Tesco Troubleshooting

Troubleshooting Guide
HCI(S) Top Drive System
500/650T HCI(S) 750/1205HP
DOCUMENT NAME: 880005 REV 2
TROUBLESHOOTING GUIDE
COPYRIGHT AND DISCLAIMER
Tesco Corporation ("TESCO") has made every effort to ensure that this document contains all of the
information necessary to troubleshoot an HMI top drive, however, the document is intended to be
used in conjunction with a complete training program and on-site supervision and TESCO does
not warrant or guarantee that the information contained herein is either complete or accurate in every
respect and the reader hereby protects, indemnifies and holds harmless Tesco Corporation together
with its directors, officers, employees and agents from and against all liability for personal injury,
death or property damage to any person arising directly or indirectly from the use by the reader of the
information contained in the document.
This equipment was filled at the factory with TESCO ULTREX brand fluids and greases. To ensure
maximum performance and to avoid cross-contamination, we strongly recommend the continued
usage of TESCO ULTREX lubricants, unless otherwise specified.
TESCO ULTREX is a trademark and TESCO is a registered trademark of Tesco Corporation.
Tesco Corporation 2009
Contact Information
Corporate Head Office
3993 W. Sam Houston Parkway No., Suite 100
Houston, Texas, 77043
USA
www.tescocorp.com
www.tescoparts.com
Telephone: (713) 359-7000
Fax: (713) 359-7001
After Market Sales and Service Contact
Toll Free North America: 1-877-TESCO-77
International: 713-359-7295
CONTACT: 1-877-TESCO-77
INTL: 713-359-7295
500/650T HCI(S) 750/1205HP

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REVISION INFORMATION
Revision Information
Version
Date
Description of Changes
Rev A
2003
First release
Rev 1
2007
Updated as a result of periodic review.
Rev 2
May 2009
Added TESCO ULTREX recommendations and updated the footer to contain

contact information.
INTL: 713-359-7295
500/650T HCI(S) 750/1205HP

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TABLE OF CONTENTS
CHAPTER 1: ABOUT THIS DOCUMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
CHAPTER 2: CLOSED LOOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Preparing to Troubleshoot the Closed Loop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Mechanical Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Charge Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Saver Pumps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Low Pump Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Interpreting Pump Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Circulating Pump Case Drain Flow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Interpreting Case Drain Flow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Top Drive Shifting Manifold (Speed, Cold Climate and Torque) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Shifting Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Shifting Hi/Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Torque Max/Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Loop Free Flow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Top Drive Closed Loop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Quill Will Not Rotate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Unable to Achieve Full System Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Motor Case Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Increasing Motor Case Drain Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Sundstrand Pilot Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Checking Pump Controller Function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Checking Pump Controller Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
CHAPTER 3: HYDRAULIC FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Checking the Auxiliary Pump and Master Relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Auxiliary Hydraulic Manifold and Integrated Reliefs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
General Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Checking the Unloader Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Checking Circulating Pressure, Hoses and Couplers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Multiple Functions Operating When One is Selected (Hydraulic Causes) . . . . . . . . . . . . . . . . . . . . . . 17
Checking for a Stuck Directional Valve Spool (Solenoid). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Checking the Rotary Seal for Port Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Grabber Lift Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Grabber Lift Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
INTL: 713-359-7295
500/650T HCI(S) 750/1205HP

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Elevator Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

Elevator Close . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Extend Forward . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Extend Retract . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Grabber Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Grabber Close . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Pipe Handler Unlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Pipe Handler Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Mud Saver Valve Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Mud Saver Valve Close . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Link Tilt Forward. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Unbalanced Bail Movement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Link Tilt Float . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Link Tilt Reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Unbalanced Bail Movement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Link Tilt Float . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Gearbox Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
CHAPTER 4: COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

Cooling Fan (Modine). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Hot Oil Shuttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Adjusting the Hot Oil Shuttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Adjust the Hot Oil Sequence Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Re-Circulation Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
Cold Climate Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
CHAPTER 5: ELECTRIC COMPONENT - HYDRAULIC FUNCTIONS . . . . . . . . . . . . . . . . . . .37

Wiring Notes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
Testing Solenoids. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
General Electrical Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
Conducting a Pig Tail Continuity Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
Testing for Generalized Power Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Multiple Functions Operating when one is Selected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
Checking for Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
Testing the Diode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
Grabber Lift-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Grabber Lift-Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
Pipe Handler-Unlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
Pipe Handler-Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
Link Tilt-Forward . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
INTL: 713-359-7295
500/650T HCI(S) 750/1205HP

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Link Tilt-Back. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Link Tilt-Float . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Extend-In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Extend-Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Elevator-Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Elevator-Close. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Elevator Close at Brake Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Grabber-Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Grabber-Close. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Grabber-Close Holding Contact Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Grabber/Pipe Handler Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Grabber/Drawworks Interlock Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Mud Saver Valve-Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Mud Saver Open Timer Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Direction Holding Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Mud Saver Valve-Close. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Mud Saver-Close Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Optional Current Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
CHAPTER 6: POWER UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Write down the following: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Perform These Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Restart the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Motor Starter Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Motor Keeps Quitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Motor Quits and Will Not Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Motor is Not Receiving Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Auxiliary Pump/Motor Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Auxiliary Pump Motor Will Not Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Auxiliary Pump Operates from Main Panel but not the Driller's Panel . . . . . . . . . . . . . . . . . . . . . . 70
Auxiliary Pump - Driller's Panel Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Engineering Sign-Off 77
INTL: 713-359-7295
500/650T HCI(S) 750/1205HP

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INTL: 713-359-7295
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CHAPTER 1: ABOUT THIS DOCUMENT

This guide provides information on troubleshooting the HCI(S) Top Drive.
Table 1-1: Where to Find More Information
For information on
Refer to
system components
HCIS System Description
installing the top drive

rig up procedure
commissioning
pre-operational checklists
rig out procedure
HCIS Installation Guide
setting torque and speed

drillers panel function and operating descriptions
making connections
drilling ahead
tripping
stuck pipe
HCIS Operations Guide
load path inspections

maintenance/service schedules
component assembly and disassembly
TESCO manufactured parts and part numbers
electrical schematics
hydraulic schematics
INTL: 713-359-7295
HCIS Parts List

HCIS System Schematics
available options and spares
HCIS Maintenance Guide
TESCO Representative
500/650T HCI(S) 750/1205HP

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ABOUT THIS DOCUMENT
INTL: 713-359-7295
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CHAPTER 2: CLOSED LOOP

INTRODUCTION
TESCO closed loop systems interface a Saver Sundstrand electro-hydraulic control valve and
the motor pot board. This interface allows the operator to control the pump volume and
direction from the driller's panel. Volume and direction determine the speed and direction of
the top drive's hydraulic motors.
Pump control redundancy equipment is provided in case of electrical interface failure. A small
control lever on the face of the Sundstrand valve (the manual control) can also be used to
control pump speed and direction during troubleshooting. Redundancy equipment includes:
joystick
pressure reducing valve
four 150 ft hoses
PREPARING TO TROUBLESHOOT THE CLOSED LOOP

Before you begin troubleshooting, you should become familiar with your closed loop system
by determining the following:
charge circuit pump arrangement

pump control (pot board or joy stick)
top drive shift (speed control)
torque relief
filtration
hot oil shuttle
location of all gauges
TESCO has incorporated pressure and temperature gauges that monitor all critical loop
components. These include flow meters for the following:
forward loop flow
hot oil shuttle flow
motor case drain
Test gauge ports are also provided on the filter manifold and top drive switching manifold.
!
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Caution: All manifold test ports are straight-thread ORB. Do not

attempt to screw tapered thread fittings into these ports.
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CLOSED LOOP
MECHANICAL INSPECTION
This is a list of general checks that can be performed as part of preliminary troubleshooting for
the closed loop system:
1. Before troubleshooting the hydraulic system, visually inspect equipment. Look
for the following:
mechanical damage to shafts or couplings (prime mover and pump drive)
kinked or ruptured hoses in the service loop
proper valve position
adequate oil reservoir level (site glass valve open)
2. If possible, listen for peculiar noises from the motors, pumps, and transmission.
3. Ensure that the flow rate is adequate to produce the desired pressure.
4. If the system is not functioning properly, check to see if the same problem occurs
in both forward and reverse.
5. Pressure test the motors in various quill positions as follows:
close the grabber
pressure test the first position
rotate the quill 20
repeat the pressure test
continue moving and testing the quill in 20 increments until each position has
been tested
6. Pressure test the pumps against closed valves at the power unit using the control
lever on the face of the Sundstrand valve.
CHARGE PRESSURE
IMPORTANT: This equipment was filled at the factory with TESCO
ULTREX brand fluids and greases. To ensure maximum performance
and to avoid cross-contamination, we strongly recommend the continued
The charge pump is a fixed displacement gear pump. On four pump prime mover
configurations, each saver pump has a small gear pump attached to the back side of the main
pump. On six pump prime mover configurations, a gang of gear pumps is located opposite the
input shaft, at the center of the pump drive.
Charge pump flow rate varies with the rpm of the prime mover but remains proportionally
constant with the maximum available loop flow. The ratio of charge flow to maximum
available loop flow is .25:1.
The charge pumps maintain a pressurized closed loop, provide control pressure, cool and
lubricate the piston pumps, allow loop oil exchange through the hot oil shuttle and make up for
loop leakage.
If fluid losses in the closed loop exceed the charge pump output, the charge pressure will drop.
Pressure drop below normal operating range (minimum 333 psi) will cause damage to the
main closed loop pumps. Pressure loss points are indicated in the illustration below.
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CLOSED LOOP
Figure 2-1: Pressure Losses that Effect Charge Pressure
Hydraulic
Motor
Filter
Manifold
Closed Loop
Pump
Hot Oil Shuttle

Case
Drain
Pump Case
Drain to Tank
Cooler
Charge
Filter
Tank
Charge
Pump
Indicates flow that may effect charge pressure.
Note: A drop in charge pressure does not always signify a problem with the
charge pump. Other factors must be considered.
Perform the following checks:
1. Ensure that the charge pump has adequate oil supply.
2. Check the pressure differential across the charge pump filter.
Note: If the differential is higher than 100 psi, change or service the charge pump
filter.
3. Check the case drain from the top drive.
Note: With the auxiliary pump turned off, the case drain flow should be between
2-6 gpm at low operating pressure. If the case drain flow is higher than this, there
may be excessive system fluid losses in one or both motors.
4. Check the saver pumps.
Note: Check the output of all saver pumps using the main flow meters If pumps
are operating normally, output from all pumps should be nearly equal (+/- 5%).
Check the case drain temperature from all pumps. Elevated case drain temperature
indicates possible fluid loss over the pump relief.
Warning! Important: Elevated case drain temperature or

improper pump outputs indicate that a problem
may exist. Either condition will effect charge
pressure. Investigate immediately.
5. Check the hot oil shuttle setting.

Note: The hot oil shuttle should be set to 35-50 gpm. If the hot oil shuttle is set
higher than this, charge pressure may be adversely effected.
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CLOSED LOOP
6. If all other checks have been performed, and no significant problem is uncovered,
you can increase charge pressure by reducing the hot oil shuttle setting.
Warning! If you reduce the hot oil shuttle setting, carefully

monitor system temperature to ensure that
adequate cooling is taking place. A fine balance
must be maintained to ensure adequate charge
pressure and adequate cooling.
7. If the checks above do not reveal the source of the problem, investigate charge
pump or pumps for possible causes.
SAVER PUMPS
Saver pumps operate very reliably. If a problem arises it will usually be indicated by one or
more of the following:
reduced pump flow (according to main flowmeters)
elevated case drain temperature
unable to achieve full system pressure
Low Pump Flow

If the flowmeter indicates that pump output is low, check the pump history to confirm that the
pump is operating outside of normal range. Also, ensure that the flowmeter is operating
properly. This can be done by switching flowmeters and confirming low pump output.
Interpreting Pump Flow

Pump flow is metered at the filter manifold forward header. To check the ratio of total pump
flow produced to useful work performed (rpm), refer to the flow rate efficiency chart (see HCI
Torque and Flow Charts). If the actual flow rate: rpm ratio does not correspond to the chart
ratio (+/- 10%), cross port leakage may be occurring at the motor vanes, relief or directional
logic poppit or a shuttle valve.
Note: Shuttle valves are located in the shifting manifold and filter manifold.
Circulating Pump Case Drain Flow

Pump case drain is the combined flow of internal pump leakage and charge pressure relief
valve discharge. Charge flow rate varies with engine rpm. For specific flow information, refer
to the flow chart for your system.
Note: The charge pressure relief valve setting is 23 bar (350 psi).
In a normally operating system, the maximum pump case drain flow should not exceed the
theoretical charge flow rate. A minimum flow rate of 3 gpm/per pump should be maintained.
This will ensure adequate case flush and pump temperature control.
Note: There is no flowmeter that monitors pump case drain. If required, a
flowmeter can be teed into the case drain line, ahead of the collector manifold.
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CLOSED LOOP
Case drain temperature for each pump is monitored using gauges provided. All pumps receive
the same work command and are subjected to identical load. Therefore, case drain temperature
should not vary from pump to pump.
If the closed loop system is operating correctly, the sum of the motor case drain, pump case
drain, and the hot oil shuttle flow should equal the theoretical charge flow. Therefore, pump
case drain can be calculated using this formula:
theoretical charge flow (hot oil shuttle + motor case drain flow) = pump case drain flow
INTERPRETING CASE DRAIN FLOW

