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.
INTRODUCTION 01

GENERAL INFORMATION 01

PART I OPERATION
Normal Operation 02
Alternate Operating Method 03
Emergency Operation 03

PART II MAINTENANCE
Preparation for Disc Assembly Change Out 05
Disc Assembly Change Out 08
Turning Fork Disassembly/Assembly 10
Piston Gauge Protector 11
Preloading the Hydraulic Pressure Lines 12
Position Indicator System 13
Digital Rate Meter 16
Flo-Tork Actuator Assembly 16

PART III TEST PROCEDURES

PART IV TROUBLESHOOTING
Choke Will Not Open or Close 20
Improper Open/Close Operation 21
Stroke Counter Malfunction 22
Improper Pressure Gauge Readout 23
Position Indicator Malfunction 23

APPENDIX DRAWINGS, PARTS LIST AND INSTRUCTIONS

Choke Valve Assembly FIG. 1
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
Flo-Tork Actuator Maintenance Instructions A-1
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
1. Make sure all
valves between Choke
and well head are closed
2. Insure valves downstream
of choke outlet are open if
possible.
3. Rotate the choke to full
open regardless of setting
of Position Indicator.
4. Open the OPEN/CLOSE
lever on the control panel.
5. Check the Position
Indicator gauge to tell
when choke is open.
6. Confirm choke is at full
open by checking the
Indicator Head.
Safety Concern
High pressure.
Trapped pressure.
Position Indicator may be
faulty. Air line broken, bent
or plugged, giving incorrect
reading.
Choke could be in closed
position.
Remote possibility that
malfunction could occur
which would cause choke
plates not to open even
though Position Indicator
would show them to be open.
Indicator Head did not
rotate to the open position.
CONTINUES NEXT PAGE
Recommended Safe Job
Procedures
Manually check to insure valves
are closed.
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.
Hold choke control lever to open
position; if hydraulic pump strokes,
hold until choke is fully open.
Insure hydraulic pressure is
available to Flo-Tork by checking
hydraulic gauge under control panel.
Operate choke control lever to partly
close choke. Check Position Indicator
for proper operation. Open choke.
Use cross over tub on hydraulic
fitting, insert bar in Indicator Head
and rotate. If hard to rotate, pressure
may be trapped in choke.
>> Page 05
 PREPARATION FOR DISC ASSEMBLY CHANGE OUT
ON THE T3 ENERGY SERVICES SUPER CHOKE
Sequence of Basic
Job Steps Prior
To Choke Assembly
7. If pressure gauge
indicates zero pressure or
low pressure, check line
from gauge protector for
rigidity (indicating pressure).
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.
9. If there is or is not
pressure, go through exact
procedure as outlined in
Step 8.
Page 06
Safety Concern
Pressure gauge may be
plugged or broken; a rigid
line would indicate pressure.
If choke plates are open, line
from choke could be plugged.
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.
Any debris and/or gas
could blow into face. Gas
may ignite.
CONTINUES NEXT PAGE
Recommended Safe Job
Procedures
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.
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 bro-
ken. 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.
Same as 8.
>>
 PREPARATION FOR DISC ASSEMBLY CHANGE OUT
ON THE T3 ENERGY SERVICES SUPER CHOKE
Sequence of Basic
Job Steps Prior Recommended Safe Job
Safety Concern
To Choke Assembly Procedures

10. Tear down to outlet High pressure may exist; High pressure/fire – personnel
flange and physically check possible ignition of gas should stand clear of outlet flange
through outlet flange to see debris in outlet flange. using a straight rod with a curved
if choke plates are actually handle at the hand portion.
open. Use rod to pry in the
open end of choke to
determine the position of
the plate (OPEN/CLOSE).

11. If choke plate are not Same as 8 and 9. Choke Same as 8 and 9. Have all personnel
open, first attempt to open outlet is now open. If plates stand clear of area during opening
them by using the console open, any trapped debris procedure.
controls. If indicator head and/or gas will be expelled.
does not move, plates may
have slipped or turning fork
may be broken. It is then
necessary to continue
disassembly operation.

