Lubrication and
Maintenance
Transmission ...................................................... 3-2
Selecting the proper gearbox oil .................................... 3-2 1
Lubrication schedule ..................................................... 3-2
Recommended gear oils ............................................... 3-3
Gearbox lubrication ............................................ 3-4
2
Hydraulic system ................................................ 3-5
Precautions ................................................................... 3-5
Lubrication schedule ..................................................... 3-5
Recommended hydraulic fluid ....................................... 3-6
3
Hydraulic lubrication ...................................................... 3-7
Motors ................................................................. 3-8
Lubrication schedule ..................................................... 3-8
Recommended motor grease ........................................ 3-8
4
Motor lubrication ............................................................ 3-9
General purpose lubrication ............................... 3-10
Lubrication schedule ..................................................... 3-10
Recommended lubricants .............................................. 3-11 5
General lubrication ........................................................ 3-12
TDS-11SA Rev. B
Lubrication
Transmission
Selecting the proper gearbox oil
TDS transmissions operate under a combination of heavy and
shock loads. Under these conditions oil tends to extrude out of the
gear mesh. Keeping an effective film of oil on the gear mesh
requires oil with an AGMA “extra pressure” rating (EP), and a
minimum viscosity of 100 SUS at internal operating temperature.
Varco Top Drives also operate under a wide variety of ambient
temperatures. Select lubrication for the TDS based on the minimum
ambient temperature (surrounding air) to be expected before the
next oil change. Under all but the most severe operating conditions,
Varco recommends changing the oil every six months. Introducing
an oil viscosity greater than required by the ambient temperature
3 can:
❏ Damage the gearbox due to reduced oil flow
❏ Damage the oil pump because of excessive load
Lubrication schedule
Description Frequency
Replace the Gearbox Oil Following Intial Break-in Following first month of operation
Replace the Gearbox Oil and Perform an Oil Analysis Every 6 Months
Oil viscosity should be adjusted based on expected ambient conditions for next six months
Replace the Gearbox Oil Filter (P/N 30111013-1) Every 3 Months
Remove, clean and replace the Magnetic Drain Plug Yearly
The first oil change should be performed after the first month of
operation since new units often contain metal contaminates and
contaminates caused by initial break-in.
3-2 Varco Systems
Lubrication
Transmission
Recommended gear oils
Ambient Temperature Range
-6˚ to 16˚ C 7˚ to 30˚ C Above 21˚ C
(20˚ to 60˚ F) (45˚ to 85˚ F) (Above 70˚ F)
Manufacturer
Castrol Alpha LS-68 Alpha LS-150 Alpha LS-320
Chevron NL Gear 68 NL Gear 150 NL Gear 320
Exxon Spartan EP68 Spartan EP150 Spartan EP320
Gulf EP Lube HD68 EP Lube HD150 EP Lube HD320
Mobil MobilGear 626 MobilGear 629 MobilGear 632
Shell Omala 150 or Omala 150 Omala 320 or
Spirax 80W-90 GL5 Spirax 85W-140 GL5
3
Statoil Loadway EP68 Loadway EP150 Loadway EP320
Texaco Meropa 68 Meropa 150 Meropa 320
Total Carter EP 68 Carter EP 150 Carter EP 320
Union Extra Duty NL4EP Extra Duty NL4EP Extra Duty NL6EP
76 MP Gear Lube 76 MP Gear Lube
80W-90 GL5 85W-140 GL5
Viscosity Index
AGMA 4EP 5EP 6EP
ISO Viscosity Grade 150 220 320
! Oils of insufficient viscosity can damage gears by allowing metal to
metal contact.
i For minimum temperatures below 20°F, the TDS must be warmed
up by rotating at a very light load (less than 200 Amps) and at very
slow speeds (less than 50 rpm) until the oil temperature climbs
above 20°F. If drilling conditions dictate oil temperatures below 20°F,
consult Varco service center.
If the oil temperature rises above 200°F, Varco recommends shutting
down or reducing drilling loads to stabilize the oil temperature below
200°F If drilling conditions dictate oil temperatures above 200°F,
consult Varco service center.