If the sum of the hot oil shuttle and motor case drain becomes equal to or greater than the
theoretical charge flow the following can occur:
charge pressure falls below the relief setting (350 psi)
the saver pumps do not receive sufficient suction pressure (resulting in cavitation)
lack of oil at the charge reliefs causes inadequate case flush and case drain temperature
rises rapidly
Note: If this condition occurs, the case drain temperature for one pump may begin
to rise. This is because relief setting may vary +/- 5 psi from one pump to another.
The pump with the greatest relief setting will show a temperature increase because
the pump case is not being flushed.
Standby operations can cause pump case drain temperature to rise. This occurs because all
charge oil is forced over the charge reliefs when the motors are not rotating and the shuttle is
not activated.
Excessive pump case drain flow or temperature increase may be caused by pump damage. If
case drain flow increases suddenly when the pumps are shifted out of neutral (using the
manual joystick control), serious pump damage is likely.
TOP DRIVE SHIFTING MANIFOLD (SPEED, COLD CLIMATE AND

TORQUE)
Shifting Manifold
The function of the shifting manifold is to direct or prevent flow to the top motor. This makes
it possible to control forward torque and allow free flow through the loop during stand-by
operations in cold weather.
The shifting manifold contains two high-flow poppits and a shuttle valve. Poppit control
components include two directional valves (3F speed and 1A Max Torque) and two Bosch
pilot relief valves (Max and Set).
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CLOSED LOOP
Shifting Hi/Low
The shifting manifold shuttle valve directs loop high pressure to the 3F valve. The 3F valve
directs control pressure to the appropriate high-flow poppit as selected at the driller's Panel
range Hi/Low switch. Range Hi/Low determines one or two motor operation.
Torque Max/Set
Control interface and valve design allows the two high flow poppits to function
simultaneously as pressure reliefs and directional control valves.
The Bosch pilot reliefs Max and Set are configured in a way that allows the user two torque
limits to be applied to the drill string. When energized, the 1A directional valve isolates Set
torque, and Max torque becomes the active torque relief.
Loop Free Flow

When the cold climate button is pushed, the power that energizes the speed control is
interrupted. This allows loop free flow through the shifting manifold during cold weather
stand-by operations.
TOP DRIVE CLOSED LOOP

Quill Will Not Rotate
The shifting manifold operates very reliably. If the power unit is functioning properly and the
quill will not rotate, check the shifting manifold control components.
1. Ensure that the pipe handler is not locked.
2. Ensure that the cold climate switch has not been activated.
3. Ensure that the hi/low speed control 3F directional valve is energized and shifting.
4. Ensure that the Bosch pilot relief valves are properly set.
5. Ensure the shuttle valves (located in the shifting manifold and filter manifold) are
sound.
Note: Remove and inspect.
6. If pressure in the loop rises and the quill will not rotate check the loop lines for
blockage (s) or closed valve(s).
7. If all valves are open and the quill will not rotate, ensure that the quill is not
obstructed.
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CLOSED LOOP
UNABLE TO ACHIEVE FULL SYSTEM PRESSURE

If only partial pressure is obtained on the loop header gauges when you select forward or
reverse, switch the manual control to determine whether the problem is electric or hydraulic.
1. Ensure that the mechanical transmission items (engine speed, pump drive, engine)
in the power train are operating properly.
2. Ensure charge pressure is adequate (330 375 psi).
3. Check the pressure differential at the pump servo control ports.
4. Ensure the flow rate is adequate to produce the desired pressure.
Note: A minimum flow rate of 75 gpm is required to achieve full system pressure.
5. Ensure the pipe handler is locked and the cold climate switch is not engaged.
6. Ensure the shuttle valves (located in the shifting manifold and filter manifold) are
sound.
Note: Remove and inspect.
7. Observe auxiliary system circulating pressure.
Note: Blockage in the case drain hose will effect poppet function and system
pressure.
Note: If all these checks do not reveal a problem and you are unable to achieve
full system pressure, perform the following steps:
8. Isolate the power unit by closing the high-pressure valves at the hose reel.
9. Install an override cap on the reverse torque relief directional valves.
Note: Reverse torque is located at the filter manifold.
10. Function the pumps using the manual control lever and redundancy equipment
(joystick).
Warning! The active pressure relief (located at the saver

pump) is now 4,500 psi. Oil flow over this relief
will cause a dramatic temperature increase.
Pump failure can occur very quickly when
operating in this condition. Carefully monitor
pump case drain temperature.
If you are unable to achieve full pressure at the isolated power unit then consider
the following:
a. One of the combination high-pressure relief/ charge make-up valves may be
damaged, sticking or leaking.
Note: If pressure will not build up in one direction, inspect these valves. Heat
may be present at the faulty valve. If a faulty valve is found, change out the
valve.
b. If pressure will not build up in both forward and reverse a faulty valve is not
the likely cause (unless, by coincidence, both a forward and reverse valve are
faulty).
c. If pressure will not build in both forward and reverse, and flow is lagging or
absent at one flow meter, the problem is likely a faulty pump spline or pump
coupling. Replace pump or repair pump drive, as required.
d. If there is no pressure build up when operating in reverse only, the reverse
torque relief may be faulty.
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CLOSED LOOP
e. If full system pressure can be developed when the pumps are deadheaded at
the power unit valves, but cannot be developed with the grabber closed to
stall the quill, one of the following may apply:
f.
If the fault occurs in specific quill positions in forward and reverse, the
problem may be a stuck vane. The faulty motor can be determined by testing
in both high and low range.
g. If the fault occurs regardless of quill position or fluid direction, the problem is
likely the top drive shift (3F directional valve speed control). Troubleshoot for
electrical causes, or change out the 3F valve. Ensure that the pipe handler is
in the locked position and check the cold climate button and shuttle valve.
h. If the fault exists only in forward, check the pilot relief valve and forward
torque relief system (motor manifold).
MOTOR CASE DRAIN

Rineer motors require case drain to lubricate moving parts. The case drain flows between the
rotors and timing plates, and between the vanes and timing plates. As it leaves the motor, the
case drain flushes the motor shaft bearings.
IMPORTANT: This equipment was filled at the factory with TESCO
ULTREX brand fluids and greases. To ensure maximum performance
and to avoid cross-contamination, we strongly recommend the continued
Increasing Motor Case Drain Flow
Caution: The case drain flowmeter is located at the power unit

(electrical panel side). It displays the case drain flow from the
motors plus the return auxiliary hydraulic oil flow. When calculating
motor case drain, always turn off the auxiliary pump to get an accurate motor case drain reading. If it is not possible to turn off the
auxiliary pump, subtract seven gpm from the flowmeter reading to
get an approximate case drain value.
Note: The pilot to open check valve in the 11-station manifold blocks loop
pressure when drilling ahead. If this valve fails to check:
You will observe high flow at the motor case drain flow meter
You may observe lack of torque at the quill
These observations may lead you to assume high motor case drain and a fauly motor. Always
check the CP-458-2-B valve when high case drain is observed.
During normal operations, motor case drain flow ranges from 0.5 to 1.5 gpm.
This figure may vary depending on the operation being performed and the condition of the
motors. Operations that are more demanding result in higher case drain flow. Worn motors
also tend to have higher case drain flow.
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CLOSED LOOP
If there is a sudden significant rise in motor case drain volume, damage to internal motor
components, or debris in the motor vanes is the likely cause.
Any immediate surge in motor case drain flow should be investigated immediately, as high
case drain increases the flow demand on the charge pumps.
Note: Excess case drain results in loss of rpm and mechanical efficiency. It may
be a symptom of a cracked timing plate.
If excess case drain combined with hot oil shuttle flow exceeds the theoretical charge flow, the
loop pumps may cavitate and pump failure may occur.
SUNDSTRAND PILOT VALVE

If you are unable to get full flow from the pumps, or if the pumps are not stroking (no output/
flow, no rotation), there may be problem with the Sundstrand Pilot Valve or the electrical
connections required to operate it.
Checking Pump Controller Function

1. Ensure the power unit is running.
2. Ensure it is safe to rotate the quill.
Caution: If it is not safe to rotate the quill, you can perform the following test with the system in Cold Climate mode. Cold Climate
mode allows you to circulate closed loop oil without rotating the
quill. The Cold Climate switch is located on the side of the driller's
panel. It is interfaced with the speed control and interrupts power
flow to the speed control when pushed in.
3. Locate the pump controller manual control toggle.

Note: This is located at the power unit, on the front of the pump controller.
4. Idle the power unit.
5. Manually operate the pump controller toggle.
6. Observe the pump flowmeters.
If pump flow is evident when the toggle is manually operated, there is likely a
problem with the control electronics.
If no pump flow is evident, there may be problem with the controller itself, or
with a pump actuator.
7. To determine if there is a pump controller problem, do the following:
Watch the control gauges on top of the first pump. At zero strokes, both gauges
will read the same. To create stroke, the controller changes the differential
between the forward and reverse lines.
When the controller is manually actuated, the gauges should respond
accordingly.
If the differential is not changing, there is a controller problem.
Note: Actual pressure values are not as important as the differential change.
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CLOSED LOOP
Checking Pump Controller Electrical Connections

The Sundstrand Pilot Valve is operated by a current signal from the motor pot board. To check
output from the motor pot board to the controller, you must check the following:
Check the motor pot board output as follows:
1. Ensure your digital multi-meter is set to 10A- DC Amp mode.
2. At the motor pot board, remove wire 239 from terminal 9.
3. Attach the negative lead of the DMM to terminal 9.
4. Attach the positive lead to wire 239.
5. At the drillers panel, select Pump Direction-Forward.
Note: The power unit (prime mover) does not need to be running.
6. Using the Pumps Speed switch, increase and decrease pump speed.
7. Observe the DMM. It should rise and fall when pump speed is increased and
decreased.
If the meter does not read at all there is likely a break in the electrical control
lines. Connect the DMM directly across terminals 9 and 10 (with the wires
removed). If there is no power, it is likely that the problem resides with the
motor pot board. Using the appropriate electrical schematics, check all inputs to
the motor pot board.
If proper current is observed, the motor pot board is operating correctly. This
indicates there may be a problem with the pump controller. Using the correct
electrical schematics, troubleshoot the circuit as required.
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CHAPTER 3: HYDRAULIC FUNCTIONS

Many hydraulic system problems exhibit similar symptoms. To pinpoint the exact cause of any
difficulty you must follow an organized testiUse the following procedure to confirm that the
auxiliary pump and master relief valve are functioning properly.
Confirm proper operation of the following hydraulic system components before performing
more detailed hydraulic system checks:
auxiliary pump
master relief valve
hoses and couplers
auxiliary manifold
unloader valve
If any one of these primary system components is faulty, repair or replace as required. If these
components are functioning correctly, troubleshoot specific functions as defined in the
following sections.
CHECKING THE AUXILIARY PUMP AND MASTER RELIEF

Use the following procedure to confirm that the auxiliary pump and master relief valve are
functioning properly.
1. Disconnect the auxiliary pump discharge and return at the power unit.
Note: This will isolate the pump and master relief valve from the remainder of the
hydraulic circuit. The auxiliary pump will be deadheaded into the master relief
valve.
2. Start the auxiliary pump.
3. Observe the pressure gauge located at the front of the auxiliary oil tank, left of the
auxiliary pump.
Note: Pressure should build to 2,100 psi (+/- 50).
Caution: Operating in this mode causes hydraulic oil heat build-up.
Do not allow the system to operate for extended periods.
4. If pressure does not build to 2,100 psi (+/- 50), ensure that:
the motor is running at full rpm
the auxiliary pump suction is not restricted or drawing air
the suction lines are properly connected to the pump
the valve on the suction line is open
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HYDRAULIC FUNCTIONS
5. If the checks above do not reveal a problem, check the relief valve for heat buildup.
Note: Heat build up indicates that there is flow over the relief valve. If full auxiliary pressure cannot be developed and flow is evident at the master relief valve,
the master relief valve may be faulty. Repair or replace as required.
6. If auxiliary pump pressure is adequate and the master relief is functioning properly, go to testing the Auxiliary Hydraulic Manifold and Integrated Reliefs.
Note: Low circulating pressure (<325 psi) can indicate pump fatigue. Normal
circulating pressure when oil temperature is 20C, is 375 psi. Circulating pressure
will vary with oil temperature.
Caution: The auxiliary tank contains a suction strainer. If oil supply
to the pump is being restricted, a flow check may be required to
determine the condition of the strainer. This check should only be
performed after other flow related problems have been ruled out.g
procedure, beginning at the auxiliary pump.
AUXILIARY HYDRAULIC MANIFOLD AND INTEGRATED RELIEFS

The auxiliary hydraulic system incorporates several relief valves. All hydraulic functions are
connected to the master relief. Some functions also incorporate a dedicated relief valve. These
function specific relief valves have a lesser pressure value than the master relief.
The manifold pressure passage allows hydraulic oil flow to all currently energized functions.
If two or more functions are energized, the relief valve with the lowest pressure setting
becomes the active relief. No function with a pressure requirement higher than the active relief
valve can be operated.
If you are experiencing trouble with a specific function, always ensure that no other functions
have been energized.
Note: The Grabber-Close function is interfaced with the pipe handler lock. The
pipe handler lock always energizes when Grabber-Close is selected.
GENERAL TESTING
If one or more hydraulic functions are not operating correctly, perform these checks to
determine if the problem is mechanical or electrical.
If these general checks do not resolve the problem, refer to the troubleshooting topic for the
specific function(s) that are not working.
1. Is the hydraulic oil level adequate?
If not adequate, fill oil and check hydraulic function.
2. Are the auxiliary pump and master relief operating properly?
If no, inspect and repair the auxiliary pump or master relief as required, then
check hydraulic function.
If yes, go to the next step.
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HYDRAULIC FUNCTIONS
3. Are there any significant leaks in the hydraulic system?

