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Installation, Operation & Maintenance Instructions for the Manifold Valve Choke & Control Console

WARRANTY POLICY Each of the companies comprising of T-3 Energy Services (each, a “Seller”) warrants the products it manufactures and/or remanufactures to be free from defects in materials and workmanship which materially and adversely impact performance or safety under normal use and services for a period of one year after initial installation or 18 months from invoice date, whichever comes first. Products found to be defective will be repaired or replaced, at Seller’s option, in a timely fashion at no charge to the customer for such repair or replacement by Seller. Seller will not be responsible for product damage caused by the process service conditions or damage caused by customer misapplication or improper maintenance. Seller also shall not be responsible for normal wear and tear.

TABLE OF CONTENTS PAGE NO. 01

INTRODUCTION GENERAL INFORMATION PART I

PART II

OPERATION Normal Operation Alternate Operating Method Emergency Operation

02 03 03

MAINTENANCE Preparation for Disc Assembly Change Out Disc Assembly Change Out Turning Fork Disassembly/Assembly Piston Gauge Protector Preloading the Hydraulic Pressure Lines Position Indicator System Digital Rate Meter Flo-Tork Actuator Assembly

05 08 10 11 12 13 16 16

PART III

TEST PROCEDURES

PART IV

TROUBLESHOOTING Choke Will Not Open or Close Improper Open/Close Operation Stroke Counter Malfunction Improper Pressure Gauge Readout Position Indicator Malfunction

APPENDIX

01

20 21 22 23 23

DRAWINGS, PARTS LIST AND INSTRUCTIONS FIG. 1 Choke Valve Assembly Piston Gauge Protector Assembly FIG. 2 Console Assembly FIG. 3, 4, 5 Test Procedure Layout FIG. 6 Limit Switch Assembly FIG. 7 Choke Bean Closure Chart FIG. 8 Rear Manifold Assembly FIG. 9 Actuator and Piston Indicator Assembly FIG. 10 A-1 Flo-Tork Actuator Maintenance Instructions SC Hydraulic Pump Maintenance Instructions A-2 H2S Safety Procedures A-3

T3 ENERGY SERVICES SUPER CHOKE INTRODUCTION The T3 Energy Services Super Choke should be operated only by, or under the supervision of, qualified experienced operators. Should questions arise or operating problems occur, it is suggested you contact a T3 Energy Services representative for assistance. The T3 Energy Services Super Choke should be inspected on a regular basis by qualified personnel. The inspection should cover both the choke valve and the control console.

GENERAL INFORMATION The Hydraulic Choke is a hydraulically operated variable choke providing any opening from a maximum of 1.93 square inches (1250 mm2 ) (1 9/16 “ equivalent bean diameter) to full shutoff. Working pressure rating of the choke is 10,000 psi (700 Kg/cm2 ). Two tungsten carbide discs, each with a semi-circular opening, form the “choke.” Various openings are obtained by rotating the upstream disc against the stationary downstream disc. The main choke operating lever marked OPEN, HOLD, and CLOSE controls the movement of the upstream disc. Speed of operation is controlled by the HYDRAULIC REGULATOR valve in the lower right corner of the panel. The AIR SUPPLY valve on the left side of the control panel controls the flow of rig air to the air-powered hydraulic pump and to the position indicator. (A minimum of 100 psi (7.0 Kg/cm2) air pressure required.) Moving the choke control lever to the CLOSE position directs hydraulic pressure to the hydraulic pistons which rotate the choke towards “closed” and moving the lever to the OPEN position reverses the operation. When the control lever is released, it will return to the HOLD position and the upstream disc will remain where it is.

Page 01

The POSITION INDICATOR gauge located on the right side of the control panel shows the approximate position of the “choke” in terms of degree of closure. The accompanying chart shown in Appendix A relates amount of closure to approximate choke bean size in inches.

OPERATING INSTRUCTIONS Operation of the choke should start with the choke in the “OPEN” position. At the start of a kick the choke should not be closed for the shut-in pressure reading until after the preventers have been closed and fluid is flowing through the choke. A. Normal Operating Method (Fast Response) 1. Move AIR SUPPLY valve (Figure 3, Item 8) to “ON” position. 2. Open HYDRAULIC REGULATOR (Figure 3, Item 6) valve approximately 1 1/2 to 2 turns. 3. To close (or reduce) opening through choke, move control lever to “CLOSE.” Observe POSITION INDICATOR (Figure 3, Item 5) dial for movement of choke disc. Alternately shift control lever to “CLOSE” and release to neutral position until the casing pressure has been raised to the desired level. It may be necessary to change the HYDRAULIC REGULATOR setting if choke is operating too fast or too slow. 4. Be prepared to shift control lever in either direction to maintain the desired casing or drill pipe pressure. In case of plugging, shift the main control lever to “OPEN” and open the HYDRAULIC REGULATOR. As soon as the plug is cleared the control lever must be shifted to “CLOSE” long enough to return the choke to the previous opening. Then the HYDRAULIC REGULATOR valve may be returned to original position. 5. When the job is complete, open choke and turn AIR SUPPLY valve off to remove all pressure from hydraulic system. Page 02

B. Alternate Operating Method (Fine Control for High Pressure) 1. Start with HYDRAULIC REGULATOR valve closed. 2. To close (or reduce) opening through choke, hold control lever in “CLOSE” position and slowly open HYDRAULIC REGULATOR valve (1/4 to 1 turn). By keying the amount which this valve is opened or closed to the rate of casing pressure buildup and movement of the orifice disc as shown on the position indicator dial, the desired pressure can be obtained. When this is reached the main control lever should be released and the HYDRAULIC REGULATOR valve closed or returned to the “just cracked” position. 3. Be prepared to shift control lever in either direction and to open the HYDRAULIC REGULATOR valve to keep the casing pressure or drill pipe pressure at the desired level. Fine pressure adjustments can be made easily by barely “cracking” the HYDRAULIC REGULATOR valve. If the choke plugs, the main control valve must be placed in “OPEN” position and HYDRAULIC REGULATOR valve should be opened rapidly. After the plug has been cleared, the main control lever must be shifted to “CLOSE” position long enough to return the choke to the previous setting. 4. When job is complete, open choke and turn AIR SUPPLY valve off to remove all pressure from hydraulic system. C. Emergency Operation Case 1: Air Supply or Air Pump Failure a. Install pump handle on hand pump (Figure 5, Item 17) mounted on base of the control skid. b. To change choke opening, hold operating lever in desired position while stroking hand pump.

Page 03

Case 2: Rupture in Hydraulic Line or Connection a. If break is in “OPEN” line, cut the short “CLOSE” line that connects the two Flo-Tork cylinders together. If “CLOSE” ruptures, cut short “OPEN” line. b. Insert 5/8” rod into one of the holes in the indicator head assembly (the piece connecting Flo-Tork shaft to choke body) and manually position choke as desired.

MAINTENANCE Preparation for Disc Assembly change out (chart on next page)

Page 04

PREPARATION FOR DISC ASSEMBLY CHANGE OUT ON THE T3 ENERGY SERVICES SUPER CHOKE Sequence of Basic Job Steps Prior To Choke Assembly

Recommended Safe Job Procedures

Safety Concern

1. Make sure all valves between Choke and well head are closed

High pressure.

Manually check to insure valves are closed.

2. Insure valves downstream of choke outlet are open if possible.

Trapped pressure.

Insure valves are open to relieve trapped pressure. If it is not possible to leave downstream valves open, make sure choke pressure was bled off before closing valves.

3. Rotate the choke to full open regardless of setting of Position Indicator.

Position Indicator may be faulty. Air line broken, bent or plugged, giving incorrect reading.

Hold choke control lever to open position; if hydraulic pump strokes, hold until choke is fully open.

4. Open the OPEN/CLOSE lever on the control panel.

Choke could be in closed position.

Insure hydraulic pressure is available to Flo-Tork by checking hydraulic gauge under control panel.

5. Check the Position Indicator gauge to tell when choke is open.

Remote possibility that malfunction could occur which would cause choke plates not to open even though Position Indicator would show them to be open.

Operate choke control lever to partly close choke. Check Position Indicator for proper operation. Open choke.

6. Confirm choke is at full open by checking the Indicator Head.

Indicator Head did not rotate to the open position.

Use cross over tub on hydraulic fitting, insert bar in Indicator Head and rotate. If hard to rotate, pressure may be trapped in choke.

CONTINUES NEXT PAGE

>>

Page 05

PREPARATION FOR DISC ASSEMBLY CHANGE OUT ON THE T3 ENERGY SERVICES SUPER CHOKE Sequence of Basic Job Steps Prior To Choke Assembly

Safety Concern

Recommended Safe Job Procedures

7. If pressure gauge indicates zero pressure or low pressure, check line from gauge protector for rigidity (indicating pressure).

Pressure gauge may be plugged or broken; a rigid line would indicate pressure. If choke plates are open, line from choke could be plugged.

Insure all downstream valves have been opened to relieve pressure. Be sure downstream discharge line is anchored to prevent whipping action in case line ruptures.

8. Check well casing pressure gauge at choke panel. Also check pressure gauge at wellhead if there is a pressure gauge at wellhead. If no indication of pressure on either gauge, then begin teardown procedures, downstream of choke outlet.

Possible malfunction of pressure gauges could indicate zero pressure even though pressure existed. If pressure exists downstream, you could have liquid/gas (or combination) when seal flange or union seals are broken.

If pressure is indicated, repeat the above steps before removing choke from manifold. NOTE: Loosen flange nuts one turn each until seal or ring gasket is broken. When seal is broken and it is determined there is no pressure inside choke, it is safe to remove flange. CAUTION: Do not use pry bar to remove flange.When breaking down flange, make sure no one is standing near plane or flange or seal. Make sure that safety glasses and hard hats are used to insure personal protection. Insure no open flame is near when breaking out choke.

9. If there is or is not pressure, go through exact procedure as outlined in Step 8.

Page 06

Any debris and/or gas could blow into face. Gas may ignite.

