DQ450DBZ Top Drive Device Maintenance Instruction PDF

DQ450DBZ Top Drive Device
Maintenance Instruction
DQ004-SC
November, 2011
DQ450DBZ Direct Driving Top Drive Maintenance Instruction
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
I
4.2 Brake device................................................................................................................ 10
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) ................................................................. 24
5.2.3 General spot check (once a year) ............................................................................. 24
5.2.4 Precautions in maintenance of hydraulic source and system ................................... 24
5.3 Maintenance of accumulator ....................................................................................... 25
II
5.3.1 Check of nitrogen pressure ...................................................................................... 25
5.3.2 Charging of nitrogen ................................................................................................ 26
5.4 Maintenance of hydraulic pipe.................................................................................... 26
5.5 Maintenance of brake device ...................................................................................... 26
5.5.1 Check ....................................................................................................................... 26
5.5.2 Air discharge of brake oil line ................................................................................. 27
5.5.3 Replacement of brake friction plate ......................................................................... 27
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
III
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 DQ450DBZ direct
driving top drive ................................................................................................................ 41
IV
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.
1
2 Periodic maintenance
2.1 Daily maintenance positions
Lubricating positions
Lubricating
No. Positions Lubricant
points
Lubricating
1 Washpipe assembly 1
grease
Roller of remote control IBOP control Lubricating
2 2
mechanism grease
Lubricating
3 Backup tong alignment wheel 4
grease
Fill lubricating grease at marked lubricating positions.
Check positions
No. Positions Contents Measures
Bolt, safety locking wire, split pin Repair or
1 Main motor assembly
etc replace
Repair or
2 Washpipe assembly Wear and leakage
replace
Reliable operation and adequate Repair or
3 Remote control IBOP
lubrication replace
Reliable operation and adequate Repair or
4 Manual IBOP
lubrication replace
Bolt, safety locking wire, split pin Repair or
5 Pipe handler
etc replace
Adjust or
6 Backup tong Locking and tong die wear condition
replace
Connecting pin, split pin and round
7 Guide rail and trolley Replace
nut etc of guide rail
All fasteners of top
8 Looseness condition Refasten
drive
2
Liquid level, pressure, oil

9 Hydraulic system Add or replace
temperature and cleanness etc
Pipes of hydraulic System leakage, surface condition of Repair or
10
system pipes and cables, hose joint etc replace
Adjust or
11 Oil cylinder joint Looseness condition
replace
Wear, fracture, joint looseness and Repair or
12 Cables
damage etc replace
2.2 Weekly maintenance positions
Lubricating positions
No. Positions Lubricating points Lubricant
Lubricating
1 Bail pin 2
grease
Lubricating
2 Upper gland seal 1
grease
Lubricating
3 Power rotating head 2
grease
Lubricating
4 Oil cylinder pin of tilting mechanism 4
grease
Lubricating
5 Pulley bearing wheel assembly 16
grease
Lubricating
6 Pulley guiding wheel assembly 4
grease
Fill lubricating grease at marked lubricating positions.
Check positions
1 Air outlet of main motor Damage condition of shutter Replace
Repair or
2 Cable of main motor Damage condition
replace
3 Fan assembly Looseness or loss of bolt, wind Adjust or
3
pressure, radiator at air inlet replace

4 Floating brake Wear condition of brake pad Replace
Wrenching torque, sealing and Repair or
5 IBOP
wear condition replace
Roller of remote control Repair or
6 Wear condition
IBOP control mechanism replace
7 Guide sheave Damage and wear conditions Replace
8 Guide rail Crack condition of weld joint Repair welding
Wear condition of bearing wheel
9 Pulley Replace
and guide wheel
Reverse torque beam Adjust or
10 Looseness or loss of fastener
assembly replace
Adjust or
11 Fixed beam assembly Looseness or loss of fastener
replace
2.3 Monthly maintenance positions
Check positions
Corrosion generated due to
1 Upper main shaft liner Replace
washpipe leakage
Hydraulic cylinder pin of
2 elevator link tilting Wear Replace
mechanism
Hydraulic cylinder pin of
3 Wear Replace
counterbalance system
Crown block padeye and Repair
4 Damage or crack at weld
guide rail connecting padeye welding
Replace
Loss of split pin
Replace
5 Hanging plate assembly Wear of pin
Replace
Wear of shackle and bolt
Repair or
Wear of hanger plate hole
replace
Perform after the drilling time is 250h accumulatively.
4
2.4 Seasonal maintenance positions
Check positions
Hydraulic oil of hydraulic
1 Oil sample analysis Replace
system
2 Filter Blockage Replace
2.5 Semi-annual maintenance positions
Check positions
1 Bail and bail pin Damage Replace
2 Main shaft Offset Adjust
Replace air bag or
3 Accumulator Nitrogen pressure
accumulator
2.6 Annual maintenance
Years Maintenance contents