TDS-11SA Rev. B 3-3
Lubrication
Gearbox lubrication
3
Cork Ball
(Level Sight
Indicator) Glass
Gearbox
Oil Drain
i
Gear Oil
Sight Gauge
Check with Top Drive
“OFF” Replace gear oil every
6 Months
Gearbox Oil Fill
Clean area before
i
removing plug, then
use a 1 3/8 inch, 12 point
socket to remove plug
“Pop-up”
Dirt
Alarm Procedure
Check oil level, prior to adding oil
(do not mistake the tan colored
foam for the dark brown oil)
Ensure that the unit is turned OFF
Gear Oil Filter
Replace every The area must be wiped clean
prior to adding gearbox oil
3 Months
Recheck oil level and replace the
plug after adding oil
Yearly Run the unit and recheck the oil
level (not foam level), after the unit
Magnetic Drain Plug has been running and the
Remove and clean contamination transmission oil is warm
3-4 Varco Systems
Lubrication
Hydraulic system
Precautions
Release all hydraulic oil pressure by bleeding
accumulators before disconnecting hydraulic lines.
Turn the counterbalance valve to shutdown mode to
bleed the hydraulic system. Hydraulic oil under
pressure can penetrate skin and cause serious injury.
Before opening the hydraulic system, thoroughly clean
work area, and maintain system cleanliness by
promptly capping all disconnected lines. Dirt is 3
extremely harmful to hydraulic system components
and can cause equipment failure and subsequent injury
to personnel.
! Use care when handling components to prevent nicking close
tolerance finishes.
! Use care to prevent contamination from entering the hydraulic
system during maintenance activities.
Lubrication schedule
Description Frequency
Perform Hydraulic System Oil Analysis Every 6 Months
Replace the Hydraulic Fluid Yearly, or Earlier Based on Oil Analysis
Replace the Hydraulic System Filter (P/N 114416-1) Every 3 Months
TDS-11SA Rev. B 3-5
Lubrication
Hydraulic system
Recommended hydraulic fluid
Oil Temperature Range
-15˚ to 75˚ C -10˚ to 85˚ C
(5˚ to 167˚ F) (14˚ to 185˚ F)
Manufacturer
Castrol Hyspin AWS-32 Hyspin AWS-46
Chevron AW Hyd oil 32 AW Hyd oil 46
Exxon Nuto H32 Nuto H46
Gulf Harmony 32AW Harmony 46AW
Mobil DTE 24 DTE 25
Shell Tellus 32 Tellus 46
3 Statoil Hydraway HMA 32 Hydraway HMA 46
Texaco Rando oil HD32 Rando oil HD46
Total Azolla ZS 32 Azolla ZS 46
Union Unax AW32 Unax AW46
Viscosity Index
ISO Viscosity Grade 32 46
3-6 Varco Systems
Lubrication
Hydraulic system
Hydraulic lubrication
Procedure
The area must be clean prior to adding hydraulic fluid
Remove dust plug from the male quick disconnect at
the TDS hydraulic oil fill
Remove dust plug from the female quick disconnect
on the lubrication kit and connect it to the male fitting
Pump fluid until the level reaches the middle of the
Cork Ball sight glass as shown
(Level Indicator) After adding fluid, replace the dust plugs
Sight
Glass
Replace
hydraulic fluid
3
Yearly
Sight Hydraulic or earlier based
Glass Oil Sight on oil analysis
Gauge Red
“Pop-up”
Hydraulic
Dirt Alarm
Oil Fill
Male Quick
Disconnect
Replace every
3 Months
Hydraulic
Oil Filter Dust Plug
Female
Quick
Disconnect
Hydraulic
Lubrication Kit
55 gal Drum
Varco P/N 92643
Hydraulic
Oil Drain
TDS-11SA Rev. B 3-7
Lubrication
Motors
Varco recommends that lubrication of all AC motors
should be done by the rig electrician.
Lubrication schedule
Description No. of Points Frequency Type
Lubricate the AC Drilling Motor 4 Every 3 Months Motor Grease
Lubricate the AC Blower Motor 4 Every 3 Months Motor Grease
Lubricate the Hydraulic Pump AC Motor 2 Every 3 Months Motor Grease
3 Recommended motor grease
Motor Grease
Manufacturer
Chevron Black Pearl EP2 (Do Not Substitute)
3-8 Varco Systems
Lubrication
Motors
Motor lubrication
i Grease Fittings
Apply motor grease
to designated Grease
grease fittings Fitting
with hand grease gun 1/8 inch
Varco P/N
53201
3 Months
!