CONTINUES NEXT PAGE

Same as 8.

>>

PREPARATION FOR DISC ASSEMBLY CHANGE OUT ON THE T3 ENERGY SERVICES SUPER CHOKE Sequence of Basic Job Steps Prior To Choke Assembly

Safety Concern

Recommended Safe Job Procedures

10. Tear down to outlet flange and physically check through outlet flange to see if choke plates are actually open. Use rod to pry in the open end of choke to determine the position of the plate (OPEN/CLOSE).

High pressure may exist; possible ignition of gas debris in outlet flange.

High pressure/fire – personnel should stand clear of outlet flange using a straight rod with a curved handle at the hand portion.

11. If choke plate are not open, first attempt to open them by using the console controls. If indicator head does not move, plates may have slipped or turning fork may be broken. It is then necessary to continue disassembly operation.

Same as 8 and 9. Choke outlet is now open. If plates open, any trapped debris and/or gas will be expelled.

Same as 8 and 9. Have all personnel stand clear of area during opening procedure.

—

—

—

—

12. Loosen inlet flange bolts using same procedure as outlet flange bolts in Step 10. 13. When seal is broken and it is determined there is no pressure inside choke, it is safe to remove flange at face of choke body.

Page 07

MAINTENANCE For your own safety, the procedures listed for choke plate removal should be followed step by step when tearing down an T3 Energy Services Super Choke that is installed in a manifold or when removing an T3 Energy Services Super Choke from a manifold. You will find a safety section in the Appendix A-3 that discusses general safety and H2S safety procedures in the field.

DISC ASSEMBLY CHANGE OUT 1. Rotate the choke to full OPEN. CAUTION: ON THE T3 ENERGY SERVICES SUPER CHOKE, TAKE EXTREME CAUTION TO ASSURE THAT THERE IS NO PRESSURE TRAPPED IN THE CHOKE VALVE OR CHOKE MANIFOLD. FOLLOW STEPS OUTLINED IN “PREPARATION FOR DISC ASSEMBLY CHANGE OUT. USE PROPER SAFETY PRECAUTIONS IF H2S GAS MAY HAVE BEEN IN CHOKE VALVE. ONLY PERSONNEL WHO HAVE RECEIVED INSTRUCTIONS ON THE HAZARDS OF H2S AND THE PROPER EQUIPMENT AND PROCEDURES TO BE USED IN WORKING IN AREAS WHERE H2S MIGHT BE PRESENT SHOULD BE PERMITTED TO WORK ON THE T3 ENERGY SERVICES SUPER CHOKE IF THERE IS ANY POSSIBILITY THAT H2S GAS MIGHT HAVE BEEN IN THE CHOKE VALVE. THE HYDROGEN SULFIDE GAS SAFETY PROCEDURES ARE LOCATED IN APPENDIX A-3 OF THIS MANUAL AND IS INCLUDED AS PART OF THE OPERATING AND SERVICE MANUAL FOR THE T3 ENERGY SERVICES SUPER CHOKE. IT SHOULD BE READ BEFORE WORKING IN AREAS WHERE H2S MIGHT BE ENCOUNTERED, AND IT SHOULD BE COMPLIED WITH THOROUGHLY. 2. Carefully loosen the bolts on the outlet side of the choke valve. After all the bolts are loosened, the seal should be broken. If there is no pressure present, the bolts may be removed. 3. Check to see if plates are open (Step 10) before carefully loosening the bolts on the inlet of the choke valve in the same manner as Step 2 above. Page 08

4. Unbolt the outlet flange (Fig. 1, Item 1) by removing ferry cap screws (Fig. 1, Item 4). 5. Insert the disc puller and GENTLY bump the discs (Fig. 1, Item 9 and 10) out. DO NOT CHIP THE DISCS. If there is sand or barite around the discs, a water hose should be used to wash the sand or barite from the discs. 6. Wash and clean both disc assemblies, and the inside of the choke body (Fig. 1, Item 11). 7. Inspect all O-ring seals for wear or damage, and replace as necessary. 8. Remove the spring locator pin(s) (Figure 1, Item 6) and replace with new pins. 9. Lubricate the disc carrier ring with a good grade of grease, and wipe faces with a CLEAN cloth. Avoid getting grease on the disc faces as it may cause the choke to leak on test. 10. Insert the rotating disc assembly (Fig. 1, Item 10) so that the half-moon opening is toward the choke inlet flange. BE SURE THAT THE FINGERS AND LOCATOR PIN OF THE TURNING FORK (FIG..1, ITEM 12) ALIGN PROPERLY WITH THE FRONT DISC ASSEMBLY. 11. Align the proper groove in the rim of the outlet end of the stationary disc assembly with the locator pin, (Fig. 1, Item 25) and insert it into the choke body. 12. Inspect the Tungsten Carbide wear sleeves, (Fig. 1, Item 2 and 3) and the inside of the outlet flange assembly for wear. Replace worn parts as necessary. 13. Reassemble the outlet flange assembly to the choke body with the cap screws. Tighten these screws uniformly. 14. Clean and check the flange faces and ring groove. Reassemble the choke into the manifold. The BX 153 rings should be replaced. Page 09

DISASSEMBLING AND INSPECTING THE TURNING FORK (Fig. 1, Item 12) NOTE: (THE TURNING FORK SHOULD BE REMOVED PERIODICALLY AND RELUBRICATED WITH A LIGHT APPLICATION OF EP GREASE.) 1. Remove the actuator assembly by removing the four screws. 2. Remove cap screw (Fig. 1, Item 22) to release indicator head from turning fork. 3. Remove the eight cap screws (Fig. 1, Item 23) and bonnet (Fig. 1, Item 24). NOTE: MARK THE BONNET AND VALVE BODY TO ASSURE THAT THE BONNET IS REPLACED CORRECTLY. 4. Push the turning fork (Fig. 1, Item 12) out of the bonnet, being careful not to damage the turning fork. 5. Clean and inspect the turning fork to determine if it has been damaged or worn. If it is either damaged or worn, the turning fork should be replaced. The turning fork should be lubricated with a light application of EP grease. To reassemble, follow the reverse of the above procedure, observing the following precautions. 1. Inspect all O-rings and the Delrin Thrust Bearing (Fig. 1, Item 13) for damage and/or wear. Replace O-rings and Delrin Bearing, if necessary. If the Delrin Bearing shows any wear, it should be replaced. 2. Reinstall turning fork in bonnet and reinstall bonnet on valve body, being careful to realign the two marks as indicated in note above.

Page 10

3. Rotate the turning fork until the choke discs are fully open. 4. Place the indicator head on the turning fork so that the large scribe on the bonnet is aligned with the open mark on the indicator head. 5. If necessary, connect the actuator assembly to the control console and operate the control lever to assure that the actuator is in the open position. With the choke discs and the actuator in the open position, the actuator assembly may now be connected to the choke valve assembly, in whichever choke manifold position is needed.

PISTON GAUGE PROTECTOR The piston gauge protector (Figure 2) uses a piston for transmitting fluid pressure, such as mud pressure, to a gauge. The piston separates the filling fluid being measured from a clean hydraulic fluid in the transmission hose and gauge. The hydraulic fluid in the system must be absolutely free of air, or full fluid pressure cannot be read on the gauge due to compression of the air. It has been found advisable to maintain a sealed fluid system from the protector to the gauge, since a few drops of oil escape each time the hose connections are coupled or uncoupled. To remove the piston, (Figure 2, Item 2) proceed as follows: 1. Remove the internal snap ring (Figure 2, Item 4) from the mud side of the gauge protector. 2. Insert a 1/2“ bolt in the threads provided at the mud side end of the piston. 3. Pull the piston out of the cylinder, using the 1/2” bolt as a handle. 4. Inspect all three O-rings (Figure 2, Item 3) for wear and replace if necessary. 5. After new O-rings have been installed on the piston, apply a small film of grease on the piston and insert the piston back into the cylinder. 6. Replace internal snap ring.

Page 11

PRELOADING THE HYDRAULIC PRESSURE LINES To preload the fluid system: 1. Place the piston gauge protector near the control console panel, and in a vertical position with the internal retainer ring down, with the hose connected tightly to the piston gauge protector. (Piston needs to be against retaining ring at full stroke.) 2. Remove the plug on the body (Figure 2, Item 8). 3. Remove cap (Figure 9, Item 2) and attach the hand pump loosely to the check valve, on the back of the control panel (Figure 9), for the proper casing pressure or drill pipe pressure. Do not tighten this connection yet. 4. Slide the cover of the hand pump to one side and fill the reservoir with hydraulic fluid. While purging, keep the hand pump reservoir at least 1/2 full to avoid putting more air into the lines. 5. Pump slowly, purging air from the pump at the loose connection. When the line is purged of air, tighten the connection. 6. Turn the damper valve on the gauge counter (Figure 3, Item 1) clockwise several turns to relieve the damping effect. Turning even further will allow bleeding through it. 7. Lay the hose (Figure 2, Item 9) out as straight and flat as possible, below the level of the gauge. 8. Remove the pipe plug on the top of the gauge to allow bleeding of air. 9. Pump fluid into the system until no more air appears at the plug on the gauge. Tighten the plug and push the damper valve in, turning clockwise to engage the threads again.

Page 12

10. Again pump into the system to purge all air from the hose and from the space behind the piston, bleeding it out at the opening where the plug has been removed. 11. When all the air is purged from the system, the piston should be placed 1/4” from end of cylinder to allow for heat expansion and then replace the plug (Figure 2, Item 8) on the protector body and tighten. 12. Close the hand pump cover, and remove the pump from the check valve. 13. Replace the check valve cap.