Flaw detection of main bearers (such as guide rail, trolley, bail and bail pins
1 year
etc)
2 years Lubricating grease replacement of main motor
3 years Equipment repair
4 years Equipment overhaul
All positions needing maintenance must be checked and maintained in

Notice
time as per the field practical condition of the top drive.
5
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
Method:
6
3.3 Lubrication of washpipe assembly

Position:
1 position on side surface of washpipe.
Method:
3.4 Lubrication of upper gland seal
Position:
1 position at lower side of washpipe
assembly.
Method:
3.5 Lubrication of bail pin

Positions:
1 position on two bail pin
Method:
7
3.6 Pin of tilting oil cylinder

Positions:
2 positions on left and right tilting oil cylinder
(4 positions) in total.
Method:
3.7 Lubrication of backup tong

Positions:
In clamping frame, guide wheel (4 positions)
Method:
Coat butter before assembly
8
3.8 Lubrication of remote control IBOP control mechanism

Positions:
1 position on rollers on left and right sides
(2 positions in total).
Method:
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.
9
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 Ω , bake motor when the insulation
resistance is less than 0.8 M Ω , 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.
10
2. Replacement of friction block
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.
Friction block loses braking capacity after being polluted by oil or
Note
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.
11
4.4 Gooseneck
Check:
1. Periodically check the wear and
corrosion of gooseneck.
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.
12
4.5 Washpipe assembly

Check:
Leakage of washpipe.
Maintenance:
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
13
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
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.
14
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.
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.
15
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:
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.
16
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.
17
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 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.
18
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
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.
After the thread locking device is placed properly,
Notice
screw up locking bolt and install locking steel wire.
19
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 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.
20
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.
In the drawing, 悬挂板总成=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.
21
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.
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
22
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.
The temperature of hydraulic equipment and hydraulic oil may be

Notice
quite high, and the approachable temperature can be reached after a
period of time of cooling.
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.
23
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.
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.
24
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
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
25
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
Notice 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.
3) Leakage of hydraulic brake pipe.
Notice 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.
26
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.
27
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
types Trouble diagnosis Troubleshooting
Repair or regulate stroking
Failure of stroking mechanism
mechanism
Too small actual inclination angle of Increase inclination angle of
inclined tray inclined tray
Insufficient
Pump cannot have self suction due
flow or no Replace return disk
to damage of return disk.
oil
Return disk returns insufficiently or
discharge
cannot return as central spring is Replace spring
broken.
Sealing loss between cylinder and
Replace relevant parts
valve plate
Serious wear between cylinder and Grind contact surface, adjust
valve plate clearance or replace valve plate
Insufficient
Serious wear between plunger and Grind contact surface or replace
output
cylinder hole plunger
pressure
Failure of pressure regulating (Please refer to description
mechanism below)
Purify oil liquid, dredge and
Blockage of small hole on control
clean small hole of control oil
oil line
line.
Due to mechanical jamming,
Failure of
Complete jamming of spring in grind and repair spring mandrel;
pressure
pressure regulating mechanism due to oil liquid pollution, purify
regulating
oil liquid.
mechanism
Due to mechanical jamming,
Complete jamming of conical valve
grind and repair piston; due to
core in pressure regulating
oil liquid pollution, purify oil
mechanism
liquid.
Complete jamming of plunger and Disassemble, clean, grind and
cylinder reassemble
Inflexible Improper assembly, fall of piston
Reassemble
rotation shoes
Improper assembly, breakage of ball
Reassemble and replace plunger
of plunger
28
Disassemble, clean, replace with
Too dirty working medium and
working medium meeting
jamming of mechanism
cleanness grade
6.1.2 Common trouble diagnosis and troubleshooting of plunger pump
Trouble
Trouble diagnosis Troubleshooting
types
Fill oil liquid as per oil
Insufficient oil liquid in oil tank
pointer
Bad sealing of pump, leakage of contact Tighten connectors and
surface or pipe joint, air mixing replace seals if necessary
Elastic element in coupling
is worn and needs replaced,
Impact of coupling of pump and motor and pay attention to axiality
requirement during
High noise
installation
or serious
Screw up mounting screw of
pressure Looseness of mounting screw of pump
pump
fluctuation
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
on oil suction pipe of pump is not
suction line
opened completely
Too small axial clearance and radial Repair or replace parts of
clearance of shaft pump
Inflexible Unfavorable assembly Reassemble
rotation or
jamming of Bad axiality between pump and motor Adjust axiality
pump Strictly prevent dirt around
Impurities in oil liquid are sucked in
from entering oil tank, and
pump.
keep oil liquid clean
Serious Replace proper hydraulic oil
Too high viscosity of oil liquid
heating of liquid
29
pump (pump Too small radial clearance and axial Adjust clearance or adjust
temperature clearance of pump gear
shall be Replace with high-speed
Actual rotation speed of pump exceeds
lower than pump or decrease rotation
serviceable range
65℃) 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
Trouble diagnosis Troubleshooting
types
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
Pressure Clean element, dredge

