage, please check with wooden chip or card.
Keep friction material clean and prevent it from being in contact with

Note

oil or grease. Brake pad loses friction force if being polluted by oil or
grease, and replace the brake pad.

5.5.2 Air discharge of brake oil line

Apply pressure to oil line of brake device system.
Use a hose in air bleeder pipe and carefully open it, and close it after air is discharged
completely.
Close the air discharge pipe.
Repeat processes 1-3 on two brake oil cylinders.
5.5.3 Replacement of brake friction plate
When the friction material of brake fiction plate is 2mm, replace the brake friction
plate. The new brake friction plate reaches rated torque after a period time of running-in.
(please refer to installation instruction.)
1) Discharge oil pressure of brake device.
2) Move away guide pin and return spring screw.
3) Move brake pad upwards and outwards.
4) Slide new brake friction plate.
5) Install guide pin and return spring screw, and screw up screw.

25

6 Trouble diagnosis and troubleshooting

6.1 Common trouble diagnosis and troubleshooting of hydraulic elements
6.1.1 Common trouble diagnosis and troubleshooting of plunger pump
Trouble
Trouble diagnosis
types
Insufficient Failure of stroking mechanism
flow or no
oil discharge Too small actual inclination angle of
inclined tray
Pump cannot have self suction due
to damage of return disk.
Return disk returns insufficiently or
cannot return as central spring is
broken.
Sealing loss between cylinder and
valve plate
Insufficient Serious wear between cylinder and
output
valve plate
pressure
Serious wear between plunger and
cylinder hole
Failure of pressure regulating
mechanism
Failure of Blockage of small hole on control
pressure
oil line
regulating
mechanism Complete jamming of spring in
pressure regulating mechanism

Complete jamming of conical valve

core
in
pressure
regulating
mechanism
Inflexible
rotation

Troubleshooting
Repair or regulate stroking
mechanism
Increase inclination angle of
inclined tray
Replace return disk
Replace spring

Replace relevant parts

Grind contact surface, adjust
clearance or replace valve plate
Grind contact surface or replace
plunger
(Please refer to description
below)
Purify oil liquid, dredge and
clean small hole of control oil
line.
Due to mechanical jamming,
grind and repair spring mandrel;
due to oil liquid pollution, purify
oil liquid.
Due to mechanical jamming,
grind and repair piston; due to
oil liquid pollution, purify oil
liquid.
Disassemble, clean, grind and
reassemble
Reassemble

Complete jamming of plunger and

cylinder
Improper assembly, fall of piston
shoes
Improper assembly, breakage of ball Reassemble and replace plunger
of plunger

26

Too dirty working medium and Disassemble, clean, replace with

jamming of mechanism
working
medium
meeting
cleanness grade
6.1.2 Common trouble diagnosis and troubleshooting of plunger pump

Trouble
Trouble diagnosis
types
High noise Insufficient oil liquid in oil tank

Troubleshooting

or
serious
Bad sealing of pump, leakage of contact
pressure
surface or pipe joint, air mixing
fluctuation
Impact of coupling of pump and motor

pointer
Tighten connectors and
replace seals if necessary
Elastic element in coupling

Fill oil liquid as per oil

is worn and needs replaced,

and pay attention to axiality

Looseness of mounting screw of pump

requirement
during
installation
Screw up mounting screw of

pump
Unsmooth oil suction of pump due to Dredge and clean oil suction
impurity accumulation in oil suction line line of pump
of pump
Air suction of pump as valve on oil Check and open valve on oil
suction pipe of pump is not opened
suction line
Unsmooth oil suction of pump as valve Check and open valve on oil