If yes, inspect and repair leaks as required, then check hydraulic function.
If no, go to the next step.
4. Is the circulating pressure adequate (375 psi +/- 50)?
If circulating pressure is high, see Checking Circulating Pressure, Hoses and
Couplers on page 16.
If circulating pressure is low, check the auxiliary pump for internal wear.
5. Are solenoids receiving power?
If no, refer to the Electrical troubleshooting section.
If yes, manually function the solenoid valve(s) for any function that is not
working.
6. Do the solenoids travel freely when manually operated (without electrical power)?
If no, replace the solenoid (s).
Note: Some resistance is expected when operating with hydraulic pressure.
7. Does the function(s) work after the solenoid has been manually cycled?
If no, check internal hosing for leaks. If no leaks are found, refer to the
troubleshooting section for the specific function(s) that are not working.
Checking the Unloader Valve

If one or more hydraulic functions are not working correctly, and the general system checks
have turned up nothing, the problem may be the unloader valve. This valve is located on the
auxiliary hydraulic manifold and functions as follows.
When any hydraulic function (except Link Tilt Float) is commanded, the unloader valve
energizes. This dead heads the pressure line from the auxiliary pump. The line pressure rises
and flows across the relief for the selected function, or across the main system relief.
Note: If no function is selected, the oil is allowed to circulate at system pressure
(375 psi +/- 50).
If the unloader valve is manually closed and pressure is less than 2,100 psi, the performance of
all hydraulic functions may be compromised. To overcome this problem you may have to
troubleshoot the pump and main relief.
System pressure can be monitored using the pressure gauge at the power unit.
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HYDRAULIC FUNCTIONS
CHECKING CIRCULATING PRESSURE, HOSES AND COUPLERS

Frequent shifting of the unloader valve results in pressure build up/unload in hydraulic oil
supply hoses. This may eventually cause internal hose rupture, it may loosen screw on type
connectors, or it may damage quick couplers. Any of these problems will result in increased
circulating pressure, reduced flow rate, and slow cylinder movement.
Normal standby circulating pressure at 20C is 375 psi (+/- 50). Note that pressure varies with
oil temperature.
If high circulating pressure is encountered perform the following tests. Recheck the
circulating pressure after each step.
1. Inspect the circuit for damaged, kinked, or misshapen hoses.
Note: Replace damaged hoses immediately and check circulating pressure.
2. 2.Inspect all quick couplers and tighten all screw on connectors.
Note: Check circulating pressure.
3. Check the K-10 return filters for hose particles and debris.
Note: These filters are located on the auxiliary oil return to tank. Important: If the
filters are clogged, they should be changed.
Warning! If hose particles are present, check all hoses for

visible damage. If metal flakes are present,
inspect the auxiliary pump for cylinder wear or
damage.
4. If internal hose rupture is suspected (hose lining is found in the oil filter, or oil is
weeping from a hose jacket), remove the 3/4" x 225' auxiliary pressure hose from
the top drive at the JIC fitting, before the coupler.
Note: This coupler tends to screen debris from the hydraulic oil.
6. Displace the hydraulic oil between the hose saddle and JIC (approximately two
gallons)
Note: This will flush accumulated debris from the hydraulic line.
7. If circulating pressure is still high, remove the unloader directional valve.
8. Inspect the pressure passage through the unloader valve and auxiliary manifold
for partial blockage or debris.
Caution: When servicing the auxiliary manifold, remove auxiliary
pressure and return hoses at the top drive. This will block hydrostatic pressure exerted from the height of the hose saddle.
9. Check hoses and couplers at the mechanical section for blockage.

10. If the circulating pressure problem is not solved using these procedures, and
electrical causes have been ruled out, contact a qualified TESCO representative.
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HYDRAULIC FUNCTIONS
MULTIPLE FUNCTIONS OPERATING WHEN ONE IS SELECTED

(HYDRAULIC CAUSES)
When more than one hydraulic function operates, when only one is selected, the likely causes
are:
one of the directional valve spools (solenoids) is stuck
the rotary seal is damaged and is allowing hydraulic oil flow from one port to another
If the Grabber Lift and Grabber Open/Close are operating together when only one is selected,
the problem may be related to damage in the star valve located in the pipe handler manifold.
Checking for a Stuck Directional Valve Spool (Solenoid)

1. Ensure that the auxiliary pump, master relief, and system plumbing are all
operating correctly.
3. Ensure that circulating pressure is in the normal range.
4. Ensure no function valves are energized (no switches are on).
5. Install an override cap on the unloader valve.
6. Allow system pressure to build to 2,100 psi (+/-50).
7. If any hydraulic function operates, the solenoid for that function is faulty.
8. Repair or replace the solenoid as required.
Caution: When replacing solenoids, always ensure the correct
replacement model is used.
Checking the Rotary Seal for Port Communication

Port communication refers to the flow of hydraulic oil past ruptured or damaged seals within
the rotary seal. This flow may activate unrequested hydraulic functions.
1. Remove the hoses from the inner and outer sleeve of port where seal damage is
suspected.
Note: All ports have two hydraulic connections. They are located above the load
collar, between the pipe handler and main frame.
2. Cap the hoses.
Note: Leave the rotary seal ports open to atmosphere.
3. Function the auxiliary hydraulic circuits on either side of the suspect port.
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HYDRAULIC FUNCTIONS
4. Observe the open rotary seal port for hydraulic oil leaks.
Note: Leakage from the open port indicates that the rotary seal is damaged.
Caution: If the rotary seal is damaged, it should be changed as
soon as operations allow. As a temporary measure you may do the
following:
Cap the rotary seal port when the damage was noted.
Use a jumper hose to bypass the damaged seal.
Warning! If a bypass hose is installed, you will not be able

to rotate the pipe handler.
GRABBER LIFT UP
Before using this troubleshooting procedure:
Refer to General Testing for a more general list of checks to perform.
Using the Grabber Lift switch, select Down. This will confirm that the leg is not at the
top if its stroke.
Ensure the Grabber is open.
1. Is the grabber lift needle valve closed?
Note: This valve is located above the kidney manifold on the off-driller side.
If no, close the valve and check the function again.
If yes, remove the hydraulic line from the rotary seal area.
Install a 3,000 psi pressure gauge at the end of the line.
Function grabber up and monitor the gauge.
2. Is the pressure adequate (2,050 psi main relief)?
If no, manually cycle the solenoid.
3. Is pressure observed?
If no, check the auxiliary system pump relief and reset as required.
If yes, reconnect the hydraulic line with gauge teed in.
Install a 3,000 psi gauge into the Grabber down line.
Function the grabber up.
If the pressure rises on the return line, there may be leak from the pressure side
to the tank side.
4. Did the grabber lift?
If no, check for mechanical binding.
5. Is there a mechanical obstruction?
If yes, repair as required.
If no, check pressure on the Grabber Down circuit.
If pressure is less than 400 psi, remove the Grabber lift cylinder and inspect for
integrity.
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HYDRAULIC FUNCTIONS
GRABBER LIFT DOWN

Before using this troubleshooting procedure:
Refer to General Testing on page 14 for a more general list of checks to
perform.
Using the Grabber Lift switch, select Up. This will confirm that the leg is not at
the bottom if its stroke.
1. Operate the grabber lift down function.
2. Observe the pressure on the grabber accumulator manifold gauge.
3. Is pressure adequate (600 psi)?
If no, set pressure reducing valve to 600 psi.
Check the function again.
4. Does the function work?
If no, check for mechanical binding.
5. Is there an obstruction?
If yes, repair as required.
If no, remove the grabber cylinder and inspect for integrity.
ELEVATOR OPEN
Before using this troubleshooting procedure, refer to General Testing on page 14 for a more
general list of checks to perform.
The following procedures should be performed when it is determined that auxiliary line
pressure is building up, but the elevators will not open.
Warning! Elevators are extremely powerful and can cause

serious injury. Never place hands, arms, or tools
into the elevators when they are operating
unpredictably.
Warning! Unexpected closing of elevators may result in
serious injury.
1. Check the quick couplers at the elevators.

2. Are the open and close lines connected properly?
If no, reconnect lines and check the function.
If yes, install a 3,000 psi pressure gauge into the open line and cycle the Open
function.
3. Is there adequate pressure (1,800 psi) in the open line?
If no, check the relief setting and reset as required.
If yes, crack the Close side fitting on manifold and check for pressure lock.
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HYDRAULIC FUNCTIONS
4. Do the elevators open slightly when the fitting is cracked? Is the close side over
pressured?
If yes, this indicates that there is a blockage on the Close side.
If no, proceed to the next step.
5. Crack the fittings on the Open side of the main body cylinder, and the elevator
latch cylinder.
Caution: Exercise caution. The hydraulic oil pressure is 1,800 psi.
6. Do the cylinders move?

If yes, it is likely that the main hinge of the latch or body hinge are seized.
Repair as required.
ELEVATOR CLOSE
The following procedures should be performed when it is determined that line pressure is
building up, but the elevators will not close.
!
!
Warning! Elevators are extremely powerful and can cause

serious injury. Never place hands, arms, or tools
into the elevators when they are operating
unpredictably.
Warning! Unexpected closing of elevators may result in
serious injury.
1. Check the quick couplers at the elevators.

2. Are the open and close lines connected properly?
If no, reconnect lines and check the function.
If yes, install a 3,000 psi pressure gauge into the close line and cycle the Close
function.
3. Is there is adequate pressure (1,800 psi) in the close line?
If no, check the relief setting and reset as required.
If yes, crack the Open side fitting on manifold and check for pressure lock.
4. Do the elevators close slightly when the fitting is cracked? Is the open side over
pressured?
If yes, this indicates that there is a blockage on the Open side.
If no, install two 3,000 psi pressure gauges, one on the close side of the main
body cylinder and one on the close side of the latch cylinder.
Ensure the sequence valve is set to 1,500 psi.
Function the elevator close and watch gauges.
The gauge on the main body cylinder should rise to 1,500 psi, then the latch
cylinder should rise to 1,500 psi.
5. Is the pressure up sequence correct?
If no, check for obstruction in hoses.
If yes, check for mechanical obstruction of the elevators latch.
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HYDRAULIC FUNCTIONS
EXTEND FORWARD
building up, but the extend forward function will not operate.
1. Are the extend quick couplers properly connected?
If no, reconnect and try the function again.
2. Is the speed control valve located in-line properly set?
If no, reset and try the function again.
If yes, install a pressure gauge in the forward side line, as close as possible to the
cylinder. Try the function again, and monitor the pressure.
3. Does the pressure build to 1,800 psi?
If no, there is likely a line blockage on the forward side.
If yes, the problem may be a mechanical bind in the extend mechanism, or a
blockage on the Retract side.
4. Crack the fitting on the retract side.
5. Is there a build up of pressure on the retract side?
If yes, there is likely a blockage on the retract side. Investigate and repair as
required.
If no, there is likely a mechanical bind in the extend mechanism. Investigate and
repair as required.
EXTEND RETRACT
building up, but the extend retract function will not operate.
1. Are the extend quick couplers properly connected?
If no, reconnect and try the function again.
2. Is the flow control valve located in-line properly set?
If no, reset and try the function again.
If yes, install a pressure gauge in the retract side line, as close as possible to the
cylinder. Try the function again, and monitor the pressure.
3. Does the pressure build to 1,800 psi?
If no, there is likely a line blockage on the retract side.
If yes, the problem may be a mechanical bind in the extend mechanism, or a
blockage on the forward side.
4. Crack the fitting on the forward side.
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HYDRAULIC FUNCTIONS
5. Is there a build up of pressure on the forward side?