POSITION INDICATOR SYSTEM This system utilizes a 3 to 15 psi (0.21 to 1.05 Kg/cm) air signal to operate an indicator gauge (Figure 3, Item 5) on the choke panel. The signal comes from a plunger type regulator (Figure 10, Item 1). As the choke is rotated toward the “close” position, a cam (Figure 10, Item 6) directly connected to the Flo-Tork shaft causes movement of the pivot arm assembly. The pivot arm assembly pushes the regulator plunger in and increases the air signal. At the fully open position, the signal is 3 psi; at fully closed position, the signal is 15 psi. The POSITION INDICATOR gauge is labeled OPEN and CLOSE with a mark at the middle position to indicate 1/2 or 50% open. The graph in the operating instructions (Figure 8) can be used to relate the estimated choke position to the approximate equivalent diameter opening, or choke bean size. The important thing is for the operator to remember is that casing and drill pipe pressures should indicate the need for movement of the choke plates. The POSITION INDICATOR serves only as an aid in observing the direction and speed of changes being made in the effective choke size. Installation and Adjustment Connect the supply air tubing to the Black (left) poly-flo fitting, and connect the signal air tubing to the orange (right) poly-flo fitting on the bottom of the housing (Figure 10).

Page 13

To zero the “Position Indicator” gauge: 1. Open the choke fully. 2. Loosen the 1/4” nut and set screws on the camshaft (Figure 10, Item 9) so the cam turns on its shaft. Adjust as follows in steps 3 through 8. 3. Rotate cam so that the short end of the scribe mark is lined up with cam follower bearing (Figure 10, Item 8). 4. Tighten shaft nut and set screws. NOTE: ONCE THE CAM HAS BEEN POSITIONED, IT SHOULD NOT BE NECESSARY TO REPEAT THIS UNLESS THE CAM IS REMOVED FOR SOME REASON. 5. Loosen pivot block (Figure 10, Item 4), locking screw on rear of mounting plate and turn “O” adjustment screw until signal output is 3 psi on a test gauge, or “open” on the position indicator gauge. 6. Tighten pivot block locking screw. 7. Be sure output is 3 psi when locking screw is tight, as movement during tightening may slightly change the setting, and this will result in inaccurate readings of the position indicator. If output is not 3 psi, adjust pivot block as indicated above to obtain 3 psi signal output. 8. Close the choke and check to see that there is a 15 psi signal, or that the position indicator gauge reads “CLOSED.” If not, it will be necessary to adjust the span of the transmitter.

Page 14

To adjust the “span” of the indicator: 1. Rotate the choke plates to the closed position. This puts the long end of the scribe mark on the cam, at the cam follower. Output should be near 15 psi on the test gauge, or closed on the position indicator gauge. 2. If below 15 psi, loosen socket head cap screws and move regulator bracket (Figure 10, Item 2) slightly away from the pivot bolt; if above 15 psi, move regulator bracket slightly toward the pivot bolt. 3. Tighten socket head cap screws. 4. Rotate the choke plates 180°. If output is not 3 psi, adjust pivot block as before to 3 psi output. 5. Check other end of rotation, as before, for 15 psi output. 6. Repeat until 3 and 15 psi outputs are obtained. NOTE: IF IS IT NOT CONVENIENT TO USE THE CONTROL PANEL TO TURN THE CHOKE, USE A SHORT ADAPTER CONNECTION BETWEEN THE OPEN AND CLOSE CONNECTORS, AND TURN THE CHOKE BY HAND; HOWEVER, IT IS BEST TO CHECK THE CONTROL PANEL AND CHOKE VALVE AS A PAIR. As indicated in the preceding steps, it is often preferable to calibrate the position indicator using the console indicator gauge directly, instead of using a separate test gauge. In this procedure 3 psi will be about the center of the wide black mark on the OPEN side of the dial, and 15 psi will be about the center of the wide black mark on the CLOSE side of the dial, and 15 psi will be about the center of the wide black mark on the CLOSE side of the dial. The calibration screw on the face can be used to set the 3 psi point if necessary. The full closure (OFF on the calibration band) should then be indicated at the CLOSE reading. On new discs, actual shut-off will occur about 10° before the full 180° rotation is made. Page 15

Battery Powered Digital Rate Meter The rate meter (Figure 3, Item 2) is designed with simplicity of controls. Located along the bottom edge of the rate meter housing are two switches whose functions are labeled. The left switch resets the counter to zero when momentarily switched to the left. The right hand switch is the selector and has three positions: pump 1, pump 2, and test. In the pump 1 or pump 2 position, the meter counts and displays rate for either pump 1 or 2 as selected. In the test function, an internal source is selected and the rate meter counts and displays 128 SPM. This feature is invaluable as a troubleshooting aid. Should the battery become nearly exhausted, the rate meter will detect this condition. When there are a few weeks life left in the battery, the display flashes on and off about twice per second. At this time, the battery pack should be replaced. The liquid crystal display may be damaged or burned out if the dead battery pack is not removed from the circuit. Digital Pump Rate Meter/Counter The rate meter contains three modules that are not field repairable; however, they were designed for easy field replacement. Before replacing modules, make the following check: place the selector switch in the test SPM position. If the rate is 128 and the counter counts, the problem is probably with the wiring or the pump stroke limit switches. The rate meter is OK. If neither wiring or the switches are bad, replace the switch module and try again.

FLO-TORK ACTUATOR ASSEMBLY Disassembly 1. Fully open the choke before disconnecting the Flo-Tork (Figure 10, Item 10). 2. Note shaft relationship to rack position for timing at the fully open position.

Page 16

Scribe marks may be added on the shaft end and the housing help in remembering this positioning. 3. Replace O-rings on pinion shaft and bearing cap. 4. Replace O-rings and backup rings on piston racks and cylinder heads. Reassembly 1. Slide piston racks back into cylinder barrels with care to prevent cutting the Orings or backup rings when entering the bores. Rack teeth should face the pinion cavity. 2. Locate the piston racks at the fully open position. Viewed from the back end (opposite from the shaft), the upper rack will then be all the way to the right and the lower rack all the way to the left. NOTE: IMPORTANT – REPLACE PINION WITH THE SHAFT IN ORIGINAL RELATIONSHIP TO RACK TEETH. (THIS PROVIDES THE TIMING OF THE PINION AND SHAFT TO THE RACK(S). THE SCRIBE MARKS AS SUGGESTED ABOVE SHOULD BE ALIGNED. 3. Replace cylinder heads: Replace cylinder head tie rod nuts, and torque evenly at 360 to 410 in. lb. (4.1 to 4.7 kg – m) on lubricated threads. 4. Replace the bearing and bearing cap. 5. Replace the socket head cap screws in the bearing cap. Piston Seal Replacement Only Cylinder barrels can be removed to expose the piston seals for easy replacement without removing the Flo-Tork from the machine.

Page 17

General 1. Flo-Tork rotary actuators require clean, filtered hydraulic oil for satisfactory operation. The standard Buna-N seals are designed for high aniline point fluids. 2. Flo-Tork rotary actuators may be checked for piston seal leakage as follows: a. Set up actuator with relief fitting up. b. Pressurize cylinder ports individually. c. If oil flows from relief port after piston has completed its travel and has remained for 3 minutes under pressure, all piston seals should be replaced.

TEST PROCEDURE FOR THE T3 ENERGY SERVICES SUPER CHOKE VALVE Test of Choke Body 1. Connect test flangeds to choke according to Figure 6 drawing, with choke in FULL OPEN position. Raise discharge end of choke until discharge flange is parallel to the floor. 2. Connect water line at Water Inlet Valve. 3. Connect test line at Valve A. 4. Open Water inlet, Valve A and Valve B. 5. Slowly fill choke with water thru Valve A. 6. As water begins to flow form Valve B, partially close to increase pressure on air. 7. After choke is purged of air and filled with water, turn off water, close Valve B. Page 18

8. Open air inlet to test pump. 9. Slowly raise pressure on choke to 10,000 psi with test pump and look for leaks. If a leak occurs, stop immediately. 10. Isolate pump from gauge and hold pressure for 3 minutes. 11. Watch pressure gauge. If pressure begins to bleed down, inspect choke for leaks. 12. With Valve B still closed, release the pressure from the test pump. Test of Choke Discs 1. Open Valves A and B. 2. Slowly close the choke, allowing the water to displace air. 3. When no more air is carried out, fully close the choke discs. 4. Open air inlet to test pump. 5. Start the test pump and pressure up to 2,000 to 2,500 psi. 6. Watch gauge and Valve B for sign of leakage through discs. If there is any leakage, open and close plates several times to clear their faces, and repeat Steps 1 thru 5. 7. If leakage continues, disassemble the choke and check the discs, seals, and valve interior to determine the reason for leakage. Make any necessary repairs or replacements. 8. After a successful test at 2,000 to 2,500 psi, open the choke to relieve all pressure. 9. Repeat Steps 1 thru 7 at 10,000 psi.

Page 19

TROUBLESHOOTING Choke Will Not Open Or Close In most instances when the choke fails to open or close, the problem can be solved by one of the following procedures: 1. Check fluid level in the reservoir. If fluid level is low, add enough fluid to bring to proper level. 2. Check that the hookup of hydraulic lines is correct. 3. See that available hydraulic pressure is approximately 1500 psi (105 Kg/cm2) at the gauge. Check gauge and replace if needed. 4. If pressure is less than 1500 psi when pump is not stroking, increase supply air pressure to pump by adjusting 1/2” air regulator on rear of panel. 5. If air pump strokes, but 1500 psi still cannot be reached a. Check that the bleed valve built into the hand pump is closed. b. See that the pressure regulating relief valve is set slightly above 1500 psi. c. Check inlet and outlet check valves on the SC pump. 6. Check delivery of hydraulic fluid to the Flo-Tork actuator. If there is no flow, check both hydraulic hoses and the hydraulic regulator needle valve for plugging. Stray pieces of teflon from the threaded connections and other trash can plug both the hydraulic regulator and the check valves in the quick disconnect hose couplings. 7. Check hydraulic control valve: Disconnect hoses from Flo-Tork and snap on quick disconnect fittings to hose fittings. Observe if there is fluid leakage through the valve. Move control valve to open, then to close. Observe if there is fluid flowing as it should. Page 20

8. Remove the choke from the actuator shaft. If actuator turns properly, then disassemble choke. If turning fork is frozen in place, replace entire fork and bonnet assembly. 9. If turning fork turns but choke discs do not open, inspect choke disc to see that they are properly secured to the steel carrier rings. Choke Opens and Closes Too Slowly 1. If choke is too slow to react due to high viscosity of hydraulic fluid at low temperatures, change to a light grade of good quality hydraulic oil. 2. Check for partial plugging in the hydraulic regulator needle valve and in the check valves of the quick disconnect hose couplings. 3. If faster reaction than normal is desired, increase the air pressure to the hydraulic pump to provide about 1800 psi (125 Kg/cm2) hydraulic pressure. DO NOT EXCEED 1800 PSI. If turning fork were frozen, hydraulic pressure greater than 1800 PSI could result in over torquing and “twisting off ” the turning fork. This would make it impossible to control the position of the choke plates. When the hydraulic pressure is increased, it will be necessary to adjust the hydraulic relief valve.