Inflexible
rotation
jamming
pump

on oil suction pipe of pump is not suction line

opened completely
Too small axial clearance and radial Repair or replace parts of
or clearance of shaft
of Unfavorable assembly

pump
Reassemble

Bad axiality between pump and motor

Adjust axiality

Impurities in oil liquid are sucked in Strictly prevent dirt around

pump.
from entering oil tank, and
keep oil liquid clean
Serious
Too high viscosity of oil liquid
Replace proper hydraulic oil
heating
of
liquid
pump (pump Too small radial clearance and axial Adjust clearance or adjust
clearance of pump
gear

27

temperature
Actual rotation speed of pump exceeds Replace with high-speed
shall
be serviceable range
pump or decrease rotation
lower
65)

than

speed of pump
Too high speed of oil in pipe and too Thicken oil pipe and adjust
large pressure loss
system layout

6.1.3 Common trouble diagnosis and troubleshooting of pressure regulating valve

Trouble
types
Pressure
fluctuation

Trouble diagnosis

Troubleshooting

Unfavorable driving fit between Replace valve core or make

conical valve core and valve seat
valve core and valve seat
Serious scratch of conical valve core
Replace valve core
Deformation of spring

Replace spring

Improper installation of valve core

8.3 Reinstallation

Dirt is mixed in oil liquid to block Clean

element,
dredge
damping hole
damping hole, and replace
hydraulic oil liquid if
necessary.
Air is mixed in hydraulic system.
Discharge air of system

Regulation
failure

Set pressure valve of overflow valve is Adjust pressure of overflow

too approximate to the output pressure valve properly
of pump, and the system pressure is
instable.
Complete jamming of valve core
Clean and repair
Deformation or breakage of spring

Replace spring

Blockage of damping hole

Clean and dredge damping

hole
Incapable closing of valve core due to Clean element
impurities between valve core and
valve seat
Unsmooth oil return
Dredge oil return pipe
Noise and
vibration

Serious wear of valve core

Replace valve core

Deformation of spring

Replace spring

Air is mixed in system

Discharge air of system

28

Resonance with other elements

Change natural frequency of

resonant system or change
pressure value

6.1.4 Common trouble diagnosis and troubleshooting of check valve

Trouble types

Trouble diagnosis

Troubleshooting

Valve core cannot return Check valve core for jamming

to initial oil seal position in valve hole
after being opened.
Jamming phenomenon of valve
core due to breakage or
excessive bending of spring
6.1.5 Common trouble diagnosis and troubleshooting of accumulator

Trouble types

Trouble diagnosis

No working
output

Troubleshooting

pressure No
charged
air
for Charge accumulator with air
accumulator
as per working parameter
Trouble of oil charging Repair and replace
valve of accumulator
Fracture of capsule in Repair and replace
accumulator
Oil valve of safety ball Check oil valve of safety
valve of accumulator is not ball valve of accumulator.
opened.
Insufficient output flow
Too high charging pressure Charge accumulator with air
of accumulator, and small as per working parameter
volume of pressure medium
in accumulator
Too low charging pressure Charge accumulator with air
of accumulator, and small as per working parameter
volume of pressure medium
discharged
from
accumulator (small volume
change of air bag)
Small total volume of Enlarge total volume of
accumulator
accumulator
6.1.6 Common trouble diagnosis and troubleshooting of explosion-proof electromagnetic
reversing valve

29

Trouble types
Power up electromagnet,
but valve core does not
reverse, and cut off
power, but the valve core
does not return

Trouble diagnosis

Troubleshooting

Check power voltage of Halt, check and correct

electromagnet
for
conformity
with
requirement,
if
power
voltage is too low, the
electromagnet
has
insufficient pushing force
and cannot push valve core
to reverse normally.
Jamming of valve core Halt, release pressure, repair
Check
whether
use and replace
conditions exceed specified
index or not. Such as
working pressure, flow, oil
temperature, and filtration
precision of oil liquid.
Check return spring for
breakage or jamming.