If yes, there is likely a blockage on the forward side. Investigate and repair as
required.
If no, there is likely a mechanical bind in the extend mechanism. Investigate and
repair as required.
GRABBER OPEN
The following procedures should be performed when it is determined that auxiliary line
pressure is building up, but the grabber open function will not operate.
1. Install the following pressure gauges at the grabber cylinder port extensions:
one 5,000 psi pressure gauge on the close side
one 3,000 psi gauge on the open side
2. Function the grabber open and observe the gauges.
3. Does the pressure gauge on the open side reach 2,000 psi?
If no, check the internal needle valve on the kidney manifold and ensure it is
closed.
Note: If this valve is open, the grabber will attempt to lift whenever open is
selected.
If yes, proceed to the next step.
4. Are any of the following conditions true?
There is pressure at the grabber open solenoid and at the auxiliary manifold, but
not at the grabber cylinder. This indicates there is likely a line blockage between
these two points. Inspect and repair as required.
There is pressure at the open piston, but not on the close side. This indicates
there is likely a mechanical bind in the grabber mechanism. Inspect and repair as
required.
The pressure gauge on the close side rises when the open function is requested.
One of two conditions may exist: there may be a blockage in the grabber close
line or there may be a faulty pilot operated check valve (on pipe handler
manifold). Inspect and repair as required.
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HYDRAULIC FUNCTIONS
GRABBER CLOSE
Before using this troubleshooting procedure. If no solution is found, refer to General Testing
on page 14 for a more general list of checks to perform.
The HCI grabber is operated using auxiliary system hydraulic power. An intensifier powered
by the closed loop system provides additional clamping pressure when making and breaking
connections. Full auxiliary system pressure is critical to intensifier function and must be
achieved before loop pressure is applied.
building up, but the grabber close function will not operate.
1. Locate the following gauges:
Pipe handler manifold gauge (port M)
Loop pressure gauge next to the Bosch relief valves (top drive main frame)
2. Install the following pressure gauges at the grabber cylinder port extensions:
one 5,000 psi pressure gauge on the close side
one 3,000 psi gauge on the open side
3. Function the grabber closed and observe the gauges.
4. Does the gauge on the close side rise to auxiliary closing pressure (2,000 psi)?
If there is 2,000 psi on both the Close side and the Open side, there may be a line
blockage or there may be a problem with the "pilot to open" check valve in the
11 station manifold (CP-45B-2-B).
If there is 2,000 psi at the Close side piston, and the Open side has return
auxiliary line pressure, there may be a mechanical bind in the grabber box or
piston. Inspect and repair as required.
If there is no pressure at the cylinder, check the pressure gauge at the pipe
handler manifold (port M).
Remove the hose from port 2 of the rotary seal.
Install a 2,000 psi pressure gauge.
Function Grabber-Close and monitor the pressure. If there is no pressure,
there may be a problem between the rotary seal and the auxiliary manifold.
The problem may be a line blockage, or a faulty solenoid.
If the Close side shows partial pressure, ensure that all checks described in
General Testing have been performed then:
Test the rotary seal ports 3 and 4 for communication from port 2.
Test the "pilot to close" check valve for possible leakage to the loop.
Ensure no other functions are energized (e.g. Elevaor-Close)
Test the pipe handler lock cylinder for leakage.
Note: The lock is energized when the grabber is closed and may effect the
Grabber-Close function.
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HYDRAULIC FUNCTIONS
PIPE HANDLER UNLOCK

building up, but the pipe handler unlock function will not operate.
1. Crack the fitting on the pipe handler lock function.
2. Is there is pressure build-up on the lock side?
If yes, there may be blockage on the lock side of the hydraulic system.
If no pressure build up, go to the next step.
3. Crack the fitting on the unlock side.
If there is pressure on the unlock side, there may be mechanical bind in the lock
mechanism or in the piston.
PIPE HANDLER LOCK

building up, but the pipe handler lock function will not operate.
1. Crack the fitting on the pipe handler unlock function.
2. Is there is pressure build-up on the unlock side?
If yes, there may be blockage on the unlock side of the hydraulic system.
If no pressure build up, go to the next step.
3. Crack the fitting on the lock side.
If there is pressure on the lock side, there may be mechanical bind in the lock
mechanism or in the piston.
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HYDRAULIC FUNCTIONS
MUD SAVER VALVE OPEN

building up, but the mud saver valve open function will not operate.
Caution: Do not service the mud saver valve unless the top drive is
disconnected form the drill string. Never service the mud saver
valve while pumping fluid through the quill.
Caution: The piston racks have a vent between the open and close
piston seals. A ruptured seal will vent to atmosphere.
1. Install a 2,000 psi pressure gauge on the open and close side lines.
2. Function open and monitor the pressure gauges.
3. Is there pressure in the open line?
If no, check the pressure relief on the mud saver for proper setting (1,500 psi).
If yes, there may be a ruptured seal in the mud saver valve. Check the seals as
follows:
Remove the close hose from the valve actuator.
Leave the test gauge on the close port.
Function the mud saver open.
If both gauges read 1,500 psi, then the seals are bypassing.
Service seals as required. If the seals are good, put close hose on, function
open and monitor pressure gauges, then go to next step.
4. Is there pressure in close line?
If yes, there may be a problem with the shuttle valve. Inspect and repair as
required.
If no, there may be a mechanical bind in the actuator or mud saver valve. Inspect
and repair as required.
Note: The actuator drive keys can be removed to determine whether the actuator
is working. Actuator function can be confirmed without operating the mud saver
valve.
MUD SAVER VALVE CLOSE

building up, but the mud saver valve close function will not operate.
1. Install a 2,000 psi pressure gauge on the open and close side lines.
2. Function close and monitor the pressure gauges.
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HYDRAULIC FUNCTIONS
3. Is there pressure in the close line?

If no, check the pressure relief on the mud saver for proper setting (1,500 psi).
If yes, there may be a ruptured seal in the mud saver valve. Check the seals as
follows:
Remove the open hose from the valve actuator.
Leave the test gauge on the open port.
Function the mud saver open.
If both gauges read 1,500 psi, then the seals are bypassing.
Service seals as required. If the seals are good, put open hose back on,
function close and monitor pressure gauges, then go to next step.
4. Is there pressure in close line?
If yes, there may be a problem with the shuttle valve. Inspect and repair as
required.
If no, there may be a mechanical bind in the actuator or mud saver valve. Inspect
and repair as required.
Note: The actuator drive keys can be removed to determine whether the actuator
is working.
LINK TILT FORWARD

general list of checks to perform. Also, ensure there is no electrical signal at the float solenoid.
building up, but the link tilt forward function will not operate.
1. Function link tilt forward.
2. Observe the flow control valve.
3. Is the forward side of the control valve closed?
If yes, open and retry the function.
4. Install a 3,000 psi pressure gauge on the forward line.
5. Retry the function and observe pressure.
6. Is pressure adequate?
If yes, check for mechanical binding, or look for factors that may impede bail
movement.
7. Install a pressure gauge on the link tilt reverse line.
8. Try the link tilt forward function.
9. Is there pressure on the reverse line?
If yes, the problem may be a blockage between the cylinder and the auxiliary
manifold.
Note: Both forward and reverse have a relief valve in the auxiliary manifold.
These reliefs should be set to 1,800 psi. If there is pressure at the link tilt cylinder,
but it is less than required, check for proper relief settings.
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HYDRAULIC FUNCTIONS
Unbalanced Bail Movement

The link tilt forward line has a flow divider valve that equalizes flow to each side of the bails.
This equalizes the movement of the left and right bails. If one bail is moving more than the
other, there may be a problem with the flow divider valve. Inspect and repair as required.
Also, if air has entered the system, the flow divider will operate incorrectly and may cause
unbalanced bail movement.
Link Tilt Float

Using the Float function opens the flow path between the forward and reverse link tilt lines.
When pressure on the forward and reverse side is mixed, the bails float to the vertical (neutral)
position.
If pressure on either the forward or reverse link tilt will not build to required pressure, the float
valve may be stuck. If this valve is partially open, it may result in reduced pressure to the link
tilt forward or reverse functions.
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Caution: Using the float function allows the bails to move in any
direction that will relieve force on the cylinders. If the bails are subject to external stresses when the float function is used, the bails
may move in an unanticipated direction. See the illustration below
for an example.
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HYDRAULIC FUNCTIONS
Figure 3-1: Unanticipated Bail Movement
LINK TILT REVERSE

general list of checks to perform. Also, ensure there is no electrical signal at the float solenoid.
building up, but the link tilt reverse function will not operate.
1. Function link tilt reverse.
2. Observe the flow control valve.
3. Is the reverse side of the control valve closed?
If yes, open and retry the function.
4. Install a 3,000 psi pressure gauge on the reverse line.
5. Retry the function and observe pressure.
6. Is pressure adequate?
If yes, check for mechanical binding, or look for factors that may impede bail
movement.
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HYDRAULIC FUNCTIONS
7. Install a pressure gauge on the link tilt forward line.

8. Try the link tilt reverse function.
9. Is there pressure on the forward line?
If yes, the problem may be a blockage between the cylinder and the auxiliary
manifold.
Note: Both forward and reverse have a relief valve in the auxiliary manifold.
These reliefs should be set to 1,800 psi. If there is pressure at the link tilt cylinder,
but it is less than required, check for proper relief settings.
Unbalanced Bail Movement

The link tilt forward line has a flow divider valve that equalizes flow to each side of the bails.
This equalizes the movement of the left and right bails. If one bail is moving more than the
other, there may be a problem with the flow divider valve. Inspect and repair as required.
Link Tilt Float

Using the Float function opens the flow path between the forward and reverse link tilt lines.
When pressure on the forward and reverse side is mixed, the bails float to the vertical (neutral)
position.
If pressure on either the forward or reverse link tilt will not build to required pressure, the float
valve may be stuck. If this valve is partially open, it may result in reduced pressure to the link
tilt forward or reverse functions.
Caution: Using the float function allows the bails to move in any
direction that will relieve force on the cylinders. If the bails are subject to external stresses when the float function is used, the bails
may move in an unanticipated direction.
GEARBOX LUBRICATION
The HCI gearbox incorporates flood design lubrication. Oil level is maintained above the top
bearing. Gear train movement causes the oil to circulate throughout the gearbox.
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HYDRAULIC FUNCTIONS
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CHAPTER 4: COOLING SYSTEM

COOLING FAN (MODINE)
The Modine cooling fan can be used to cool system hydraulic oil to slightly above ambient
temperature. The cooling fan operates more efficiently in humid environments than in dry
ones.
If ambient temperatures are above the desired operating temperature, then additional cooling
will be required. Most units are equipped with a Trane fluid-to-fluid plate exchanger for
supplemental cooling.
If the Modine cooling fan motor will not start, check for physical obstructions in the cooler
and fan. If none are present, consult the section called Motor Starter Problems on page 68.
HOT OIL SHUTTLE

The purpose of the hot oil shuttle is to divert hydraulic oil from the low pressure side of the
loop to the Modine cooler and Tranter plate exchangers.
The hot oil shuttle is pressure relief operated.
Figure 4-1: Hot Oil Shuttle
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COOLING SYSTEM
During normal operations, the hot oil shuttle should be set between 35-70 gpm. Shuttle flow
into the top side of the Modine cooler can be monitored using a gauge mounted opposite the
power unit's main electrical panel.
If loop temperature is rising beyond acceptable levels, you may need to increase the hot oil
shuttle volume.
Caution: Increasing the hot oil shuttle results in a closed loop flow
loss. The charge pump must compensate for this flow loss. If the
demands on the charge pump become too great, the system may
actually start to increase temperature rather than decrease.
Caution: If you are performing high flow/pressure operations and

pump case drain temperatures are rising above acceptable levels,
increasing the hot oil shuttle may actually make the problem worse.
Adjusting the Hot Oil Shuttle

To adjust the hot oil shuttle, the unit should be operating and the oil warmed to operating range
(approximately 120F, depending on ambient temperatures and oil blend).
Warning! Charge pressure should always be monitored

when the hot oil shuttle is adjusted. Never allow
the charge pressure to fall below 350 psi.
1. At the drillers panel, use the Pump Direction switch, select Forward.
2. Using the Increase/Decrease switch, increase pump speed.
Note: 1000 psi is required to activate the shuttle.
3. Unlock the shuttle control knob (aft side of the filter manifold).
Figure 4-2: Adjusting Hot Oil Shuttle
Caution: If sequence is set too low, shuttle will occur in reverse and
reverse pressure will relieve over the shuttle.
4. Observe the flow meter on the right side of the Modine cooler (opposite the main
electrical panel).
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COOLING SYSTEM
5. Adjust the shuttle flow by rotating the shuttle control knob.