Page 21

Stroke Counter Malfunction If the meter does not indicate in the test position, try substituting for the logic module. A troubleshooting symptom-cure table follows: PROBLEM / SYMPTOM

CURE

Displays flashing

Low battery or bad batteries

No display

Replace batteries or check connection to battery pack. If OK, then try substituting logic module.

Display on but does not count or display rate including in test mode

Replace logic module.

Display on but does not count or indicate correct rate except OK in test mode or only one pump

Check wiring or pump switches.

Only one input P1 or P2 works, OK in test mode

Check wiring or pump switches.

Count Display not all digits

Replace logic module.

Displays all “8”’s for rate or count

Replace logic module.

Reads 128 SPM continuously

Check switch position, check switch module for stuck or bad switch.

Page 22

Pressure Gauges Not Reading Or Not With Rig Gauges The pressure gauges on the T-3 Energy Services Super Choke control console will, in almost all cases, be the gauges which are used to determine drill pipe pressure and casing pressure during operations involving the use of the T-3 Energy Services Super Choke. If these gauges are not working, or if they are not working satisfactorily, repairs should be made to these gauges before operations involving the T-3 Energy Services Super Choke are undertaken. Check that the damping valve on the gauge is not closed too much. If failure is primarily at higher pressures, check for air in the hydraulic lines. Due to necessary design limitations, this pressure reading system cannot be accurate below 75-100 psi. Position Indicator System Not Working Check air supply gauge on back side of panel—should be 20-22 psi (1.4 – 1.5 Kg/cm2). The air supply to position indicator will be the same pressure as S.C. hydraulic pump. Check air supply and signal lines for leaks. Make sure the cam is tight on the shaft and the shaft connected to the Flo-Tork unit is also tight. The cam should turn a full 180 degrees when the choke is changed from fully open to fully closed, or from fully closed to fully open. Check indicator gauge. 3 psi applied directly to the gauge should indicate the OPEN range of the gauge, and 15 psi should indicate in the CLOSE range if the gauge is in good condition.

Page 23

APPENDIX

Page 24

CHOKE BODY - H2S SERVICE 22 21 20 23

19 24 18 17 16 15 14 13 12 11 10

9

25

8 7

6 5

FIGURE 1

4

3 1

2

Page 25

CHOKE BODY - H2S SERVICE

Page 26

ITEM

QTY

PART NO.

DESCRIPTION

1

1

94-36-230

SPOOL, OUTLENT 2 9/16” 10M

2

3

96-11-111

SLEEVE, WEAR T.C.

3

1

96-11-216

FLANGE, PROTECTOR WEAR SLEEVE ASSY.

4

16

94-36-213

SCREW, FERRY HD 7/8” – 9 x 3”

5

1

6

2

7

1

O’RING, VITON

8

1

O’RING, VITON

9

1

96-11-215

BACK DISC ASSY.

10

1

96-11-214

FRONT DISC ASSY.

11

1

94-36-105

BODY AND INLET FLANGE ASSY.

12

1

94-36-130

FORK, TURNING

13

1

94-36-050

BEARING, THRUST

14

2

O’RING, TEFLON

15

2

O’RING, VITON

16

1

17

1

18

1

94-36-207

PIN

19

1

94-36-065

BUSHING, SHAFT

20

1

39-66-338

O’RING, VITON

21

1

94-36-160

HEAD, INDICATOR

22

1

14-08-083

SCREW, SOCKET HD CAP

23

12

94-36-210

SCREW, FERRY HD 3/4” – 10 x 2 1/2”

24

1

94-36-035

BONNET, W/ITEM 13 AND 19

25

1

96-11-170

PIN, BACK DISC

26

1

94-36-180

KIT, O’RING # 5, 7, 8, 14, 15, 16, 17, 20

O’RING, VITON 94-36-200

39-66-237

PIN, SPRING 3/8” x 11/4”

O’RING, VITON O’RING, VITON

PISTON GAUGE PROTECTOR ASSEMBLY PN 96-11-336

FIGURE 2

ITEM

QTY PART NO.

DESCRIPTION

1

1

B96-11-337

BODY, GAUGE PROTECTOR

2

1

A96-11-338

PISTON

3

3

39-65-224

O’RING

4

1

36-12-200

RING, RETAINER

5

1

39-73-005

RING, SEAL

6

1

50-41-100

UNION, FEMALE THREADED HALF

7

1

13-05-991

NUT, WING

8

1

56-03-650

VALVE, BLEEDER

9

1

20-10-041

COUPLER, QUICK DISCONNECT

10

1

20-32-781

HOSE 10,000 PSI X 50’ (NOT SHOWN)

REV 3 1 -95 Page 27

CONTROL CONSOLE ITEM

Page 28

QTY

PART NO.

DESCRIPTION

1

2

24-22-242

GAUGE, 1-10,000 PSI WP

2

1

96-11-332

LOGIC MODULE W/COVER

3

1

96-11-325

SWITCH MODULE

4

1

96-11-328

BATTERY PACK (NOT SHOWN)

5

1

96-11-143

GAUGE, POSITION INDICATOR

6

1

56-03-368

VALVE, NEEDLE BRASS

7

1

56-03-292

VALVE, 4 – WAY

8

1

56-03-156

VALVE, OPEN/CLOSE BRASS

9

1

24-22-080

GAUGE, 0 – 3,000 PSI WP

10

1

11

1

16-02-226

FILTER, AIR

12

1

52-01-142

REGULATROR, AIR

13

1

28-02-100

LUBRICATOR, AIR

14

1

34-91-500

MUFFLER, AIR

15

1

34-03-005

PUMP, AIR OVER HYDRAULIC

16

1

96-11-157

TANK, HYDRAULIC RESEVOIR

17

1

34-03-052

PUMP, HYDRAULIC HAND (EMERGENCY)

18

1

56-03-225

VALVE, PRESSURE RELIEF

19

1

96-11-063

ADAPTER, MANIFOLD

20

1

94-36-145

HANDLE, PUMP 16” (NOT SHOWN)

REAR MANIFOLD ASSEMBLY

CONTROL CONSOLE (FRONT VIEW)

FIGURE 3 Page 29

CONTROL CONSOLE (REAR VIEW)

FIGURE 4 Page 30

CONTROL CONSOLE (RIGHT SIDE VIEW) FIGURE 5

Page 31

TEST PROCEDURE

FOR THE T-3 ENERGY SERVICES SUPER CHOKE

FIGURE 6

Page 32

LIMIT SWITCH ASSEMBLY PN 96-11-049

ITEM QTY PART NO.

DESCRIPTION

1

1

96-98-401

SWITCH, LIMIT EXPLOSION PROOF

2

1

93-89-037

ROD, ACTUATOR

3

1

65-60-054

CONNECTOR, CABLE

4

1

79-06-111

CABLE, 150’

5

1

96-11-055

PLATE, SWITCH

6

1

96-11-124

C-CLAMP

FIGURE 7

Page 33

EQUIVALENT BEAN SIZE CHART

FIGURE 8 Page 34

REAR MANIFOLD ASSEMBLY ITEM QTY

PART NO.

DESCRIPTION

1

1

96-11-061

PLATE, MANIFOLD

2

2

50-78-079

TEE, STEEL

3

2

56-03-650

VALVE, CHECK W/CAP

4

1

20-12-021

DUST, CAP

5

1

20-10-041

COUPLING, MALE QUIK

6

1

20-10-040

COUPLING, FEMALE QUIK

7

1

20-12-097

PLUG, DUST

8

2

54-15-180

CONNECTOR, AIR TUBING

9

4

54-17-567

ELL, STEEL

10

2

50-15-232

COUPLING, AIR HOSE

FIGURE 9

Page 35

ACTUATOR AND POSITION INDICATOR ASSEMBLY

FIGURE 10

ITEM

QTY

PART NO.

DESCRIPTION

1

1

52-01-09

REGULATOR, TRANSMITTER

2

1

96-11-038

BRACKET, REGULATOR

3

1

96-11-040

CLAMP, PIVOT ADJ. SCREW

4

1

96-11-037

BLOCK, ADJ. PIVOT

5

1

96-11-042

GUIDE, ARM

6

1

96-11-039

CAM

7

1

96-11-102

SHAFT, CAM

8

1

04-02-235

BEARING, CAM FOLLOWER

9

1

96-11-036

ARM, CAM FOLLOWER

10

1

96-11-118

ACTUATOR, HYDRAULIC FLO-TORK MODIFIED

11

1

20-10-040

COUPLING, FEMALE QUIK

12

1

20-10-041

COUPLING, MALE QUIK

13

1

20-12-097

PLUG, DUST

14

1

20-12-021

CAP, DUST

15

1

96-11-098

BRACKET, ACTUATOR

FLO-TORK ROTARY ACTUATOR MAINTENANCE INSTRUCTIONS MAXIMUM OPERATING PRESSURE – 3000 psi NON-SHOCK KEY CONSIDERATION IN THE DISASSEMBLY OF THE UNIT IS DETERMINING THE PINION SHAFT KEYWAY RELATIONSHIP TO THE RACK POSITION TO MAINTAIN PROPER TIMING AT RE-ASSEMBLY NOTE: STANDARD UNITS ARE TIMED WITH THE PINION SHAFT KEYWAY AT 12 O’CLOCK HIGH WHEN LOOKING AT THE MOUNTING HOLD SIDE AS SHOWN ON THE ENCLOSED TYPICAL DRAWING. GENERAL FLO-TORK ROTARY ACTUATORS REQUIRE CLEAN, FILTERED HYDRAULIC OIL FOR SATISFACTORY OPERATION THE SAME AS ANY OTHER HYDRAULIC COMPONENT. THE STANDARD BUNA-N-SEALS ARE DESIGNED FOR PETROLEUM BASE FLUIDS.