6.2 Troubles for hydraulic source

Trouble types

Trouble diagnosis

Measures

Internal load release in Analyze and check the

hydraulic system due to element which possible has
failure of element
failure in hydraulic system
by referring to system
schematic diagram until
failure is eliminated
Unstable
working Improper rotation direction Check and correct rotation
pressure of system
direction of motor
of motor
Ball valve on oil suction Open ball valve on oil
pipe of pump is not opened. suction pipe
Key fall phenomenon of Check coupling and key and
coupling of hydraulic pump ensure reliable connection
and motor
No flow output of pump Improper rotation direction Check and correct rotation
of motor
direction of motor
Ball valve on oil suction Open ball valve on oil
pipe of pump is not opened. suction pipe
Load release

30

Key fall phenomenon of Check coupling and key and

coupling of hydraulic pump ensure reliable connection
and motor
Too high of hydraulic oil Radiator is not opened.
Open cooling water or
temperature
cooling fan
Damage to fan
Repair or replace fan
Low
pressure
hydraulic pump

of Overflow
closed.

valve

is

not Regulate overflow pipe so

that the pressure reaches a
specified value.
Looseness
of
pressure Regulate pressure regulating
regulating valve of pump
valve of pump so that the
pressure reaches a specified
value.
Too low pressure regulation Regulate overflow valve of
of overflow valve of balancing system so that the
balancing system
pressure is regulated to the
specified value of about
160bar
Leakage of pipelines
Check and repair system

6.3 Troubles for hydraulic valve set

Trouble types
Electromagnetic
does not work.

Reasons
valve Whether PLC works or not.

Measures

Check state of 24V power

supply and check line of
electromagnet
Whether 24V power supply Check state of 24V power
is normal or not.
supply
Whether wiring loop of Check line of electromagnet
electromagnet
is
disconnected or not
Complete jamming of valve Press electromagnetic vale
core
button
so
that
the
electromagnetic vale button
works, replace it if pushing
is not available.

31

6.4 Troubles for IBOP hydraulic actuating mechanism

Trouble types

Reasons

Measures

Imprecise closing or Too big sleeve resistance

insufficient opening of
IBOP
Improper
installation
position of oil cylinder
Sleeve of IBOP acts but Breakage of sleeve
ball valve is not closed spanner
or opened.
Breakage
of
Allen
wrench
Abnormal work of IBOP Wear of rotary seal

Check shell of IBOP and

increase pressure of pressure
reducing valve of IBOP oil line
Adjust installation position of
oil cylinder
Replace spanner
Replace Allen wrench
Replace seal

6.5 Troubles for elevator link swinging mechanism

Trouble types

Reasons

Measures

Elevator link cannot stop Too

small
pressure
of
at any position.
balancing valve
Leakage of pipe and oil
cylinder
Action of elevator link Bad regulation or reverse
has stagnation or shake installation of two-way and
phenomenon.
one-way choke valves

Adjust balancing valve

Check and replace seal of
pipe and oil cylinder
Adjust the two-way and
one-way choke valves or
reinstall the valves

6.6 Troubles for revolving head

Trouble types

Reasons

Measures

Non-uniform running or Too

large
resistance Regulate installation
non-action of revolving between lower barrel body
head
and revolving head, bad
assembly precision
Electromagnetic valve does Repair
electromagnetic
not act.
valve

32

Locking oil cylinder does Check loop of locking oil

not return.
cylinder
Hydraulic
motor
goes Replace motor
wrong.
Too large hanging load
When the hanging load of
hanger does not exceed the
weight of one stand column,
and it is forbidden to trip
hanging load with elevator
link,
operate
rotating
mechanism.
Too quick or slow Looseness of handle of Regulate speed regulating
rotation
speed
of speed regulating valve
valve so that the rotation
revolving head
speed of revolving head is
6-8rpm.
Too
large
revolving Regulate revolving head so
resistance
that the clearance between
revolving body and nonrevolving body is proper
Notic
e

When 10 Parker rotary sealing rings of swiveling head need

replaced, assemble new rotary sealing ring with specially made
assembly tool and guide sleeve.