Note: For six pump power units, the hot oil should be set to 50 gpm. For four
pump power units, the hot oil shuttle should be set 30 gpm.
6. Monitor charge pressure to ensure it does drop below acceptable levels.
7. Lock the shuttle control knob in place.
8. Monitor system temperature to ensure adequate cooling.
9. Adjust hot oil shuttle flow, if required.
Note: Only the flow control should be adjusted. The sequence control setting
should not require adjustment.
Adjust the Hot Oil Sequence Control

If the sequence control is not operating properly, it can be reset as follows. Sequence control is
factory set and should require no further adjustment.
1. Increase the hot oil shuttle control (bottom control) to an elevated level.
Note: Do this by rotating the control knob counter-clockwise past the normal
operating position. This will allow you to perform a visual check when setting the
sequence control.
2. Increase sequence control by rotating the control knob clockwise as far as it will
go.
3. Ensure the quill is not rotating.
4. Close the grabber on the saver sub.
5. Ensure that the pipe handler is locked.
6. Ensure pump speed is at zero.
7. At the driller's panel, select Mode Drill, Direction - Forward.
8. Gradually increase pump speed until there is a differential pressure between the
forward and reverse loop.
Note: Increase until there is 1,000 psi forward pressure.
9. Slowly decrease the sequence control (turn knob slowly in the counter-clockwise
direction) until flow is registered on the hot oil shuttle flowmeter (right side of the
Modine).
10. At the driller's panel, select Direction Neutral.
11. Key lock the sequence control (if lock is present).
12. Refer to Adjusting the Hot Oil Shuttle on page 32 for information on resetting
the oil flow to 35 50 gpm.
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COOLING SYSTEM
RE-CIRCULATION PUMP
The re-circulation pump moves oil from the storage tank through the Modine cooler and back
to tank. The re-circulation pump provides supplemental cooling of tank oil during demanding
operations.
Figure 4-3: Re-circulation pump
If the re-circulation pump will not start, see Motor Starter Problems on page 68.
Caution: There is no gauge to monitor flow from the re-circulation

pump. You can confirm pump operation by listening for pump
noise. Alternately, you can place a current meter on the pump's 480
V leads (in the electrical junction panel). Proper operating current is
approximately eight amps.
Always ensure that the pump's suction valve is open before starting the re-circulation pump.
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COOLING SYSTEM
COLD CLIMATE SWITCH

When operating in cold climates (-20C or lower) the Cold Climate switch can be used to
circulate and warm hydraulic oil before operating, or when the top drive is not in use.
Activating the Cold Climate button (pulling out the red mushroom button on the side of the
driller's panel) opens a relief poppit and the high/low poppit in the top drive manifold. Closed
loop oil crosses directly to the return line without going to the top drive motors. This allows
you to circulate oil through the closed loop system without rotating the quill.
If the power unit is operational, but you are unable to achieve quill rotation, check the Cold
Climate switch to ensure it has not been accidentally activated.
If the Cold Climate switch does not function refer to Chapter 5: Electric Component Hydraulic Functions.
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COOLING SYSTEM
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CHAPTER 5: ELECTRIC COMPONENT HYDRAULIC FUNCTIONS

!
Warning! All electrical troubleshooting must be conducted

by a qualified TESCO representative or
electrician. All electric troubleshooting
procedures should be used in conjunction with
the wiring schematics provided as part of the
HCI(S) System Schematics document set.
WIRING NOTES
The 37 conductor cable that runs from the top drive to the drillers panel and from the driller's
panel to the power module contains 37 colour coded wires.
Each colour-coded wire corresponds to a single terminal number. For example, conductor wire
5 (solid yellow wire) will be connected to terminal number 5 at the top drive, drillers panel
and power module.
For additional information, refer to the HCI System Schematics.
TESTING SOLENOIDS
You can confirm whether solenoids are receiving power using a simple magnetism test.
Hold any ferrous tool close to the solenoid. If magnetism is detected, the solenoid is receiving
power.
When testing for power, always test both sides of the solenoid. If both sides are receiving
power, the associated function may not work properly. This is because power supplied to both
sides simultaneously will tend to hold the function in the neutral position.
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ELECTRIC COMPONENT - HYDRAULIC FUNCTIONS
GENERAL ELECTRICAL TESTING

If one or more hydraulic functions are not operating correctly, perform these checks to
determine if the problem is mechanical or electrical.
If these general checks do not resolve the problem, refer to the troubleshooting topic for the
specific function(s) not working.
1. Is the hydraulic oil level adequate?
If not adequate, fill oil and check hydraulic function.
2. Is the auxiliary pump on and operating properly?
If no, inspect and repair the auxiliary pump as required, then check hydraulic
function. If pump motor was replaced, check for proper rotation.
3. Are there any significant leaks in the hydraulic system?
If yes, repair leaks as required, then check hydraulic function.
If no, go to the next step.
4. Are solenoids receiving power?
Note: You can easily check this using any ferrous tool. Hold the tool close to the
solenoid. If magnetism is detected, the solenoid is receiving power. This does not
rule out electrical problems but provides a good indication that the problem is
related to hydraulics.
If yes, manually function the solenoid valve(s) for any function that is not
working.
If no, go the to the next step.
5. Are the operating switches (contact blocks) at the drillers panel receiving power?
If yes, check the contact block and switch actuator.
If no, check the B conductor power terminals DPB 17/18 (+24 VDC) and DPB
19/20 (24V return).
6. Are the power terminals receiving power from the main panel?
If no, check the Pyle National B conductor pig tail and 37C cable for continuity
(see the following procedure).
If yes, check all wires leading into the operating switches (contact blocks). A
poor connection may result from loose wires.
7. If the B conductor pig tail and 37C cable continuity is sound, refer to Testing for
Generalized Power Problems on page 39.
Conducting a Pig Tail Continuity Check

Using a digital multi-meter (DMM), check continuity as follows:
1. Turn off 24 VDC power supply.
2. Switch the DMM to OHM mode.
3. Press the range button to select 0-400 ohm.
4. Disconnect the B conductor pig tail.
5. Install the DMM leads across pin 1B pig tail to terminal 1B terminal strip.
Note: The DMM should read .2 ohms, which indicates continuity.
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6. Install the DMM leads across pin 1B pig tail to terminal 2B terminal strip.
Note: The DMM should read OL-, which indicates "open line" or no continuity.
7. Check pin 1 across B terminals 3 37.
Note: Ensure that the DMM read OL- on all terminals. Continuity would indicate that a short is present.
8. Repeat the continuity check for all pins.
9. Follow the procedure described above to check the 37C cable and Pyle national
connectors for soundness.
Testing for Generalized Power Problems

1. Using a digital multi-meter (DMM), check for 24V power out of the power supply
as follows:
Connect the positive lead to the positive terminal off the power supply.
Connect the negative lead to the 24V return terminal off the power supply.
If no voltage is present, proceed to the next step (2).
If voltage is present, follow through to MPB 17/18 +24VDC and MPB 19/20,
24V return.
If 24 VDC is present at the main panel but not in the driller's panel, carefully
check the 37C cable and all B connectors for continuity.
2. If there is no power output from the 24V power supply, check the on board 25
amp fuse as follows.
Check the power into the fuse with the DMM.
If 24 VDC is present into the fuse, turn off the power and remove the fuse.
Using the DMM in Ohm range, check the fuse for continuity.
3. If there is no power to the fuse, check the 120 VAC supply to the power supply as
follows:
With the DMM on the AC range, place the positive lead on wire 15 at the supply
and the negative lead on the neutral wire.
Ensure power is restored.
If power is present, check connection on power supply. If connections look good
there may be a faulty component on the power supply.
4. If there is no 120 VAC to the power supply, check the 120 VAC inline fuse as
follows:
Using the DMM check for voltage into the fuse, FU-5.
If voltage is present into the fuse, turn off the power and remove the fuse from
the holder.
Using the DMM in Ohm range, check the fuse for continuity.
5. If no power is present into the fuse, restore power and check the 15 amp breaker
feeding the power supply as follows.
Ensure that the breaker has not been tripped.
Using the DMM in AC range, check voltage to the breaker (L1 off the 20 kVa
transformer).
6. If no voltage is present from the transformer, check the 480V side of the
transformer.
Note: The feed is three-phase power and should read 480V between L1 and L2 or
L2 to L3 etc.
Note: Ensure the 30 amp breaker feeding the transformer is closed.
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7. If no power is present to the breaker, check the power unit supply from the rig and
the main 80 amp fuses in the top left of the main panel, fuse 1,2 and 3.
8. If you have performed all of these tests and have not located the trouble source,
contact TESCO.
Multiple Functions Operating when one is Selected

If more than one function operates when only one is selected, the likely cause is:
a bad diode
a faulty Pyle National connection
a loose wire shorting between function wires
All diodes are installed in the drillers panel. They prevent voltage from one function from
back-feeding to another, non-selected function. If a diode fails, power feeds to an unselected
function and operates the corresponding solenoid valve. Hydraulic pressure will be delivered
to the selected function, and the function that is receiving the faulty signal may also operate.
Diodes can be checked using a digital multi-meter (DMM). To confirm diode failure you must:
check for feedback from the requested function (the function that results in multiple
responses), to the unrequested function (the function that operates when another is
requested)
test the unrequested function diode
Checking for Feedback

1. Open the hydraulic panel at the top drive.
2. Remove the cover plate for the solenoid of the unrequested function.
3. Remove wire nuts.
4. Check for corrosion.
5. Install a digital multi-meter across the wires from 24 V return to +24VDC.
6. Operate the requested function.
7. If the DMM reads 24V, proceed to the drillers panel to test the diode.
Testing the Diode