DISASSEMBLY 1. Remove all cylinder head tie bolts/tie rods. 2. Remove cylinder heads. 3. Determine that the rack is at mid-point of travel (Equal amounts of rack extended on each side of housing.) Note & record pinion shaft keyway location for re-assembly. 4. Back off the bearing cap set screw. Using a spanner wrench, unscrew the threaded bearing cap from the housing. 5. Remove O-ring from housing. 6. Pull pinion from the housing with the bearing on it. (NOTE: Place unit over a pan or tub before doing this as the unit is filled with gear lubricating oil which will drain from the housing when the pinion is removed.) 7. Remove the cylinder tubes. 8. Remove the piston/rack(s). 9. Remove the back bearing from the housing (if necessary). 10. Remove all remaining O-rings and seals. Replace with new O-rings & seals at re-assembly. 11. Thoroughly clean & inspect all parts for wear or damage. Replace with new parts as required. Lubricate with light oil before re-assembly.

Page 37

RE-ASSEMBLY 1. Install new O-rings, back-up rings & seals in proper grooves (see drawing). 2. Install back bearing in housing. 3. Slide a cylinder tube over one end of the piston/rack assembly. If it is a double rack unit, slide a cylinder tube over one of the second piston/rack assembly. 4. Slide piston/rack assembly and cylinder tube into the housing. If it is a double rack unit slide both piston/rack assemblies & cylinder tubes into the same side of the housing. 5. Attach cylinder head(s) & bolts. Snug bolts up but do not torque until re-assembly is complete. 6. Center rack in housing. (Equal spacing of rack on both sides of housing.) 7. Install pinion with the shaft keyway location as noted during disassembly (Standard unit timing will have keyway at 12 o’clock high location when looking at the front mounting face.) 8. Install cylinder tube(s) on the other side of housing. 9. Attach cylinder head(s) & bolts. Snug bolts up but do not torque until re-assembly is complete. 10. Lay unit down & fill housing to top of the rack with SAE grade 70 oil or other equivalent gear lubricant. 11. Install front pinion bearing & O-ring. 12. Install bearing cap. Tighten bearing cap until snug, then further tighten slightly to insure a positive seal. 13. Insert nylon locking pellet in bearing cap set screw hole. Tighten set screw locking bearing cap. 14. Torque cylinder head bolts evenly by applying force alternately to opposite corners of the head. Torque values per bolt size are shown in the following chart.

MODEL NO.

Page 38

FASTENER SIZE

RECOMMENDED TORQUE FOR CYLINDER HEAD BOLTS

900 & 1800

1/4 - 20

6 lb. ft.

3700 & 7500

5/16 - 18

12 lb. ft.

15,000 & 30,000

7/16 - 14

30 lb. ft.

STANDARD MODELS 900 THROUGH 30,000

ITEM NO. 1 2 3 4 5 6 7 8 10 11 12 13 14 15 16 17 23 24 25 26

PART NAME HOUSING BEARING O-RING, BEARING CAP BEARING CAP PINION NUT, TIE ROD LOCKWASHER, TIE ROD TIE ROD O-RING, PINION RELIEF VALVE CYLINDER TUBE PISTON-BACK-UP RING SEAL, PISTON O-RING, CYL. O.D. PISTON RACK CYLINDER HEAD BACK UP, CYL. HD. O-RING, CYL. HD SET SCREW-BEARING CAP NYLON PELLET-BEARING CAP

ALWAYS USE SERIAL NUMBERS AND MODEL NUMBERS WHEN ORDERING PARTS

0° TO 5° INTERNAL ADJUSTABLE STOPS DISASSEMBLY — 0 ° TO 5 ° INTERNAL ADJUSTABLE STOPS 1. Remove cover screw & cover screw seal. 2. Remove adjustable stop-set screw. 3. With cylinder head removed from cylinder tube the adjustor can be removed by screwing out towards the inside of the cylinder head with a hex wrench. RE-ASSEMBLY — 0 ° TO 5 ° INTERNAL ADJUSTABLE STOPS NOTE: MUST BE RE-ASSEMBLED BEFORE CYLINDER HEAD IS MOUNTED TO CYLINDER TUBE. 1. Screw adjustor into cylinder head from inside of cylinder headface. Screw adjustor in until flush or below the surface of the cylinder head so that rotation can be adjusted at test. 2. Install set screw but do not tighten until adjustment is set. 3. Adjust rotation at test. Turning adjustor clockwise reduces rotation, counter-clockwise increases rotation. 4. When adjustment is complete, tighten set screw to lock position. 5. Install cover screw seal and cover screw. NOTE: ADJUSTMENTS SHOULD NOT BE MADE WHILE UNIT IS UNDER PRESSURE.

ITEM NO. PART NAME

Page 40

QTY.

32

INTERNAL ADJUSTOR-CYL. HD. 1

33

0” TO 5” INTERNAL ADJ. STOP

1

34

SET SCREW-ADJ. STOP

1

35

THREAD SEAL-COVER SCREW

1

36

COVER SCREW

1

37

NYLON LOCKING PELLET

1

0° TO 30° EXTERNAL ADJUSTABLE STOPS DISASSEMBLY — 0° TO 30° EXTERNAL ADJUSTABLE STOPS 1. Loosen jam nut & thread seal. Screw adjustor out of cylinder head. Remove thread seal & jam nut. 2. Thoroughly clean & inspect all parts for wear or damage. Replace with new parts as required. RE-ASSEMBLY – 0° TO 30° EXTERNAL ADJUSTABLE STOPS 1. Screw adjustor into cylinder head. Thread into head until the adjustor is flush with the inside of the cylinder head (Approx. 6-7 turns). 2. Install thread seal and jam nut. Adjust rotation at test. Turning adjustor clockwise reduces counter-clockwise increases rotation. NOTE: ADJUSTMENT SHOULD NOT BE DONE WHILE UNIT IS UNDER PRESSURE.

PART NO.

PART NAME

QTY.

23

BACK UP, CYL. HD.

1

24

0-RING, CYL. HD

1

28

EXTERNAL ADJUSTOR CYL. HD.

1

29

JAM NUT

1

30

THREAD SEAL

1

79

CUSHION-EXT. ADJ.FIXED

1

Page 41

CUSHION DETAILS MODELS 900 THROUGH 30,000 PART NO. 64 65 66 67 68 69 73 74 75 76 77

PART NAME CUSHION PISTON RACK CUSHION PISTON CUSHION CY. HD.-ADJUSTABLE COMPRESSION SPRING CUSHION NOSE SNAP RING O-RING-CUSHION ADJUSTOR SCREW BACK-UP RING-CUSHION ADJUSTOR SCREW CUSHION ADJUSTMENT SCREW RETAINER CARTRIDGE JAM NUT

QTY 1 1 1 1 1 1 1 1 1 1 1

DO NOT REMOVE CUSHION NEEDLE WHILE UNIT IS UNDER PRESSURE. DISASSEMBLY – ADJUSTABLE CUSHIONS 1. Remove cushion needle jam nut & cushion needle from cylinder head. 2. Remove O-ring & back-up ring. Replace with new parts during re-assembly. 3. Remove cylinder head. 4. Remove cushion nose snap ring from piston. 5. Remove spring retaining cartridge, cushion nose, & compression spring from piston. 6. Thoroughly clean & inspect all parts for wear or damage, replace parts as required. RE-ASSEMBLY – ADJUSTABLE CUSHIONS 1. Install compression spring, cushion nose, & spring retaining cartridge in piston. 2. Secure in place with the cushion nose snap ring. Page 42

3. Install new back-up ring on cushion needle making sure that the curved side faces toward the needle end. 4. Install a new O-ring on the cushion needle, making sure that the O-ring fits into the curved side of the back-up ring. 5. Re-install cylinder head. 6. Insert the cushion needle in the cylinder head, being careful not to damage the seals. Tighten as far as possible, then loosen 1/2 turn. Install jam nut. Adjust cushion at test. NOTE: ADJUSTMENT SHOULD NOT BE DONE WHILE UNIT IS UNDER PRESSURE. CUSHION ADJUSTMENT NOTE: DO NOT ADJUST WHILE UNIT IS UNDER PRESSURE. 1. The control needles of the cushion are installed & locked 1/2 turn from closed when assembled at the factory to prevent premature damaging of the actuator during installation & start up. 2. Increase cushioning – loosen cushion needle jam nut 1/2 to 1 turn. Turn cushion needle clockwise 1/8 turn. Lock jam nut & check cushion action. NOTE: NEVER COMPLETELY CLOSE CUSHION NEEDLES. 3. Decrease cushioning – loosen cushion needle jam nut 1/2 to 1 turn. Turn cushion needle counter-clock wise 1/8 turn. Lock jam nut & check cushion action. NOTE: CAUTION IS TO BE TAKEN WHEN ADJUSTING THE CUSHION NEEDLE THAT IT HAS ADEQUATE THREAD ENGAGEMENT & WILL NOT BLOW OUT OF HOLE. 4. Continue adjusting cushion needles in the above described manner until the desired cushioning effect is obtained. SEAL LEAKAGE FLO-TORK ROTARY ACTUATORS MAY BE CHECKED FOR PISTON SEAL LEAKAGE AS FOLLOWS: 1. SET UP ACTUATOR WITH RELIEF FITTING UP. 2. PRESSURIZE CYLINDER PORTS INDIVIDUALLY. 3. IF OIL FLOWS FROM RELIEF PORT AFTER PISTON HAS COMPLETED ITS TRAVEL AND SET 3 MINUTES UNDER PRESSURE, ALL PISTON SEALS SHOULD BE REPLACED. FOR FURTHER MAINTENANCE INFORMATION CONTACT YOUR NEAREST FLO-TORK REPRESENTATIVE OR FLO-TORK INC., ORRVILLE, OHIO 44667