6.7 Troubles of backup tong system

Trouble types

Reasons

Incompact clamping of Serious wear of teeth of die

backup tong
plate
Tooth groove of die plate is
filled with foreign matters.
Insufficient pressure of
hydraulic system
Leakage of backup tong oil
cylinder seal
Exposure of teeth of Too large size error of slip
backup tong plate
Too thickness of die plate

Measures
Replace with new die plate
(or slip assembly)
Clean groove with wire
brush
Increase pressure properly
Replace the sealing ring
Replace slip
Replace die plate

Return stroke of oil cylinder Start oil path so that the

does not reach limiting return stroke of oil cylinder
position
is in place
33

Failure of hydraulic lock

Ineffective seal
cylinder piston

of

Repair hydraulic component

oil Replace the sealing ring

6.8 Troubles for balancing system

Trouble types

Reasons

Measures

Balancing oil cylinder Wrong connection of pipe

does not work.
Hydraulic source is not
opened.
Low pressure of pressure
reducing valve
Damage to oil cylinder

Check connection of pipe

Open hydraulic source
Increasing
pressure
pressure reducing valve
Replace oil cylinder

of

6.9 Troubles of disk brake

Trouble types
Brake disk is
released.
Brake disk does
work or slips

Reasons

Measures

not Complete
jamming
reversing valve
not Low system pressure

of Check or replace reversing

valve
Check system pressure

Complete
jamming
of
reversing valve
Leakage of hydraulic brake
pipe
Wear inefficiency or fall of
friction plate
Pressure reducing valve
changes in set valve or is
jammed completely.
Abnormal sound in brake Contact between pipe and
rotating member
Looseness of screws of
brake plate
Insensitive braking of Excessive wear of friction
brake
plate
Low pressure of brake oil
34

Check or replace reversing

valve
Check or replace hydraulic
pipe

Adjust or replace pressure

reducing valve
Fix hose line
Screw up loosening screws
Replace the friction plate
Regulate pressure reducing

cylinder
Notic
e

valve of brake oil path and

increase working pressure

It is forbidden to brake when main motor normally runs.

35

Appendix I: Graphical symbol description of hydraulic system

36

In the drawing, GB/T786.1-93 =GB/T786.1-93 hydraulic pneumatic

symbols; =pump, motor, oil cylinder, =variable pump,

=gear pump, =diverting motor; =dual telescopic rod oil

cylinder, =single telescopic rod oil cylinder, =diverting motor;

=pressure control valve; =three-way pressure reducing valve,

=two-way pressure reducing valve, =bidirectional balancing

valve; =balancing valve, =magnetic overflow valve,

=direct-acting overflow valve; =directional control valve,

=two-position magnetic valve, =three-position magnetic valve,

37

 =two-position manual valve, =check valve, =hydraulic control

check valve, =logical valve; =auxiliary components,

=heater, =liquid level sensor, =temperature sensor,

=liquidometer, =air filter, =accumulator, =pressure test

connector, =cooler.

38

Appendix II: Lubrication and maintenance schematic diagram for

DQ225DBZ direct driving top drive

In the drawing, 2 =lubrication of bail pin: 2 positions,

once a week;

39

 =oil for HPU:

replace filter once three months and replace hydraulic oil once half a year;
=IBOP remote controller;
=lubrication of sheave and sleeve: once a day;
=lubrication of rocker arm: once a week;
2 =lubrication of elevator hole; 2 positions, once a week;
=lubrication of washpipe assembly: once a day;
= lubrication of main motor: once two years;
=lubrication of chain wheel of rotating head: once a
week;
4 =lubrication of elevator link tilting mechanism: 4
positions, once a week;
4 =lubrication of backup tong centralizing wheel: 4
positions, once a week;
20 = lubrication of pulley: 20 positions, once a week.

40