1. At the drillers panel, remove all incoming wires and the yellow diode jumper
from the unrequested function diode.
2. Switch the DMM to Diode Check mode.
3. Connect the DMM across the diode and test.
Note: The red lead should be placed on the anode (bottom of diode, inside the
contact screw). The black lead should be placed on the cathode (top of diode,
outside contact screw). A good diode will read .5 to .7 VDC. Reverse polarity
should read -O.L.-.
4. Replace if faulty.
Note: If the diode is functioning properly, the problem is likely a short in the
wiring, the DPA conductor, the pig tail, the 37C cable to the top drive, or the TDA
conductor pigtail.
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GRABBER LIFT-UP
Before using this troubleshooting tree, refer to General Electrical Testing on page 38 for a
more general list of checks to perform.
1. Open the auxiliary hydraulics panel.
2. Select Grabber Lift-Up.
3. Determine whether an electrical signal is arriving at the unloader and Grabber Lift
Up solenoids.
Note: You can determine if power is supplied using the simple magnetism test.
See General Electrical Testing on page 38.
If there is power at both of these solenoids, refer to the auxiliary hydraulic
troubleshooting procedures.
If there is no power at either solenoid the problem likely originates at the
drillers panel.
4. If there is no power to the Grabber Lift-Up solenoid only, remove the cover for the
Grabber solenoids.
5. Remove wire nuts for the Grabber Lift-Up wires.
Note: Ensure that you do not short any of the wires.
6. Check for wire breaks or corrosion on the wires.
Note: If corrosion is found, clean and retest the function. If breaks are found,
reconnect the wires and retest the function.
7. Install a digital multi-meter across the wires from 24 V return and +24VDC.
Note: The solenoid contains wires for Grabber Lift-Up, the other side contains
wires for Grabber Lift-Down. A common wire from each coil leads back to the
24V return wire.
8. Select Grabber Lift-Up and observe the DMM.
9. Ensure that when Grabber Lift-Up is functioned (with power on), there is 24V
power at the Grabber Lift-Up coil.
10. If the Grabber Lift-Up coil is not receiving power, install the DMM on wire 221
(terminal 20 on the auxiliary panel terminal strip).
Note: Ensure the negative lead is installed on the 24 V return.
11. Select Grabber Lift-Up .
12. Check the DMM to confirm that terminal 20 is receiving power.
13. If no power is received, check the Pyle National A connectors and the 37C cable
for continuity.
14. If the A connectors are properly in place, and continuity is sound, proceed to the
drillers panel.
15. Using the DMM, place the positive on the A strip terminal, and negative on the
24V return.
Note: Strip A, terminal 20 should have wire 221 connected to it.
17. If there is no power, move the DMM positive to port 221 on the back side of the
Grabber Lift-Up switch (back side of the drillers panel).
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19. If there is no power, check switch incoming wire #1, which is +24 VDC.
Note: This switch should have power all the time whether Grabber Lift-Up is
selected or not.
20. If there is no power to wire #1, check B strip red terminal blocks for +24VDC and
24 V return power.
21. If there is no power at the terminal blocks, proceed main electrical panel at the
power unit.
22. Using the DMM, check for 24V power between MPB 17/18 (24 VDC) and MPB
19/20 (24 V return).
If there is power at the MPB strip but not at the drillers panel, the problem is
likely related to improper Pyle National connections.
If there is no power to functions at the MPB strip, there may be a more
generalized power problem. Refer to Testing for Generalized Power Problems
on page 39.
GRABBER LIFT-DOWN
2. Select Grabber Lift-Down.
3. Determine whether an electrical signal is arriving at the unloader and Grabber Lift
Down solenoids.
If there is no power at either solenoid, the problem likely originates at the
drillers panel.
4. If there is no power to the Grabber Lift-Down solenoid only, remove the cover for
the Grabber solenoids.
5. Remove wire nuts for the Grabber Lift-Down wires.
Note: The solenoid contains wires for Grabber Lift-Down, the other side contains
wires for Grabber Lift-Up. A common wire from each coil leads back to the 24V
return wire.
8. Select Grabber Lift-Down and observe the DMM.
9. Ensure that when Grabber Lift-Down is functioned (with power on), there is 24V
power at the Grabber Lift-Down coil.
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10. If the Grabber Lift-Down coil is not receiving power, install the DMM on wire
223 (terminal 22 on the auxiliary panel terminal strip).
11. Select Grabber Lift-Down .
13. If no power is received, check the Pyle National connectors.
14. If the connectors are properly in place, proceed to the drillers panel.
24V return.
17. If there is no power, move the DMM positive to wire 223 on the back side of the
Grabber Lift-Down switch (back side of the drillers panel).
19. If there is no power, check switch incoming wire #1 which is +24 VDC.
Note: This switch should have power all the time whether Grabber Lift-Down is
selected or not.
20. If there is no power to wire #1, check B strip red terminal blocks DPB 17/18
(+24VDC) and DPM 19/20 (24VDC return).
21. If there is no power at the terminal blocks, proceed to the power module analog
panel.
19/20 (24 V return).
on page 39.
PIPE HANDLER-UNLOCK
2. Select Pipe Handler-Unlock.
3. Determine whether an electrical signal is arriving at the unloader and Pipe
Handler-Unlock solenoids.
drillers panel.
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4. If there is no power to the Pipe Handler-Unlock solenoid only, remove the cover
for the Pipe Handler solenoids.
5. Remove wire nuts for the Pipe Handler-Unlock wires.
Note: The solenoid contains wires for Pipe Handler-Unlock, the other side
contains wires for Pipe Handler-Lock. A common wire from each coil leads back
to the 24V return wire.
8. Select Pipe Handler-Unlock and observe the DMM.
9. Ensure that when Pipe Handler-Unlock is functioned (with power on), there is
24V power at the Pipe Handler-Unlock coil.
10. If the Pipe Handler-Unlock coil is not receiving power, install the DMM on wire
112 (terminal 15 on the auxiliary panel terminal strip).
for continuity.
drillers panel.
24V return.
16. Select Pipe Handler - Unlock.
Pipe Handler-Unlock switch (back side of the drillers panel).
Note: This switch should have power all the time whether Pipe Handler-Unlock is
selected or not.
panel.
19/20 (24 V return).
on page 39.
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PIPE HANDLER-LOCK
2. Select Pipe Handler-Lock.
3. Determine whether an electrical signal is arriving at the unloader and Pipe
Handler-Lock solenoids.
drillers panel.
4. If there is no power to the Pipe Handler-Lock solenoid only, remove the cover for
the Pipe Handler solenoids.
5. Remove wire nuts for the Pipe Handler-Lock wires.
Note: The solenoid contains wires for Pipe Handler-Lock, the other side contains
wires for Pipe Handler-Unlock. A common wire from each coil leads back to the
24V return wire.
8. Select Pipe Handler-Lock and observe the DMM.
9. Ensure that when Pipe Handler-Lock is functioned (with power on), there is 24V
power at the Pipe Handler-Lock coil.
10. If the Pipe Handler-Lock coil is not receiving power, install the DMM on wire 110
for continuity.
drillers panel.
24V return.
Pipe Handler-Lock switch (back side of the drillers panel).
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19. If there is no power, check switch incoming wire #1, which is +24 VDC.
Note: This switch should have power all the time whether Pipe Handler-Lock is
selected or not.
panel.
19/20 (24 V return).
on page 39.
LINK TILT-FORWARD
2. Select Link Tilt-Forward.
3. Determine whether an electrical signal is arriving at the unloader and Link TiltForward solenoids.
drillers panel.
4. If there is no power to the Link Tilt-Forward solenoid only, remove the cover for
the Link Tilt solenoids.
5. Remove wire nuts for the Link Tilt-Forward wires.
Note: The solenoid contains wires for Link Tilt-Forward, the other side contains
wires for Link Tilt-Back. A common wire from each coil leads back to the 24V
return wire.
8. Select Link Tilt-Forward and observe the DMM.
9. Ensure that when Link Tilt-Forward is functioned (with power on), there is 24V
power at the Link Tilt-Forward coil.
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10. If the Link Tilt-Forward coil is not receiving power, install the DMM on wire 34
for continuity.
drillers panel.
24V return.
Link Tilt-Forward switch (back side of the drillers panel).
Note: This switch should have power all the time whether Link Tilt-Forward is
selected or not.
panel.
19/20 (24 V return).
on page 39.
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LINK TILT-BACK
2. Select Link Tilt-Back.
3. Determine whether an electrical signal is arriving at the unloader and Link TiltBack solenoids.
drillers panel.
4. If there is no power to the Link Tilt-Back solenoid only, remove the cover for the
Link Tilt solenoids.
5. Remove wire nuts for the Link Tilt-Back wires.
Note: The solenoid contains wires for Link Tilt-Back, the other side contains
wires for Link Tilt-Forward. A common wire from each coil leads back to the 24V
return wire.
8. Select Link Tilt-Back and observe the DMM.
9. Ensure that when Link Tilt-Back is functioned (with power on), there is 24V
power at the Link Tilt-Back coil.
10. If the Link Tilt-Back coil is not receiving power, install the DMM on wire 36
for continuity.
drillers panel.
24V return.
Link Tilt-Back switch (back side of the drillers panel).
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Note: This switch should have power all the time whether Link Tilt-Back is
selected or not.
panel.
19/20 (24 V return).
on page 39.
Link Tilt-Float
The Link Tilt Float circuit contains two relay switches (5 and 6). These are holding contacts
for the float function.
If there is a problem with relay 6, the float function will only operate as long as float button is
held down. If the float button is released, the float action is interrupted. If you are experiencing
this problem, check the relay 6 circuit before performing the following.
2. Select Link Tilt-Float.
3. Determine whether an electrical signal is arriving at the Link Tilt-Float solenoids.
If there is power at this solenoid, refer to the auxiliary hydraulic troubleshooting
procedures.
If there is no power at this solenoid the problem likely originates at the drillers
panel.
4. If there is no power to the Link Tilt-Float solenoid only, remove the cover for the
Link Tilt solenoids.
5. Remove wire nuts for the Link Tilt-Float wires.
Note: The solenoid contains wires for Link Tilt-Float, the wires on the other side
contains are unused. A common wire from each coil leads back to the 24V return
wire.
8. Select Link Tilt-Float and observe the DMM.
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9. Ensure that when Link Tilt-Float is functioned (with power on), there is 24V
power at the Link Tilt-Float coil.
10. If the Link Tilt-Float coil is not receiving power, install the DMM on wire 32
for continuity.
drillers panel.
24V return.
Note: Strip A, terminal 8 should have wire 32/31 connected to it.
Link Tilt-Float switch (back side of the drillers panel).
19. If there is no power, check the incoming wire to the float button - #47.
20. If there is no power to wire #47, check relay 5.
Note: Relay 5 interrupts power to the float button if link tilt forward or backward are energized (terminals 14 (+24 VDC) and 15 (24 VDC return)).
21. Check wire 1 (red) to terminal 9 on relay 5.
Note: This wire should have power to it at all times. If no power is present, refer
to Testing for Generalized Power Problems on page 39.
22. If power to the float function is only present while the button is depressed,
troubleshoot relay 6.
Note: Relay 6 is energized when the float button is pressed. It holds power to the
float solenoid until Link Tilt - Forward or Link Tilt - Backward is selected.
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EXTEND-IN
2. Select Extend-In.
3. Determine whether an electrical signal is arriving at the unloader and Extend-In
solenoids.
drillers panel.
4. If there is no power to the Extend-In solenoid only, remove the cover for the
Extend solenoids.
5. Remove wire nuts for the Extend-In wires.
Note: The solenoid contains wires for Extend-In, the other side contains wires for
Extend-Out. A common wire from each coil leads back to the 24V return wire.
8. Select Extend-In and observe the DMM.
9. Ensure that when Extend-In is functioned (with power on), there is 24V power at
the Extend-In coil.
10. If the Extend-In coil is not receiving power, install the DMM on wire 52 (terminal
6 on the auxiliary panel terminal strip).
for continuity.
drillers panel.
24V return.
Extend-In switch (back side of the drillers panel).
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Note: This switch should have power all the time Extend-In is selected or not.
panel.
19/20 (24 V return).
on page 39.
EXTEND-OUT
2. Select Extend-Out.
3. Determine whether an electrical signal is arriving at the unloader and Extend-Out
solenoids.
drillers panel.
4. If there is no power to the Extend-Out solenoid only, remove the cover for the
Extend solenoids.
5. Remove wire nuts for the Extend-Out wires.
Note: The solenoid contains wires for Extend-Out, the other side contains wires
for Extend-In. A common wire from each coil leads back to the 24V return wire.
8. Select Extend-Out and observe the DMM.
9. Ensure that when Extend-Out is functioned (with power on), there is 24V power
at the Extend-Out coil.
10. If the Extend-Out coil is not receiving power, install the DMM on wire 55
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for continuity.
drillers panel.
24V return.
Extend-Out switch (back side of the drillers panel).
Note: This switch should have power all the time Extend-Out is selected or not.
panel.
19/20 (24 V return).
on page 39.
ELEVATOR-OPEN
To open the elevators you must select Elevator-Open, and simultaneously push the Elevator
safety button. The elevators will not open unless the safety button is pushed.
2. Select Elevator-Open.
3. Determine whether an electrical signal is arriving at the unloader and Elevator
Open solenoids.
drillers panel.
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4. If there is no power to the Elevator-Open solenoid only, remove the cover for the
Elevator solenoids.
5. Remove wire nuts for the Elevator-Open wires.
Note: The solenoid contains wires for Elevator-Open, the other side contains
wires for Elevator-Close. A common wire from each coil leads back to the 24V
return wire.
8. Select Elevator-Open and observe the DMM.
9. Ensure that when Elevator-Open is functioned (with power on), there is 24V
power at the Elevator-Open coil.
10. If the Elevator-Open coil is not receiving power, install the DMM on wire 9
for continuity.
drillers panel.
24V return.
Elevator-Open switch (back side of the drillers panel).
Note: This switch should have power all the time Elevator-Open is selected or
not.
(+24VDC) and DPB 19/20 (24VDC return).
panel.
19/20 (24 V return).
on page 39.
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ELEVATOR-CLOSE
2. Select Elevator-Close.
3. Determine whether an electrical signal is arriving at the unloader and ElevatorClose solenoids.
drillers panel.
4. If there is no power to the Elevator-Close solenoid only, remove the cover for the
Elevator solenoids.
5. Remove wire nuts for the Elevator-Close wires.
Note: The solenoid contains wires for Elevator-Close, the other side contains
wires for Elevator-Open. A common wire from each coil leads back to the 24V
return wire.
8. Select Elevator-Close and observe the DMM.
9. Ensure that when Elevator-Close is functioned (with power on), there is 24V
power at the Elevator-Close coil.
10. If the Elevator-Close coil is not receiving power, install the DMM on wire 13
for continuity.
drillers panel.
24V return.
17. If there is no power, move the DMM to the output side of diode 17.
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19. If there is no power, move the DMM to wire 5 (the input to diode 17).
21. If there is no power, move the DMM to wire 4 at the Elevator-Close switch at the
drillers panel.
23. If there is no power, attach DMM positive to wire 4 on the back side of the
Elevator-Close switch (back side of the drillers panel).
25. If there is no power, check the brake handle circuit as follows.
a. Attach the DMM to wire 14.
b. Select Elevator-Close.
c. If there is no power to wire 14, attach the DMM to wire 25.
d. Select Elevator-Close.
e. If there is no power to wire 25, move the DMM to terminal 2, relay 2.
Note: This is the incoming power to the brake handle switch.
f.
If there is no power, check switch incoming wire #1 which is +24 VDC.