fluctuation Dirt is mixed in oil liquid to block damping hole, and replace
damping hole hydraulic oil liquid if
necessary.
Air is mixed in hydraulic system. Discharge air of system
Set pressure valve of overflow valve is
too approximate to the output pressure Adjust pressure of overflow
of pump, and the system pressure is valve properly
instable.
Complete jamming of valve core Clean and repair
Deformation or breakage of spring Replace spring

Clean and dredge damping
Regulation Blockage of damping hole
hole
failure Incapable closing of valve core due to
impurities between valve core and Clean element
valve seat
Unsmooth oil return Dredge oil return pipe
Noise and Serious wear of valve core Replace valve core

vibration Deformation of spring Replace spring
30
Air is mixed in system Discharge air of system
Change natural frequency of
Resonance with other elements resonant system or change
pressure value
6.1.4 Common trouble diagnosis and troubleshooting of check valve
Trouble types Trouble diagnosis Troubleshooting

Check valve core for jamming
Valve core cannot return in valve hole
to initial oil seal position Jamming phenomenon of valve
after being opened. core due to breakage or
excessive bending of spring
6.1.5 Common trouble diagnosis and troubleshooting of accumulator

Charge accumulator with
No charged air for
air as per working
accumulator
parameter
Trouble of oil charging
Repair and replace
No working pressure valve of accumulator
output 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.
Too high charging pressure
Charge accumulator with
of accumulator, and small
air as per working
volume of pressure medium
parameter
in accumulator
Too low charging pressure
of accumulator, and small
Insufficient output flow Charge accumulator with
volume of pressure medium
air as per working
discharged from
parameter
accumulator (small volume
change of air bag)
Small total volume of Enlarge total volume of
accumulator accumulator
31
6.1.6 Common trouble diagnosis and troubleshooting of explosion-proof electromagnetic
reversing valve

Check power voltage of
electromagnet for
conformity with
requirement, if power
voltage is too low, the Halt, check and correct
electromagnet has
insufficient pushing force
Power up electromagnet,
and cannot push valve core
but valve core does not
to reverse normally.
reverse, and cut off
Jamming of valve core
power, but the valve core
Check whether use
does not return
conditions exceed specified
index or not. Such as
Halt, release pressure,
working pressure, flow, oil
repair and replace
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