Pipe Plug 3
AC Blower 1/8 inch
Motor (2) (remove and
3 pumps reinstall after
(2 grease fittings lubricating)
each motor)
As Viewed From Below
3 Months
AC Drilling
Motor (2)
5 pumps
(2 grease fittings
each motor) 3 Months
Hydraulic Pump AC Motor
3 pumps
(2 grease fittings)
Procedure
Remove the lubrication point plug
Install a grease fitting
Grease with a hand pump only
Re-install the plug
TDS-11SA Rev. B 3-9
Lubrication
General purpose lubrication
! The lubrication intervals described in this manual are based on
lubricant supplier recommendations. Severe conditions such as
extreme loads or temperature, corrosive atmosphere, etc., may
require more frequent lubrication.
! Worn bushings, binding parts, rust accumulations, and other
abnormal conditions indicate more frequent lubrication is
necessary. Be careful not to over lubricate parts. For example, too
much grease forced into a fitting can pop out a bearing seal. Over
3 lubrication can also affect safety since over lubricated parts can
drip, creating a potential slipping hazard for personnel.
Lubrication schedule
Description No. of Points Frequency Type
Washpipe Assembly 1 Twice Daily General Purpose Grease
IBOP Actuator Yoke, Cylinder Pins 5 Daily General Purpose Grease
IBOP Actuator Cranks 2 Daily General Purpose Grease
Stabilizer Bushing 4 Daily General Purpose Grease
Clamp Cylinder Gate 2 Daily General Purpose Grease
Upper Bonnet Seal 1 Weekly General Purpose Grease
Bail Pins 2 Weekly General Purpose Grease
Rotating Link Adapter Gear – Weekly General Purpose Grease
Rotating Link Adapter 2 Weekly General Purpose Grease
Shot Pin Assembly 1 Weekly General Purpose Grease
Upper IBOP Valve 1 Weekly General Purpose Grease
Torque Arrestor at Clamp Cylinder – Weekly General Purpose Grease
Wireline Adapter 2 Weekly General Purpose Grease
Elevator Link Eyes 4 Weekly Pipe Dope
Traveling Block Sheaves 3 Monthly General Purpose Grease
Guide Dolly Runner Shaft 12 Every 6 mos. General Purpose Grease
3-10 Varco Systems
Lubrication
General purpose lubrication
Recommended lubricants
Ambient Temperature Range
Below -20° C Above -20° C
(Below -4° F) (Above -4° F)
Manufacturer
Castrol N/R MP Grease
Chevron Avi-Motive W Avi-Motive
Exxon Lidok EP1 Lidok EP2
Gulf Gulf Crown EP31 Gulf Crown EP32
Mobil Mobilux EP1 Mobilux EP2
Shell Alvania EP1 Alvania EP2
Statoil Uniway EP1N Uniway EP2N 3
Texaco Multifak EP1 Multifak EP2
Total Multis EP1 Multis EP2
Union Unoba EP1 Unoba EP2
Viscosity Index
NGLI 1 2
TDS-11SA Rev. B 3-11
Lubrication
General purpose lubrication
General lubrication
i
Apply general purpose
grease to designated
grease fittings with
grease gun. Use a brush
when greasing other parts.
Daily
Wash Pipe
Assembly
Apply one pump
twice daily
Weekly Weekly
Bail Pins (2) Upper Bonnet Seal
Two pumps each side One pump
Use Hand Pump Only
Weekly
Weekly
Rotating Link
Rotating Link Adapter
Adapter Gear
Three pumps each
Brush with grease
3-12 Varco Systems
Lubrication
General purpose lubrication
General lubrication
i
Apply general purpose grease to
designated grease fittings with
grease gun. Use a brush when
greasing other parts.
Daily
IBOP Actuator Yoke
One pump each side
3
Daily
IBOP Actuator Cranks
One pump each side
Daily
Weekly Stabilizer Liner
One pump each side
Upper IBOP Valve
Remove 1/4" NPT plug,
install grease fitting
Apply ten pumps Weekly
Replace Clamp Cylinder Gate
! plug before
operating
One pump each side
Daily Weekly
Stabilizer Liner Elevator Link Eyes
One pump each side (4)
Pipe Dope
TDS-11SA Rev. B 3-13
Lubrication
General purpose lubrication
General lubrication
i
Apply general purpose grease
to designated grease fittings
with grease gun
Weekly
Guide Rollers
4 Places
One pump each
(if equipped)
Weekly
Guide Rollers
16 Places
One pump each
(if equipped)
Weekly
Bogies
4 Places
One pump each
(if equipped)
3-14 Varco Systems