Note: This switch should have power all the time Elevator-Close is selected
or not.
g. If there is no power to wire #1, check B strip red terminal blocks DPB 17/18
panel.
19/20 (24 V return).
If there is power at the MPB strip but not at the drillers panel, the problem
is likely related to improper Pyle National connections.
generalized power problem. Refer to Testing for Generalized Power
Problems on page 39.
Elevator Close at Brake Handle

If Elevator-Close is operated from the brake handle and the elevators will only react when the
push button is held down, there may be a problem with the holding contacts in the drillers
panel.
When relay 1 (Elevator-Close) is energized, holding contacts 9 and 5 are closed. This holds the
elevator close function.
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GRABBER-OPEN
2. Select Grabber-Open.
3. Determine whether an electrical signal is arriving at the unloader and Grabber
Open solenoids.
drillers panel.
4. If there is no power to the Grabber-Open solenoid only, remove the cover for the
Grabber solenoids.
5. Remove wire nuts for the Grabber-Open wires.
Note: The solenoid contains wires for Elevator-Open, the other side contains
wires for Elevator-Close. A common wire from each coil leads back to the 24V
return wire.
8. Select Grabber-Open and observe the DMM.
9. Ensure that when Grabber-Open is functioned (with power on), there is 24V
power at the Grabber-Open coil.
10. If the Grabber-Open coil is not receiving power, install the DMM on wire 89
for continuity.
drillers panel.
15. Using the DMM, place the positive on the A strip, terminal 1, and negative on the
24V return.
17. If there is no power at terminal 1, move the DMM to the grabber open contact
block wire 73.
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18. If there is no power at the contact block, check incoming wire #1 which is +24
VDC.
Note: This switch should have power all the time whether Grabber-Open is
selected or not.
19. If there is no power to the contact block, check B strip red terminal blocks DPB
17/18 (+24VDC) and DPM 19/20 (24VDC return).
panel.
19/20 (24 V return).
on page 39.
GRABBER-CLOSE
2. Select Grabber-Close.
3. Determine whether an electrical signal is arriving at the unloader and GrabberClose solenoids.
drillers panel.
4. If there is no power to the Grabber-Close solenoid only, remove the cover for the
Grabber solenoids.
5. Remove wire nuts for the Grabber-Close wires.
Note: The solenoid contains wires for Grabber-Close, the other side contains
wires for Grabber-Open. A common wire from each coil leads back to the 24V
return wire.
8. Select Grabber-Close and observe the DMM.
9. Ensure that when Grabber-Close is functioned (with power on), there is 24V
power at the Grabber-Close coil.
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10. If the Grabber-Close coil is not receiving power, install the DMM on wire 75
for continuity.
drillers panel.
24V return.
17. If there is power at relay terminal 76 and 81, move the DMM positive to port 2 on
the back side of the Grabber-Close switch (back side of the drillers panel).
Note: This switch should have power all the time Grabber-Close is selected or
not.
panel.
19/20 (24 V return).
on page 39.
Grabber-Close Holding Contact Circuit

This circuit maintains power to the drawworks interlock circuit and the Grabber-Close light
when Grabber-Close is reset to neutral. If the grabber is set to neutral from close, the circuit
will ensure that the top drive cannot be hoisted and the Close light stays on.
1. Position the DMM at relay 11, terminals 13.
3. If power is present, position the DMM at relay 11, terminal 14.
4. Select Grabber-neutral.
5. Check for power at terminal 14.
6. If there is no power at terminal 14, move the DMM to terminal 5.
7. If there is power at terminal 9, but not at terminal 5, then relay 11 is not operating
properly.
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8. Check diode 16.

9. If the diode is OK, check power to wire 82/8488.
If there is no power to 82/84/88, move the DMM to wire 81/181 (the input to
diode 16).
10. If there is no power at wire 75, check switch incoming wire #1 which is +24 VDC.
Note: This switch should have power all the time.
11. If there is no power to wire #1, check B strip red terminal blocks for +24 and 24 V
return power.
12. If there is no power at the terminal blocks, proceed to the main electrical panel on
the power unit.
13. Using the DMM, check for 24V power between terminals 17/18 (+24 VDC) and
19/20 (24 V return).
If there is power at the main panel strip but not at the drillers panel, the problem
is likely related to improper Pyle National connections.
If there is no power to functions at the CPB strip, there may be a more
on page 39.
Grabber/Pipe Handler Interface

When the Grabber-Close is selected, the pipe handler lock is pressured up in the lock position.
This ensures that the pipe handler will not rotate when the grabber is in the closed position.If
this safety feature is not operating correctly, and it is confirmed that the pipe handler has not
been set to unlock, then there may be a problem with the pipe handler safety lock circuit.
If a failure is suspected, perform the following checks.
1. Select Pipe Handler -Unlock.
2. Turn the Pipe Handler switch to neutral.
3. Ensure that the quill is stationary, and that the Quill Direction switch has been set
to neutral.
Note: This is an important safety precaution.
4. Select Grabber -Close.
5. If the pipe handler does not lock, check for power to wire 246.
Note: This is the input to diode 29.
6. If there is power to wire 246, check the output wire, 247.
Note: This is the output to terminal 10, relay 15.
7. If there is power to wire 247, check for power at terminal 2, relay 15, wire 248.
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Grabber/Drawworks Interlock Interface

When the grabber is closed, an interrupt circuit prevents the driller from hoisting the top drive.
This interrupt can be overridden using the drawworks interlock override button at the brake
handle.
If the override function is not working (i.e. the driller cannot hoist with the grabber closed,
although the red override button is pressed) then the override switch is faulty.
If the safety feature is not functioning properly, the driller will be able to hoist (with the
grabber closed) without using the override button. If this is the case, perform the following
procedure.
1. Ensure that the drawworks air valve and override button have been properly
installed.
2. Place the DMM positive at wire 84.
4. If power is present, move the DMM to wire 82.
5. If power is present, move the DMM to the C terminal of the F cord connector.
6. If power is present, move the DMM to the D terminal of the F cord connector.
7. If power is present, move the DMM to terminal strip B (drillers panel), terminal
38.
8. If power is present, move the DMM to the A terminal of the C cord.
9. If power is present, move the DMM to the drawworks air valve.
10. If power is present, move the DMM to the B terminal of the C cord.
11. If power is present, check wire 2, the output of the B terminal.
Note: If the DMM reads 24V, then there is a break in the wire 2.
MUD SAVER VALVE-OPEN

2. Select Mud Saver-Open.
3. Determine whether an electrical signal is arriving at the unloader and Mud SaverOpen solenoids.
drillers panel.
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4. If there is no power to the Mud Saver-Open solenoid only, remove the cover for
the Mud Saver solenoids.
5. Remove wire nuts for the Mud Saver-Open wires.
Note: The solenoid contains wires for Mud Saver-Open, the other side contains
wires for Mud Saver-Close. A common wire from each coil leads back to the 24V
return wire.
8. Select Mud Saver-Open and observe the DMM.
9. Ensure that when Mud Saver-Open is functioned (with power on), there is 24V
power at the Mud Saver-Open coil.
10. If the Mud Saver-Open coil is not receiving power, install the DMM on wire 171
for continuity.
drillers panel.
24V return.
17. If there is no power, move the DMM to wire 171.
19. If there is power at wire 171, move the DMM positive to wire 261.
21. If there is no power at 261, move the DMM positive to wire 263 at the output of
diode 30.
Note: If there is power at wire 261, then there may be problem with diode 24.
23. If there is no power at wire 264, move the DMM positive to wire 260, the input to
diode to 30.
25. If there is no power at wire 260, move the DMM positive to wire 57.
Note: This switch should have power all the time Mud Saver-Close is selected or
not.
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panel.
19/20 (24 V return).
on page 39.
Mud Saver Open Timer Circuit

The Mud Saver-Open function operates in conjunction with a timer circuit. This circuit is
designed to maintain pressure on the mud saver mechanism until the valve fully opens (holds
for 5 seconds). If the mud saver valve is not opening fully, or if it ceases to open unless the
switch is held in the Open position, there may be a problem with the timer circuit. If
applicable, perform the following timer circuit checks.
1. Connect the DMM to terminal S at the Mud Saver-Open timer cube.
2. Using the Mud Saver switch, quickly flick to Open, then release.
3. Check for power at terminal S.
4. If there is no power at the timer cube, move the DMM to wire 262.
Note: If there is power to terminal S, then the timer cube may be faulty. Replace
and retest if required.
6. If there is no power at wire 262, move the DMM to wire 60 at diode 22.
8. If there is no power, move the DMM to wire 57/260, the input to diode 22.
12. If there is no power at wire 57, continue by checking incoming power (see steps
37-40 of Mud Saver-Open procedure).
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Direction Holding Circuit

If the direction holding circuit is not functioning properly, the mud saver valve may close
when the Mud Saver switch is set to neutral from open. To check this circuit perform the
following:
1. Attach the DMM to relay 10, terminal 6.
3. If there is not power at relay 10, terminal 6, move the DMM to relay 10, terminal
10.
5. If there is no power, move the DMM to relay 16, terminal 6.
7. If there is no power to relay 6, continue by checking incoming power (see steps
37-40 of Mud Saver-Open procedure).
MUD SAVER VALVE-CLOSE

2. Select Mud Saver-Close.
3. Determine whether an electrical signal is arriving at the unloader and Mud SaverClose solenoids.
drillers panel.
4. If there is no power to the Mud Saver-Close solenoid only, remove the cover for
the Mud Saver solenoids.
5. Remove wire nuts for the Mud Saver-Close wires.
Note: if corrosion is found, clean and retest the function. If breaks are found,
Note: The solenoid contains wires for Mud Saver-Close, the other side contains
wires for Mud Saver-Open. A common wire from each coil leads back to the 24V
return wire.
8. Select Mud Saver-Close and observe the DMM.
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9. Ensure that when Mud Saver-Close is functioned (with power on), there is 24V
power at the Mud Saver-Close coil.
10. If the Mud Saver-Close coil is not receiving power, install the DMM on wire 59
for continuity.
drillers panel.
24V return.
17. If there is no power, check wire 264/59.
18. If there is power at wire 264/59, move the DMM positive to wire 59/66/264.
20. If there is no power at 59/66/264, move the DMM positive to wire 59.
22. If there is no power at wire 59, move the DMM positive relay 10, terminal 2.
24. If there is no power at relay 10, terminal 2, move the DMM positive to relay 10,
terminal 10.
26. If there is no power at relay 10, terminal 10, move the DMM to wire 256.
Note: This switch should have power all the time Mud Saver-Close is selected or
not.
panel.
19/20 (24 V return).
on page 39.
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Mud Saver-Close Light

The Mud Saver-Close Light should illuminate whenever the mud saver valve is in the closed
position, and should not shut off until Mud Saver-Open is selected. This is an important
safety indicator. If the light is not functioning, perform the following checks:
1. Confirm that the Mud Saver-Close function is operating properly.
2. Confirm that the light bulb is not burnt out or broken.
3. Install the DMM at relay 9, terminal 14.
Note: Install the negative on 24 V return.
5. If there is no power, move the DMM to wire 69/70.
14. If there is no power to relay 10, continue by checking incoming power (see steps
28-31 of Mud Saver-Close procedure).
Optional Current Sensor

A circuit for the optional current sensor is included. If installed, the current sensor detects a
signal whenever mud pumps are started and, if required, will automatically open the mud
saver valve. The current sensor also interrupts power to the Valve-Close function when a
signal is detected. If difficulty is experienced with the current sensor, contact a TESCO
representative.
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CHAPTER 6: POWER UNIT

READ THIS FIRST
If you experience a problem with the HCI(S) power module that you cannot solve, contact
TESCO for assistance.
Note: In order to solve your problem quickly and efficiently, TESCO will require
the information detailed in the following procedure. Please read this procedure
and gather the requested information before you call.
Caution: All of these procedures should be performed before you
attempt to restart the unit.
Write down the following:

1. What was the driller doing when the problem occurred?
2. What were the operating conditions (rpm and torque)?
3. What was the operating pressure of the closed loop system?
4. What were the operating temperatures for:
prime mover
case drain from saver pumps
pump drive oil temperature
oil reservoir tank temperature
5. Is there any recent operating or maintenance information that might be relevant to
the current problem?
Perform These Checks

Do a visual inspection of all power unit components including:
prime mover
pump drive
pumps
filter manifold
storage tank
cooling system
interconnecting pipework
Record any evidence of damage you encounter.
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POWER UNIT
Restart the System

If the system check reveals no problems, and if all temperatures are within operating range,
you may return pump control switches to neutral and attempt to restart the system.
MOTOR STARTER PROBLEMS

The following section applies to:
step down transformer

cooling fan
oil re-circulation pump
auxiliary pump
Each of these functions is connected to its own circuit breaker and on/off control on the main
distribution panel.
All starters are 120 VAC. Each starter circuit includes a normally open switch (located in the
power module). When a switch is closed it energizes the starter and connects the 480 V power
to the specified motor.
Each starter contains heater elements that have been sized for the running current draw of each
motor. If a motor continuously draws more power than it is designed for, the heater element
temperature sensor will trip the starter, and the motor will stop.
Note: Unlike the other motors listed, the cooling fan has a two position switch.
The settings are hand and auto. When the switch is in the hand position, 120V
power is supplied directly to the fan's motor starter. If the auto is selected, 120V
power is directed through a temperature switch in the top drive cooling tank. This
switch will close only when the fluid temperature exceeds a preset value.
Motor Keeps Quitting