Analyze and check the
element which possible has
Internal load release in
failure in hydraulic system
Load release hydraulic system due to
by referring to system
failure of element
schematic diagram until
failure is eliminated
Improper rotation direction Check and correct rotation

direction of motor
of motor
Unstable working Ball valve on oil suction Open ball valve on oil
pressure of system 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
32
Improper rotation direction Check and correct rotation
of motor direction of motor
Ball valve on oil suction Open ball valve on oil
No flow output of pump 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
Open cooling water or
Too high of hydraulic oil Radiator is not opened. cooling fan
temperature
Damage to fan Repair or replace fan
Regulate overflow pipe so
Overflow valve is not
that the pressure reaches a
closed.
specified value.
Regulate pressure
Looseness of pressure regulating valve of pump so
regulating valve of pump that the pressure reaches a
Low pressure of specified value.
hydraulic pump Regulate overflow valve of
Too low pressure regulation balancing system so that the
of overflow valve of pressure is regulated to the
balancing system specified value of about
160bar
Leakage of pipelines Check and repair system
6.3 Troubles for hydraulic valve set
Trouble types Reasons Measures

Check state of 24V power
Whether PLC works or not. supply and check line of
electromagnet
Whether 24V power supply Check state of 24V power
is normal or not. supply
Whether wiring loop of
Electromagnetic valve
electromagnet is Check line of electromagnet
does not work.
disconnected or not
Press electromagnetic vale
button so that the
Complete jamming of valve
electromagnetic vale button
core
works, replace it if pushing
is not available.
33
6.4 Troubles for IBOP hydraulic actuating mechanism

Check shell of IBOP and
Too big sleeve
Imprecise closing or increase pressure of pressure
resistance
insufficient opening of reducing valve of IBOP oil line
IBOP Improper installation Adjust installation position of
position of oil cylinder oil cylinder
Breakage of sleeve
Sleeve of IBOP acts but Replace spanner
spanner
ball valve is not closed
Breakage of Allen
or opened. Replace Allen wrench
wrench
Abnormal work of IBOP Wear of rotary seal Replace seal
6.5 Troubles for elevator link swinging mechanism

Too small pressure of
Adjust balancing valve
Elevator link cannot stop balancing valve
at any position. Leakage of pipe and oil Check and replace seal
cylinder of pipe and oil cylinder
Action of elevator link Bad regulation or reverse Adjust the two-way and
has stagnation or shake installation of two-way and one-way choke valves or
phenomenon. one-way choke valves reinstall the valves
6.6 Troubles for revolving head

Too large resistance
between lower barrel body
Non-uniform running or Regulate installation
and revolving head, bad
non-action of revolving
assembly precision
head
Electromagnetic valve does Repair electromagnetic
not act. valve
34
Locking oil cylinder does Check loop of locking oil
not return. cylinder
Hydraulic motor goes
Replace motor
wrong.
When the hanging load of
hanger does not exceed the
weight of one stand column,
Too large hanging load and it is forbidden to trip
hanging load with elevator
link, operate rotating
mechanism.
Regulate speed regulating
Looseness of handle of valve so that the rotation
speed regulating valve speed of revolving head is
Too quick or slow 6-8rpm.
rotation speed of Regulate revolving head so
revolving head that the clearance between
Too large revolving
revolving body and
resistance
non-revolving body is
proper
Notice 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

Serious wear of teeth of die Replace with new die plate
plate (or slip assembly)
Tooth groove of die plate is Clean groove with wire
Incompact clamping of filled with foreign matters. brush
backup tong Insufficient pressure of
Increase pressure properly
hydraulic system
Leakage of backup tong oil
Replace the sealing ring
cylinder seal
Too large size error of slip Replace slip
Exposure of teeth of
Too thickness of die plate Replace die plate
backup tong plate
Return stroke of oil cylinder Start oil path so that the
35
does not reach limiting return stroke of oil cylinder
position is in place
Failure of hydraulic lock Repair hydraulic component
Ineffective seal of oil
Replace the sealing ring
cylinder piston
6.8 Troubles for balancing system

Wrong connection of pipe Check connection of pipe
Hydraulic source is not
Open hydraulic source
Balancing oil cylinder opened.
does not work. Low pressure of pressure Increasing pressure of
reducing valve pressure reducing valve
Damage to oil cylinder Replace oil cylinder
6.9 Troubles of disk brake