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 CAU-
TION 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 SAFE-
TY 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 O-
rings 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 opera-
tion. 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

Replace batteries or check connection

No display to battery pack. If OK, then try
substituting logic module.

Display on but does not count or Replace logic module.

display rate including in test mode

Display on but does not count or

indicate correct rate except OK in test Check wiring or pump
mode or only one pump switches.

Only one input P1 or P2 works, OK Check wiring or pump switches.

in test mode

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

4
FIGURE 1
3

1
2

Page 25
 CHOKE BODY - H2S SERVICE
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 O’RING, VITON
6 2 94-36-200 PIN, SPRING 3/8” x 11/4”
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 39-66-237 O’RING, VITON
17 1 O’RING, VITON
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

Page 26
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 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 REAR MANIFOLD ASSEMBLY

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)

Page 28
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.

RECOMMENDED TORQUE FOR

MODEL NO. FASTENER SIZE
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.

Page 38
STANDARD MODELS 900 THROUGH 30,000

ITEM NO. PART NAME

1 HOUSING
2 BEARING
3 O-RING, BEARING CAP
4 BEARING CAP
5 PINION
6 NUT, TIE ROD
7 LOCKWASHER, TIE ROD
8 TIE ROD
10 O-RING, PINION
11 RELIEF VALVE
12 CYLINDER TUBE
13 PISTON-BACK-UP RING
14 SEAL, PISTON
15 O-RING, CYL. O.D.
16 PISTON RACK
17 CYLINDER HEAD ALWAYS USE SERIAL
23 BACK UP, CYL. HD.
24 O-RING, CYL. HD NUMBERS AND
25 SET SCREW-BEARING CAP MODEL NUMBERS
26 NYLON PELLET-BEARING CAP
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 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

Page 40
 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
PART NAME QTY.
NO.

23 BACK UP, CYL. HD. 1

24 0-RING, CYL. HD 1

EXTERNAL ADJUSTOR
28 1
CYL. HD.

29 JAM NUT 1

30 THREAD SEAL 1

CUSHION-EXT. ADJ.-
79 1
FIXED

Page 41
 CUSHION DETAILS MODELS 900
THROUGH 30,000

PART NO. PART NAME QTY

64 CUSHION PISTON RACK 1
65 CUSHION PISTON 1
66 CUSHION CY. HD.-ADJUSTABLE 1
67 COMPRESSION SPRING 1
68 CUSHION NOSE 1
69 SNAP RING 1
73 O-RING-CUSHION ADJUSTOR SCREW 1
74 BACK-UP RING-CUSHION ADJUSTOR SCREW 1
75 CUSHION ADJUSTMENT SCREW 1
76 RETAINER CARTRIDGE 1
77 JAM NUT 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

PARTS LIST
X X X X X X X X X X X X AIR MOTOR ASSY 10-550-94 1 2
X — — — — — — — — — — — HYDRAULIC ASSY I 10-550-70 1 1
— X — — — — — — — — — — 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
— — — — — X — — — — — — 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
— — — — — — — — X — — — 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
NO. ITEM
-50 -40 -30 -20 -15 -10 -8 -5 -3 -2 -1.50 -1 DESCRIPTION PART NO. REQ NO.
10-600- ___

Page 44
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

Page 45
 AIR MOTOR ASSEMBLY 10-550-94
(CONTINUED)

“O” RING 6227-66 1 12

ıı 6227-19 3 11
ıı 6230-39 2 10
ıı 6230-9 1 9
ıı 6230-1 1 8
BEARING ASSY 10-450-47 1 7
CYLINDER 10-550-4 1 6
SPRING 10-450-5-1 1 5
PISTON 10-550-25 1 4
END 10-550-2 1 3
BUMPER 10-450-12 1 2
VALVE ASSY 10-550-93 1 1
NO. ITEM
DESCRIPTION PART NO. REQ NO.

HEAD 10-550-92 1 22
“O” RING 28775-144 4 21
PILOT VALVE ASSY 10-550-27 1 20
“O” RING 28775-028 1 19
SET SCREW 1/4 - 20 FLAT POINT 1 18
BOLT 1/8 x 24 x 5 8 17
NUT 1/8 x 24 8 16
BUMPER VALVE 10-450-57 1 15
RETAINING RING RRT-262 1 14
ıı RRT-200 1 13
NO. ITEM
DESCRIPTION PART NO. REQ NO.