Page 43

SC HYDRAULIC PUMP MAINTENANCE INSTRUCTIONS PUMP ASSEMBLY 10-600 SERIES

MOUNTING DIMENSIONS

I

PARTS LIST X

X

X

—

—

X

X

X

X

X

X

X

X

X

X

X

AIR MOTOR

ASSY

10-550-94

1

2

— —

— — — — — — —

—

HYDRAULIC

ASSY

I

10-550-70

1

1

— —

— — — — — — —

—

ıı

ıı

ıı

10-550-30

1

1

— —

X

—

— — — — — — —

—

ıı

ıı

ıı

10-550-10-30

1

1

— —

—

X

— — — — — — —

—

ıı

ıı

ıı

10-550-10-20

1

1

— —

— —

X

—

ıı

ıı

ıı

10-550-10-15

1

1

— —

— —

—

—

ıı

ıı

ıı

10-550-10-10

1

1

— —

— —

— —

X

— — — —

—

ıı

ıı

ıı

10-550-10-8

1

1

— —

— —

— — —

X — — —

—

ıı

ıı

ıı

10-550-10-5

1

1

— —

— —

— — — —

—

ıı

ıı

ıı

10-550-10-3

1

1

— —

— —

— — — — —

X

—

—

ıı

ıı

ıı

10-550-10-2

1

1

— —

— —

— — — — — —

X

—

ıı

ıı

ıı

10-550-10-1.50

1

1

— —

— —

— — — — — — —

X

ıı

ıı

ıı

10-550-10-1

1

1

PART NO.

NO. REQ

ITEM NO.

— — — — — — X

— — — — —

-50 -40 -30 -20 -15 -10 -8

-5 -3

10-600- ___ Page 44

X

— —

-2

-1.50 -1

DESCRIPTION

I

• THE 10-550-10-1 THRU -30 ASSES DO NOT CONTAIN THE UPPER “O” RING AND DRAIN HOLE AND ARE FOR STANDARD HYDRAULIC FLUIDS AND WATER • THE 10-550-10A-1 THRU -30 ASSES ARE FOR SPECIAL FLUIDS • 10-600-1A THRU -30A ASSES WILL CONTAIN 10-550-10A HYD ASSYS

AIR MOTOR ASSEMBLY 10-550-94

2

Page 45

AIR MOTOR ASSEMBLY 10-550-94 (CONTINUED)

Page 46

“O” RING ıı ıı ıı ıı BEARING ASSY CYLINDER SPRING PISTON END BUMPER VALVE ASSY

6227-66 6227-19 6230-39 6230-9 6230-1 10-450-47 10-550-4 10-450-5-1 10-550-25 10-550-2 10-450-12 10-550-93

DESCRIPTION

PART NO.

HEAD “O” RING PILOT VALVE ASSY “O” RING SET SCREW 1/4 - 20 FLAT POINT BOLT 1/8 x 24 x 5 NUT 1/8 x 24 BUMPER VALVE RETAINING RING ıı

10-550-92 28775-144 10-550-27 28775-028

DESCRIPTION

PART NO.

10-450-57 RRT-262 RRT-200

1 3 2 1 1 1 1 1 1 1 1 1 NO. REQ

1 4 1 1 1 8 8 1 1 1 NO. REQ

12 11 10 9 8 7 6 5 4 3 2 1 ITEM NO.

22 21 20 19 18 17 16 15 14 13 ITEM NO.

VIEW FOR HYDRAULIC ASSEMBLIES 10-550-10 AND 10A* -1 THROUGH -10 20 21

17

1/4-28 THD 4

22

PARTS LIST 10-550-10 AND 10 X — — — — — — X — — — — — — — — — — — — X X — X X — — — — — — X X X X X

— X — — — — — — X — — — — — — — — — — X — X — X — X — — — — — X X X X X

— — X — — — — — — X — — — — — — — — X — — X — X — — X — — — — X X X X X

— — — X — — — — — — X — — — — — — X — — — — X X — — — X — — — X X X X X

— — — — X — — — — — — X — — — — X — — — — — X X — — — — X — — X X X X X

— — — — — X — — — — — — X — — X — — — — — — X X — — — — — X — X X X X X

— — — — — — X — — — — — — X X — — — — — — — X X — — — — — — X X X X X X

-1

-1.50 -2

-3

-5

-8

-10 DESCRIPTION

10-550-10- ___

BACK UP ıı ıı ıı ıı ıı ıı “O” RING 2 ıı ıı ıı ıı ıı ıı ıı ıı ıı ıı ıı ıı PISTON & CYL ASSY 2 ıı ıı ıı ıı ıı ıı ıı ıı ıı ıı ıı ıı ıı ıı ıı ıı ıı ıı INLET VALVE ASSY 2 INLET VALVE ASSY ıı ıı OUTLET VALVE ASSY 3 “O” RING TEFLON I ıı ıı ıı ıı ıı ıı ıı ıı ıı ıı ıı ıı ıı ıı ıı ıı ıı ıı BUMPER PISTON RETAINER-BUMPER WASHER-COMM EQUIV OF FLAT POINT SET SCREW #10-32 GASKET

MS28782-26 MS28782-24 MS28782-21 MS28782-17 MS28782-13 MS28782-11 MS28782-10 6227-26 6227-24 6227-21 6227-17 6227-13 6227-11 6227-10 10-550-11-10 10-550-11-8 10-550-11-5 10-550-11-3 10-550-11-2 10-550-11-1.50 10-550-11-1 10-450-31 10-450-24 10-450-23 6227-26 6227-24 6227-21 6227-17 6227-13 6227-11 6227-10 10-450-51 10-450-58 AN 936-B416 10-450-28

2 2 2 2 2 2 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

26 26 26 26 26 26 26 25 25 25 25 25 25 25 24 24 24 24 24 24 24 23 23 22 21 21 21 21 21 21 21 20 19 18 17 16

PART NO.

NO. REQ

ITEM NO.

3

*10A MODELS ARE FOR USE WITH SPECIAL FLUIDS

Page 47

HYDRAULIC ASSEMBLIES 10-550-10 AND 1 -15, -20 & -30 9 6

10

1

PARTS LIST 10-550-10 AND 10A* -15, -20 & -30 — — X — — X — — X — — X — — X X X X X X X X X X X

— X — — X — — X — — X — — X — X X X X X X X X X X

X — — X — — X — — X — — X — — X X X X X X X X X X

“O” RING TEFLON 1 3 ıı ıı ıı ıı ıı ıı ıı ıı PLATE 3 ıı ıı ıı ıı PISTON & CYL ASSY 2 ıı ıı ıı ıı ıı ıı “O” RING 2 ıı ıı ıı ıı BACKUP ıı ıı ıı ıı “O” RING 2 BUMPER-PISTON RETAINER-BUMPER WASHER COMM EQUIV OF FLAT POINT SET SCREW #10-32 FLAT HEAD SET SCREW # 5-40 RETAINER GASKET INLET VALVE ASSY 3 OUTLET VALVE ASSY 3

-15

-20 -30 DESCRIPTION

6227-6 6227-8 6227-9 10-450-40-16 10-450-40-10 10-450-40-8 10-550-11-30 10-550-11-20 10-550-11-15 6227-6 6227-8 6227-9 MS28782-6 MS28782-8 MS28782-9 6227-11 10-450-51 10-450-58 AN-936-B416

10-407-7 10-450-28 10-450-29 10-450-30

1 1 1 1 1 1 1 1 1 1 1 1 2 2 2 2 1 1 1 1 3 1 1 1 1

15 15 15 14 14 14 13 13 13 12 12 12 11 11 11 10 9 8 7 6 5 4 3 2 1

PART NO.

NO. REQ

ITEM NO.

3 3

10-550-10- __ Page 48

*10A MODELS ARE FOR USE WITH SPECIAL FLUIDS

I

• THE 10-550-10-1 THRU -30 ASSES DO NOT CONTAIN THE UPPER “O” RING AND DRAIN HOLE AND ARE FOR STANDARD HYDRAULIC FLUIDS AND WATER • THE 10-550-10A-1 THRU -30 ASSES ARE FOR SPECIAL FLUIDS • 10-600-1A THRU -30A ASSES WILL CONTAIN 10-550-10A HYD ASSYS

AIR MOTOR ASSEMBLY 10-550-94

2

Page 45

HYDRAULIC ASSEMBLIES 10-550-10 AND 1 -15, -20 & -30 9 6

10

1

PARTS LIST 10-550-10 AND 10A* -15, -20 & -30 — — X — — X — — X — — X — — X X X X X X X X X X X

— X — — X — — X — — X — — X — X X X X X X X X X X

X — — X — — X — — X — — X — — X X X X X X X X X X

“O” RING TEFLON 1 3 ıı ıı ıı ıı ıı ıı ıı ıı PLATE 3 ıı ıı ıı ıı PISTON & CYL ASSY 2 ıı ıı ıı ıı ıı ıı “O” RING 2 ıı ıı ıı ıı BACKUP ıı ıı ıı ıı “O” RING 2 BUMPER-PISTON RETAINER-BUMPER WASHER COMM EQUIV OF FLAT POINT SET SCREW #10-32 FLAT HEAD SET SCREW # 5-40 RETAINER GASKET INLET VALVE ASSY 3 OUTLET VALVE ASSY 3

-15

-20 -30 DESCRIPTION

6227-6 6227-8 6227-9 10-450-40-16 10-450-40-10 10-450-40-8 10-550-11-30 10-550-11-20 10-550-11-15 6227-6 6227-8 6227-9 MS28782-6 MS28782-8 MS28782-9 6227-11 10-450-51 10-450-58 AN-936-B416

10-407-7 10-450-28 10-450-29 10-450-30

1 1 1 1 1 1 1 1 1 1 1 1 2 2 2 2 1 1 1 1 3 1 1 1 1

15 15 15 14 14 14 13 13 13 12 12 12 11 11 11 10 9 8 7 6 5 4 3 2 1

PART NO.