Brake disk is not Complete jamming of Check or replace reversing
released. reversing valve valve
Low system pressure Check system pressure
Complete jamming of Check or replace reversing
reversing valve valve
Leakage of hydraulic brake Check or replace hydraulic
Brake disk does not pipe pipe
work or slips Wear inefficiency or fall of
friction plate
Pressure reducing valve
Adjust or replace pressure
changes in set valve or is
reducing valve
jammed completely.
Contact between pipe and
Fix hose line
rotating member
Abnormal sound in brake
Looseness of screws of
Screw up loosening screws
brake plate
36
Excessive wear of friction
Replace the friction plate
plate
Insensitive braking of
Regulate pressure reducing
brake Low pressure of brake oil
valve of brake oil path and
cylinder
increase working pressure
Notice
It is forbidden to brake when main motor normally runs.
37
Appendix I: graphical symbol description of hydraulic system
38
In the drawing, GB/T786.1-93 液压气动符号 =GB/T786.1-93 hydraulic
pneumatic symbols; 泵、马达、油缸=pump, motor, oil cylinder, 变量泵=variable
pump, 齿轮泵 =gear pump, 分流马达 =diverting motor; 双伸出杆油缸 =dual
telescopic rod oil cylinder, 单伸出杆油缸=single telescopic rod oil cylinder, 分流马
达=diverting motor; 压力控制阀=pressure control valve; 三通减压阀=three-way
pressure reducing valve, 两通减压阀=two-way pressure reducing valve, 双向平衡阀
=bidirectional balancing valve; 平衡阀 =balancing valve, 电磁溢流阀 =magnetic
overflow valve, 直动溢流阀=direct-acting overflow valve; 方向控制阀=directional
control valve, 两位电磁阀=two-position magnetic valve, 三位电磁阀=three-position
magnetic valve, 三位手动阀=two-position manual valve, 单向阀=check valve, 液控
单向阀=hydraulic control check valve, 逻辑阀=logical valve; 辅助元器件=auxiliary
components, 加热器 =heater, 液位传感器 =liquid level sensor, 温度传感器
=temperature sensor, 液位计 =liquidometer, 空气滤清器 =air filter, 储能器
=accumulator, 测压接头=pressure test connector, 冷却器=cooler.
39
40
Appendix II: lubrication and maintenance schematic diagram for
DQ450DBZ direct driving top drive
41
In the drawing, 提环销润滑：2 处，每周一次=lubrication of bail pin: 2 positions,
once a week;
液压站用油：每三个月更换一次过滤器，每半年更换一次液压油=oil for HPU: replace
filter once three months and replace hydraulic oil once half a year;
内防喷器遥控装置=IBOP remote controller;
滑轮，套筒润滑：每天一次=lubrication of sheave and sleeve: once a day;
摇臂润滑：每周一次=lubrication of rocker arm: once a week;
吊卡眼润滑：2 处，每周一次=lubrication of elevator hole; 2 positions, once a week;
冲管总成润滑：每天一次=lubrication of washpipe assembly: once a day;
主电机润滑：每两年一次= lubrication of main motor: once two years;
旋转头大齿盘润滑：每周一次=lubrication of chain wheel of rotating head: once a week;
吊环倾斜机构润滑：4 处，每周一次=lubrication of elevator link tilting mechanism: 4
positions, once a week;
背钳扶正轮润滑：4 处，每周一次=lubrication of backup tong centralizing wheel: 4
positions, once a week;
滑车润滑：20 处，每周一次= lubrication of pulley: 20 positions, once a week.
42

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DQ450DBZ Top Drive Device

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

3.1 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

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) ................................................................. 24

5.2.3 General spot check (once a year) ............................................................................. 24

5.2.4 Precautions in maintenance of hydraulic source and system ................................... 24

5.3 Maintenance of accumulator ....................................................................................... 25

5.3.1 Check of nitrogen pressure ...................................................................................... 25

5.3.2 Charging of nitrogen ................................................................................................ 26

5.4 Maintenance of hydraulic pipe.................................................................................... 26

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

5.5.1 Check ....................................................................................................................... 26

5.5.2 Air discharge of brake oil line ................................................................................. 27

5.5.3 Replacement of brake friction plate ......................................................................... 27

6 Trouble diagnosis and troubleshooting .......................................................................... 28

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

driving top drive ................................................................................................................ 41