The most common starter problems occur when a motor is consistently overloaded. If this
occurs, the temperature sensor in the heating element will open the starter and the motor will
quit. To test:
1. Restart the motor.
2. Use an amp meter to measure motor current draw on line 1, line 2 and line 3.
Note: The draw should be roughly equal across all three legs and no leg should
exceed the full load amperage of the motor (as indicated on the name plate).
Note: Heater elements and sensors will weaken each time an excessive power
draw occurs. As the elements weaken, they will trip at lower power draws. If the
power draw from the motor is within acceptable limits, but the starter continues to
open, replace the heater elements.
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POWER UNIT
Motor Quits and Will Not Start

If one heater element fails during operation, the motor may continue running using single
phase power. The additional draw on remaining lines will eventually cause one of the
remaining heater elements to open the starter. The motor will quit and, because power supply
is compromised, it will not start again.
If this condition occurs, monitor all three lines using a amp meter. The open heater line will
read zero. Replace the heater element and restart the motor.
Motor is Not Receiving Power

If you suspect that a motor is not receiving power, perform the following checks.
1. Energize the motor breaker.
2. Using a DMM, test the top side of the motor starter (the line side).
Note: There should be 480V phase to phase power between line 1 and line 2, line
1 and line 3, and line 2 and line 3. Power from any line to ground should be 277V.
3. If there is power at the starter, but the motor starter will not operate, check the
120V control circuit.
Note: Start at the motor starter and work back to the control switch on the main
power module.
AUXILIARY PUMP/MOTOR PROBLEMS

Power supply to the auxiliary pump motor is identical to the power supply for the motors
discussed in the previous section. However, the auxiliary pump motor has a unique control setup that allows the auxiliary pump to be started from either the drillers panel or the main
distribution panel.
If the motor is not functioning as required, and all standard power checks have been
performed, consult the following section.
Note: If the auxiliary pump can be started from the main distribution panel, but
not from the driller's panel, check the 37C cable for damage and Pyle-National B
connectors for continuity.
Auxiliary Pump Motor Will Not Start

1. Check for 480 V power supply as described in Motor is Not Receiving Power
on page 69.
2. If 480 V power is being supplied, but the motor will not start, proceed with
checking the 120 V control circuit at the power module.
Note: The power module control switch has one normally open and normally
closed contact.
3. Using a DMM, check the normally closed switch at the back of the auxiliary panel
(in the power module) for 120 V power.
4. If there is power at the switch, select Auxiliary Pump-On.
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POWER UNIT
5. Check wire 7.
6. If there is power on wire 7, check the auxiliary motor switch.
7. If there is no power to the switch, check wire 6, incoming power to the switch.
8. If there is power to the switch, examine the switch for defects.
9. If no switch defects are found, check wire 5.
If power is present, check switch function.
10. If no power is present at wire 5, check terminal 1 or relay 22
Note: Relay 22 is the auxiliary pump off control from the driller's panel. If relay
22 is energized, check the 24 VDC circuit and switch in the driller's panel.
11. If relay 22 is not energized, check terminal 9 of relay 22.
Note: There should be 120 VAC to this terminal from L2 of the 20 kVa transformer.
12. If there is no power to relay 22, see testing for Testing for Generalized Power
Auxiliary Pump Operates from Main Panel but not the Driller's
Panel
1. Turn the auxiliary pump off.
2. Try to start the [pump from the driller's panel.
3. Check wire 1 at the main panel.
4. If there is no power when the driller's panel control is functioned, ensure that
terminal 12 or relay 21 is being supplied 120 VAC power from L2.
Note: L2 is fused. Check the fuse before proceeding.
5. Check terminal 14 of relay 21 (+24 VDC when the pump is started from the
driller's panel) and terminal 13 of relay 21 (24V return).
6. If 24 VDC power is not present when the switch is operated, proceed to wire 144
(terminal 11 on the MPB strip).
7. If 24 VDC is not present, proceed to the drillers panel.
8. At the drillers panel, check wire 144, terminal 11 on the DPB strip.
9. If 24 VDC is not present, check wire 144 on the auxiliary pump switch.
Note: Ensure that wire 1 on the other side of the switch has 24 VDC continuously.
10. If wire 1 is not transmitting 24 VDC, refer to Testing for Generalized Power
Auxiliary Pump - Driller's Panel Controls

The following information may assist in troubleshooting auxiliary pump problems that
originate from the drillers panel.
The driller's panel switch has two normally open contacts that operate relay 21 (aux. pump on)
and 22 (aux. pump off) in the power module.
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POWER UNIT
When Auxiliary Pump-On is selected at the drillers panel, wire 144 energizes and switches
relay 21. This directs 120V current to the auxiliary start/run circuit and to the auxiliary pump
on light (power module).
When Auxiliary Pump-Off is selected at the driller's panel, wire 143 energizes and switches
relay 22. Energizing relay 22 interrupts power to the holding contact. The motor stops and the
power module indicator light shuts off.
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INDEX
Numerics
3F valve, 10
A
auxiliary hydraulic manifold
checking, 14
auxiliary pump, 69
auxiliary pumpauxpump, 71
B
bail movement
unanticipated, 29
unbalanced, 27
C
case drain
and worn motors, 10
excess, 11
flow rate for motor, 10
flowmeter, 10
increasing motor case drain, 10
interpreting flow rates, 7
motor, 10
pump, 6
surge in motor flow, 11
temperature, 7
charge pump, 4
closed loop
introductiocloop, 3
cold climate switch, 11
introduction, 35
commissioning, 1
connectors
Pyle National, 38
cooling schematics, 1
current sensor, 66
D
diode
testing, 40
direction holding circuit
mud saver valve, 64
drill ahead, 1
drillers panel functions, 1
electrical schematics, 1
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electrical testing
diode, 40
elevator-close, 55
elevator-open, 53
extend-in, 51
extend-out, 52
feedback, 40
general, 38
grabber lift-down, 42
grabber lift-up, 41
grabber/drawworks interlock interface, 61
grabber/pipe handler interface, 60
grabber-close, 58
grabber-close holding contact, 59
grabber-open, 57
link tilt-back, 48
link tilt-float, 49
link tilt-forward, 46
mud saver open timer circuit, 63
mud saver valve-close, 64
mud saver valve-open, 61
mud saver-close light, 66
multiple functions, 40
pipe handler-lock, 45
pipe handler-unlock, 43
power, 39
elevator close
hydraulic testing, 20
elevator open
elevator-close
electrical testing, 55
elevator-open
elevators, 19, 20
extend forward
extend quick couplers, 21
extend retract
extend-in
extend-out
F
feedback
tesing for, 40
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INDEX
link tilt forward, 26

link tilt reverse, 28
mud saver valve close, 25
mud saver valve open, 25
pipe handler lock, 24
pipe handler unlock, 24
unloader valve, 15
G
gearbox lubrication system
general testing
hydraulic, 14
grabber
interface with pipehandler-lock, 14
grabber close
grabber lift down
grabber lift up
grabber lift-down
grabber lift-up
grabber open
grabber/drawworks interlock interface
grabber/pipe handler interface
grabber-close
grabber-close holding contact circuit, 59
grabber-open
install the top drive, 1

integrated reliefs
checking, 14
hot oil shuttle, 11

adjusting, 32
flowmeter, 33
four pump unit setting, 33
monitoring charge pressure when adjusting, 32
purpose, 31
reducing, 6
sequence control, 32, 33
setting, 5, 32
shuttle control, 32
hydraulic schematics, 1
hydraulic testing
elevator close, 20
elevator open, 19
extend forward, 21
extend retract, 21
gearbox lubrication system, 29
general, 14
grabber close, 23
grabber lift down, 19
grabber lift up, 18
grabber open, 22
link tilt float, 27, 29
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Linde pumps, 7
charge pressure, 4
low flow, 6
troubleshooting, 6
link tilt float
hydraulic testing, 27, 29
link tilt forward
link tilt reverse
link tilt-back
link tilt-float
link tilt-forward
make connections, 1
manifold
auxiliary, 26, 29
auxiliary hydraulic, 15
checking auxiliary hydraulic, 14
grabber accumulator, 19
kidney, 18, 22
pipe handler, 22
Modine cooling fan
introduction, 31
motor case drain
flow rate, 10
increasing, 10
surge in, 11
motor pot board, 12
motor starter, 68
motor startermotorstarter, 69
mud saver open timer circuit
electrcial testing, 63
mud saver valve, 25, 26, 63, 64, 66
direction holding circuit, 64
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mud saver valve open

mud saver valve-close
mud saver valve-open
mud saver-close light
timer circuit
mud saver valve, 63
tripping operations, 1
unbalanced bail movement, 27, 29

unloader valve, 16
options and spares, 1
valve
3F, 10
unloader, 16
parts lists, 1
pipe handler lock, 24, 60
pipe handler unlock
pipe handler-lock
pipe handler-unlock
pre-operational checklists, 1
pressure losses, 4
pump controller, 11
checking, 11
electrical connections, 12
pumps
cavitation, 11
R
re-circulation pump
introduction, 34
rig out, 1
rig up, 1
rotary seal, 18, 23
checking, 17
set torque and speed, 1

shuttle control
adjusting, 33
solenoids
testing, 37
troubleshooting, 17
speed control valve, 21
stuck pipe, 1
Sundstrand, 3
checking pump controller, 11
pump controller, 11
pump controller electrical connections, 12
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INDEX
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SYSTEM DESCRIPTION
ENGINEERING SIGN-OFF
This sign-off sheet indicates that this document has been approved for release by the
Engineering Department at TESCO.
Document Complete By
Signature
Kristen Sabo
May 2009
ER ERASM
PI
ET
EN G I N
PR
O FES S I O
L
NA
Digitally signed by
Pieter Erasmus
DN: cn=Pieter
Erasmus, o=Teaco
Corporation,
ou=Engineering Sustaining,
email=pieter_erasm
us@tescocorp.com,
c=CA
Date: 2008.04.08
10:47:48 -06'00'
A LB E R T
ER S
U
Pieter
Eras
mus
Mem ber# M73574

Tesco Corp.Perm it to Practice# P06505
2008.04
.08
10:46:4
1
-06'00'
Document Reviewed/Approved
Date Signed
N
L E G INE
N A ER ERASM
T
PI
PR
A LB E R T
ER S
U
O FES S I O
Date Signed
Mem ber# M73574

Tesco Corp.Perm it to Practice# P06505
27 May 2009
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SYSTEM DESCRIPTION
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Troubleshooting Guide

HCI(S) Top Drive System

500/650T HCI(S) 750/1205HP

DOCUMENT NAME: 880005 REV 2

COPYRIGHT AND DISCLAIMER

500/650T HCI(S) 750/1205HP

Updated as a result of periodic review.

Added TESCO ULTREX recommendations and updated the footer to contain

500/650T HCI(S) 750/1205HP

CHAPTER 3: HYDRAULIC FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

500/650T HCI(S) 750/1205HP

Elevator Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

CHAPTER 4: COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

CHAPTER 5: ELECTRIC COMPONENT - HYDRAULIC FUNCTIONS . . . . . . . . . . . . . . . . . . .37

500/650T HCI(S) 750/1205HP

CHAPTER 6: POWER UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

500/650T HCI(S) 750/1205HP

500/650T HCI(S) 750/1205HP

CHAPTER 1: ABOUT THIS DOCUMENT

HCIS System Description

installing the top drive

HCIS Installation Guide

setting torque and speed

HCIS Operations Guide

load path inspections

HCIS Parts List

available options and spares

HCIS Maintenance Guide

500/650T HCI(S) 750/1205HP

ABOUT THIS DOCUMENT

500/650T HCI(S) 750/1205HP

CHAPTER 2: CLOSED LOOP

PREPARING TO TROUBLESHOOT THE CLOSED LOOP

charge circuit pump arrangement

Caution: All manifold test ports are straight-thread ORB. Do not

500/650T HCI(S) 750/1205HP

500/650T HCI(S) 750/1205HP

Figure 2-1: Pressure Losses that Effect Charge Pressure

Hot Oil Shuttle

Indicates flow that may effect charge pressure.

Warning! Important: Elevated case drain temperature or

5. Check the hot oil shuttle setting.

500/650T HCI(S) 750/1205HP

Warning! If you reduce the hot oil shuttle setting, carefully

Low Pump Flow

Interpreting Pump Flow

Circulating Pump Case Drain Flow

500/650T HCI(S) 750/1205HP

INTERPRETING CASE DRAIN FLOW

TOP DRIVE SHIFTING MANIFOLD (SPEED, COLD CLIMATE AND

500/650T HCI(S) 750/1205HP

Loop Free Flow

TOP DRIVE CLOSED LOOP

500/650T HCI(S) 750/1205HP

UNABLE TO ACHIEVE FULL SYSTEM PRESSURE

Warning! The active pressure relief (located at the saver

500/650T HCI(S) 750/1205HP

MOTOR CASE DRAIN

Increasing Motor Case Drain Flow

Caution: The case drain flowmeter is located at the power unit

500/650T HCI(S) 750/1205HP

SUNDSTRAND PILOT VALVE

Checking Pump Controller Function

3. Locate the pump controller manual control toggle.