NO. REQ

ITEM NO.

3 3

10-550-10- __ Page 48

*10A MODELS ARE FOR USE WITH SPECIAL FLUIDS

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TYPICAL INSTALLATION

GAUGE FILTER

OILER

AIR SUPPLY

AIR EXHAUST SHUT OFF VALVE

GAUGE

AIR REGULATOR

FLUID PRESSURE OUTLET FILTER FLUID SUPPLY

FLUID OFF VALVE

5

USE 10-550-11A, 10-450-23A, 10-450-24A, 10-450-29A AND 10-450-30A ON 10-550-26A ASSYS.

4

STANDARD MODELS DO NOT HAVE BLEED HOLES, PLATE, TEFLON “O” RING, FLAT HEAD AND FLAT POINT SET SCREW.

3

USED ON “A” MODELS ONLY.

2

USE SPECIAL COMPOUND ON “A” MODELS.

ALWAYS USE SERIAL NUMBERS AND MODEL NUMBERS WHEN ORDERING PARTS Page 49

INSTALLATION & OPERATING INSTRUCTIONS FOR SC HYDRAULIC PUMP- MODEL No. 10-600 PLEASE READ CAREFULLY 1. MOUNTING THE PUMP — There are two drilled and tapped holes in the base of the pump for this purpose. Size and spacing of these holes are shown on the Parts List furnished with each pump. IMPORTANT: The pump is so designed that the head may be rotated in increments of 45 degrees to facilitate connection to air and hydraulic lines. This may be done by removing the eight 3/8 “ bolts that clamp the pump together. The head may then be rotated to any desired position that will also allow proper alignment of the bolts in the head and the base. When the bolts are replaced, be sure that the Air Cylinder, Part #10-5500-4, is in proper position against the flanges on the pump head and the Air Cylinder End before tightening the bolts that clamp the Air Motor together. Use a soft hammer to position the flanges tightly against the Air Cylinder Ends BEFORE tightening the bolts. Failure to do this can result in over-tightening the bolts initially, and when bolts on the opposite side are drawn up, this may result in the bolt lugs being broken or twisted off when the assembly is drawn down into position. Bolts should be secured lightly at first and then draw up in sequence until uniform torque has been applied to all of the bolts around the perimeter of the pump. 2. CONNECTION TO AIR LINE a. A filter-regulator-lube assembly, located as close to the pump as possible, is required in the air supply line. The air input side of the pump is a 1/2” NPT inlet and is marked “AIR IN.” The Lubro assembly should be connected to it in the order named, with the lubricating unit adjacent to the pump. The pump will deliver at its rated capacity on 100 PSI of air with a 1/2” supply line. Use of a smaller size supply line will not allow the pump to operate at full capacity. b. CAUTION: WHERE THE PUMP IS TO BE CONNECTED TO AN AIR SUPPLY SOURCE IN EXCESS OF 150 PSI, THEN A POP-OFF TYPE SAFETY VALVE, SET TO RELIEVE PRESSURE AT 150 PSI MAXIMUM, IS REQUIRED IN THE AIR SUPPLY LINE TO PROTECT THE PUMP AGAINST ANY EXCESSIVE AIR PRESSURES THAT MAY, FOR ANY REASON, DEVELOP IN THE AIR SUPPLY TO THE PUMP. 3. LUBRICATION—A good grade of lubricating oil should be used, such as Turbine #9, Gargoyle DTP light weight, or any good grade of oil with equivalent properties. For good lubrication, one drop for every 20 strokes of the pump is ample. If an excessive amount of oil appears to be flowing through the pump during operation, lubrication may be somewhat reduced to avoid excessive waste. CAUTION: Do not operate the pump when too dry, as this will cause premature wear and will result in improper running of the pump, necessitating repairs. 4. AIR EXHAUST— The air exhaust is a 1” NPT outlet and is marked “AIR OUT.” A muffler is desirable for quietness of operation. If no muffler is available and noise is objectionable, exhaust may be piped away to a remote location. Pipe used for this purpose should be 1” diameter or larger so that the efficiency of the pump will not be impaired. Page 50

5. CONNECTION TO FLUID SUPPLY LINE — The size of the NPT port is shown on the Parts List and is marked “FLUID IN” on the pump. Clean fluid is very important. Grit or foreign matter in the fluid supply may damage the check valves and the Hydraulic Cylinder, resulting in improper functioning of the pump. Valve seats and the precision honed Hydraulic Cylinder and Piston must be maintained in perfect condition for maximum performance. A free flow type of filter with ports not smaller than the inlet part in the pump should be used to obtain maximum performance and avoid the possibility of cavitation. CAUTION: This pump is designed for either hydraulic oil or tap water service (as specified when ordered) and is not guaranteed to pump fluids other then specified herein, or fluids that have corrosive qualities which will deteriorate the packing or metal parts of the pump. Write to the factory for information on pumps for special fluids. 6. CONNECTION TO FLUID OUTLET OR PRESSURE SIDE — The side and type of opening is shown on the Parts List and is marked “FLUID OUT” on the pump. The same care should be taken in making connection to this port as is necessary in all high pressure connections. Only fittings with high pressure threads should be used so there will be no danger of damaging the threads in the outlet valve with a resultant leaky condition. 7. STARTING THE PUMP a. Fill lubricating unit in air supply line with oil as recommended in paragraph #3. b. Screw down the pressure regulator to “0” before turning on air into the pump. c. Release pressure side of pump to reservoir or atmosphere so the pump can prime itself. CAUTION: BE SURE THAT FLUID SUPPLY REACHES THE PUMP PROMPTLY UPON STARTING. Running the pump dry will damage the Hydraulic Piston & Cylinder Assembly. These parts are precision honed and lapped to a very close fit and must be lubricated immediately upon starting up the pump. IMPORTANT: When the pump is installed where the Hydraulic Assembly is not in a flooded condition, repeat operations a, b, & c at the beginning of each work day to be sure the pump is primed. d. Screw down the pressure regulator slowly until the pump starts. Pump should start on 10 to 15 PSI of air under normal conditions. Continue to increase air pressure to 40 to 45 PSI of air and let the pump run until all air has been purged from the system. e. Check the lubricator to see that the proper amount of oil is being supplied to the pump. f. After steps (a) through (e) have been completed, air pressure on the pump may be regulated until the desired pressure is attained in the hydraulic system. NOTE: All model of the pump are designed to operate in the range of 10 to 100 PSI air pressure. Higher air pressure may be applied on intermittent duty but not to exceed 150 PSI (see paragraph 2 (b) and is not recommended for continuous operation. The 10-600-20 and the 10-600-30 models should not be operated, except on intermittent duty at hydraulic pressures above 30,000 PSI as the life expectancy of the packing in the Hydraulic Cylinder will be relatively short when operating continuously at pressures above 30,000 PSI. The 10-600-50 model will operate on continuous duty at 50,000 PSI and will attain hydraulic pressure to 70,000 PSI static. Page 51

8. The pump has been thoroughly tested at the factory and found to be in perfect working condition. If for some reason the pump does not function properly, do not attempt to repair it, but write or wire the factory for instructions. Before doing this, the following items should be checked. a. If the pump does not prime itself promptly, look for one of the following reasons: (1) Reservoir is too far away for the pump to prime properly. (2) Filter or some other component is imposing too much restriction in the supply line, or (3) all pressure has not been removed from pressure side to allow priming. 9. LIMITED WARRANTY — This pump is under warranty for a period of 180 days from date of purchase against defects in material and workmanship. This warranty is good only under the following conditions: a. That the pump has been lubricated properly as recommended in paragraph No. 3. b. That maximum air pressure recommended in paragraph N. 2 a has not been exceeded. c. That air and fluid supply to the pump have been maintained in a properly clean condition at all times. (The pump is not guaranteed against pitting, scoring, or excessive wear of moving parts due to foreign matter being present in the air or fluid supply). d. That the proper type of fluid be pumped as recommended in paragraph No. 5. Packing is not under warranty and performance will depend largely on the air and fluid supply being kept clean at all times, and should give long and lasting service if the supply lines are kept free from contamination. This warranty is good only on condition that the pump has not been tampered with, other than with written approval from the factory. NOTICE: The factory recommends the installation of an oil lubricator in the air supply as indicated in paragraph No. 2 for maximum performance and pump life. The pumps may also be operated without a lubricator in the air system as they are packed at the factory with Moli-Valve grease lubricant. When no oil lubrication is provided, periodic servicing with Moli-Valve grease lubricant will be required. The time interval will depend upon operating conditions. With clean air, relatively free of water or other contaminants, up to 3 million cycles or more may be anticipated before the pump will require repacking with grease lubricant.

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SERVICING INSTRUCTIONS FOR SC HYDRAULIC PUMP – MODEL NO. 10-600 1. TO DISASSEMBLE THE MOTOR — Refer to Parts List for Part Numbers and cross section of the pump. a. Remove the eight 3/8 “ bolts that clamp the Air cylinder, Item # 6, between the Head Casing, Item #22, and the Air Cylinder End, Item #3. Remove the Head by tapping on a fitting screwed into either the “AIR IN” or “AIR OUT” ports with a soft hammer. b. Remover the Retaining Ring, Item #13, from the Bottom of the Air Piston, Item #4, and remove the Hydraulic Piston. The Pilot Valve Assembly, Item #20, may then be pushed out through the bottom of the Air Piston. c. Remove the Retaining Ring, Item #14, from the Head Assembly. Remove the Bearing Assembly, Item #7, by lifting or prying it out with a hammer handle or similar tool. The Air Piston Actuating Valve, (part of Item #1, Valve Assembly), may also be removed at this time. The Bearing Assembly has a molded rubber seat and should be replaced if worn or damaged. The “O” Ring, Item #8, in the Bearing Assembly, the “O” Ring, Item #11, in the upper part of the Air Piston Actuating Valve, and the “O” Ring* on the Pilot Valve Assembly head should be replaced as a routine matter while the pump is disassembled as they are especially important for maximum performance. * (This “O” Ring is Part #6227-21, see Pilot Valve Ass’y 10-550-27) d. The Head has a Rubber Bumper, Item #15, inserted in the upper portion of the body. This acts as an air seal and also a cushion for the Air Piston Actuating Valve. If worn or damaged, it should be replaced. NOTE: When worn or damaged, the Air Piston Actuating Valve and the Sleeve in which it operates are supplied as a Valve Assembly, Part #10-550-93 (See Parts List). The Sleeve may be removed from the Head Casting by means of an internal puller engaging the slots in the Sleeve. Install a new set of “O” Rings, Part 287750144, (4 required and included with Valve Assembly when ordering as a replacement part). Also coat the “O” Rings and the Sleeve O.D. with Vaseline or other suitable lubricant to avoid possibility of damage to the “O” Rings when installing the new Sleeve. CAUTION: DO NOT remove the sleeve from the Head Casting unless replacement is to be made. The Valve Assembly is precision ground and honed to very close tolerances and the Sleeve may be damaged when removed from the Head Casting. 2. REPAIRING THE PILOT VALVE ASSEMBLY — The Pilot Valve Assembly, Item #20, has an Air Check Assembly, Part #10-403-32-1, located in the lower end. Remove the Retaining Ring, Part #RRT93, which locks the Valve Seat, Part #10-403-24, in place and remove the Valve Seat with a spanner wrench. The Air Check Assembly and the Spring, Part #10-450-16-1, will then drop out and may be inspected for wear or damage. Replace the springs and won parts as required. When installing the Spring, Part #10-450-15, in the Air Check Assembly, the assembly should be screwed together until the component parts are drawn up just snugly with no travel in the bolt assembly, and then the nut should be backed off ONE COMPLETE TURN for proper adjustment. When the assembly adjustment has Page 53

been done correctly, the valve will open approximately 1/23 inch when the bolt assembly is depressed to open the valve. Deform the threads on the end of the Bolt after completion of assembly to insure the Self Locking Nut being held in proper position. NOTE: Both the O.D. and the I.D. of the stem of the Air Piston, Item #4, must be free from wear, scoring, or other damage as they must make a perfect seal with the contacting “O” Rings. While the pump will run under these conditions, satisfactory performance will not be obtained where air leakage may occur between the Piston stem and the “O” Rings. The “O” Ring, Item #12, may also be inspected at this time. Replace if necessary. 3. TO REPLACE THE PACKING IN THE HYDRAULIC CYLINDER – It is not necessary to dismantle the Air Motor. Proceed as follows: Disconnect the air supply line, remove the muffler if necessary and loosen the Set Screw in the Air Cylinder End, Item #18. Unscrew the Air Motor from the Hydraulic Cylinder. The Hydraulic Piston will be removed with the Air Motor, permitting convenient replacement of the packing in the Hydraulic Cylinder. Replace the Backup Rings and the “O” Rings. The Parts List will give the size and kind of packing required, and when installing the new packing, be sure that the Backup Rings are properly in place. If they are damaged or not installed correctly, the “O” Ring will malfunction, with resultant loss of pressure and packing failure. When replacing the Air Motor, install a new Gasket, Part #10-450-28, and see that the Hydraulic Piston is in proper alignment before screwing the Air Motor down into position. Tighten the Air Motor securely and also the Set Screw, Item #18 in the Air Cylinder End. NOTE: Models with Isolator Attachment or “V” Ring packing in the Hydraulic Cylinder will require removal of the Isolator or the Adapter on “V” Ring packed Cylinders to replace the packings. 4. THE HYDRAULIC PISTON has a Rubber Bumper, Part #10-450-51, in the head. If replacement is required remove the Retainer, Part #10-450-58, with a spanner wrench and install new Rubber Bumper and Washer, Part # AN936-B416. Apply “LOCTITE” sealant to the Retainer threads when replacing and tighten securely, but not to exceed four foot pounds of torque. NOTE: The Piston stem is chrome plated and honed and lapped to a very close tolerance with the Hydraulic Cylinder. Should it show indications of wear or being scored (usually due to foreign matter being present in the hydraulic fluid), the entire Hydraulic Piston and Cylinder Assembly, Part #10-550-11, should be returned to the factory, for repair or replacement as required. 5. REPAIRING OR REPLACING THE HYDRAULIC CHECK VALVES — These valves should not give any trouble unless foreign matter such as dirt or grit are present in the fluid supply. If a leak develops, remove the check Valves, from the Hydraulic Cylinder. Remove the “O” Ring and replace with a new one. Inspect the ball seat in the Valve while the “O” Ring is removed. If it shows any indication of wear or damage, the entire Valve Assembly should be replaced. Refer to Parts List for Part Numbers and cross section of the Valves. NOTE: There are several different model pumps. When ordering parts, give the Part Number, the Pump Model Number, and the Serial Number. 6. When Operations described in Paragraphs 1 to 5 inclusive have been completed, the entire unit will have been dismantled and all parts inspected for wear and damage. It is especially important that all parts that Page 54

operate in the “O” Rings or Packing be free from pits, scoring, or any other defects that may cause excessively rapid wear of “O” Rings and Packing, since leaks will develop almost immediately under these conditions and satisfactory performance will not result. 7. REASSEMBLING THE PUMP — Reverse the procedure used for dismantling, making sure that all Retaining Rings are properly in place and that no “O” Rings have been damaged in reassembly. IMPORTANT: When reassembling the Air Motor, be sure that the Air Cylinder, Part #10-550-4, is in proper position against the flanges on the Pump Head and the Air Cylinder End before tightening the bolts that clamp the Air Motor together. Use a soft hammer to position the flanges tightly against the Air Cylinder Ends BEFORE tightening the bolts. Failure to do this can result in over-tightening the bolts initially, and when the bolts on the opposite side are drawn up, this may result in the bolt lugs being broken or twisted off when the assembly is drawn down into position. Bolts should be secured lightly at first then drawn up in sequence until uniform torque has been applied to all of the bolts around the perimeter of the pump. (15-17 foot lbs.) 8. PUMP NOT RUNNING PROPERLY – If for any reason the pump does not run properly, look for one of the following causes: a. If the pump appears to be short stroking and running too fast without pumping properly, it usually indicates that the Air Check Assembly is not working as it should be. (See paragraph #2 for correction procedure.) b. Loss of pressure may be caused by one of two reasons, the Hydraulic Check Valves have developed a leaky condition or the hydraulic fluid is bleeding past the Packing in the Hydraulic Cylinder. (See paragraphs 3, 4, and 5 for repair instructions.) Also check air pressure at pump inlet if hydraulic pressures fluctuate. c. Should the pump commence to run erratically and in a jerky manner after a period of time, it is usually an indication that a seizing action is taking place in the Hydraulic Piston & Cylinder Assembly. (See paragraphs 1 and 3 for disassembly instructions.) This is usually caused by foreign matter, such as alkali, dirt, grit, or chemicals that do not have sufficient lubrication qualities being present in the fluid supply. If the Hydraulic Piston and Cylinder have not been damaged, a thorough cleaning will normally place the pump in operation again. d. For maximum volume of flow, make sure that a sufficient flow of air is supplied to the pump. Hooking the pump up to a smaller pipe size than the “AIR IN” port on the pump will not allow it to run at its full rated capacity. Long runs of relatively small pipe supplying air to the pump will have the same effect. e. If an excessive amount of oil or water is coming through the pump air exhaust, check the following: 1. Lubricating unit in the air supply is delivering too much oil. Adjust to about one drop of oil for every 20 strokes of the pump. 2. The filtering unit in the air supply is not functioning properly. The bowl should be cleaned periodically to assure delivery of clean air to the pump. 3. The hydraulic fluid being pumped (oil or water) may be leaking past the packing in the hydraulic cylinder into the Air Motor. (See paragraph #3 for correction procedure.) Page 55

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T-3 Energy is committed to providing the highest quality products and services to our customers. This will be accomplished without compromising our commitment to pollution prevention, the environment or the health and safety of our greatest asset – our employees.

T3 Energy Services Pressure Control Equipment Service Center 103 Venture Blvd. Houma, LA 70360 Phone: (985) 851-3160 Fax: (985) 851-5102 E-Mail: [email protected]

T3 Energy Services Pressure Control Equipment Manufacturing Center 9768 East Main St. Houma, LA 70363 Phone: (985) 851-2020 Fax: (985) 868-5913 E-Mail: [email protected]

T3 Energy Services Pressure Control Equipment Service Center 14710 Cypress N. Houston Cypress, TX 77429 Phone: (832) 237-0561 Fax: (832) 237-0546 E-Mail: [email protected]

T3 Energy Services Pressure Control Equipment Manufacturing & Service Center 119 E. Interstate Drive Jennings, LA 70546 Phone: (337) 824-6000 Fax: (337) 824-7042 E-Mail: [email protected]

T3 Oilco Energy Services Pressure Control Equipment Manufacturing & Service Center 2303A 8th Street Nisku, Alberta T9E 7Z3 Phone: 780-955-2210 Fax: 780-955-7504 E-Mail: [email protected]