Page 46
 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 — — — — — — BACK UP MS28782-26 2 26
— X — — — — — ıı MS28782-24 2 26
— — X — — — — ıı MS28782-21 2 26
— — — X — — — ıı MS28782-17 2 26
— — — — X — — ıı MS28782-13 2 26
— — — — — X — ıı MS28782-11 2 26
— — — — — — X ıı MS28782-10 2 26
X — — — — — — “O” RING 2 6227-26 1 25
— X — — — — — ıı ıı 6227-24 1 25
— — X — — — — ıı ıı 6227-21 1 25
— — — X — — — ıı ıı 6227-17 1 25
— — — — X — — ıı ıı 6227-13 1 25
— — — — — X — ıı ıı 6227-11 1 25
— — — — — — X ıı ıı 6227-10 1 25
— — — — — — X PISTON & CYL ASSY 2 10-550-11-10 1 24
— — — — — X — ıı ıı ıı 10-550-11-8 1 24
— — — — X — — ıı ıı ıı 10-550-11-5 1 24
— — — X — — — ıı ıı ıı 10-550-11-3 1 24
— — X — — — — ıı ıı ıı 10-550-11-2 1 24
— X — — — — — ıı ıı ıı 10-550-11-1.50 1 24
X — — — — — — ıı ıı ıı 10-550-11-1 1 24
X X X — — — — INLET VALVE ASSY 2 10-450-31 1 23
— — — X X X X INLET VALVE ASSY ıı 10-450-24 1 23
X X X X X X X OUTLET VALVE ASSY ıı 10-450-23 1 22
X — — — — — — “O” RING TEFLON I 3 6227-26 1 21
— X — — — — — ıı ıı ıı 6227-24 1 21
— — X — — — — ıı ıı ıı 6227-21 1 21
— — — X — — — ıı ıı ıı 6227-17 1 21
— — — — X — — ıı ıı ıı 6227-13 1 21
— — — — — X — ıı ıı ıı 6227-11 1 21
— — — — — — X ıı ıı ıı 6227-10 1 21
X X X X X X X BUMPER PISTON 10-450-51 1 20
X X X X X X X RETAINER-BUMPER 10-450-58 1 19
X X X X X X X WASHER-COMM EQUIV OF AN 936-B416 1 18
X X X X X X X FLAT POINT SET SCREW #10-32 3 1 17
X X X X X X X GASKET 10-450-28 1 16
-1 -1.50 -2 -3 -5 -8 -10 DESCRIPTION PART NO. NO. REQ ITEM NO.
10-550-10- ___
*10A MODELS ARE FOR USE WITH SPECIAL FLUIDS Page 47
 HYDRAULIC ASSEMBLIES 10-550-10 AND 1
-15, -20 & -30
9

10

PARTS LIST 10-550-10 AND 10A*

-15, -20 & -30
— — X “O” RING TEFLON 1 3 6227-6 1 15
— X — ıı ıı ıı ıı 6227-8 1 15
X — — ıı ıı ıı ıı 6227-9 1 15
— — X PLATE 3 10-450-40-16 1 14
— X — ıı ıı 10-450-40-10 1 14
X — — ıı ıı 10-450-40-8 1 14
— — X PISTON & CYL ASSY 2 10-550-11-30 1 13
— X — ıı ıı ıı 10-550-11-20 1 13
X — — ıı ıı ıı 10-550-11-15 1 13
— — X “O” RING 2 6227-6 1 12
— X — ıı ıı 6227-8 1 12
X — — ıı ıı 6227-9 1 12
— — X BACKUP MS28782-6 2 11
— X — ıı ıı MS28782-8 2 11
X — — ıı ıı MS28782-9 2 11
X X X “O” RING 2 6227-11 2 10
X X X BUMPER-PISTON 10-450-51 1 9
X X X RETAINER-BUMPER 10-450-58 1 8
X X X WASHER COMM EQUIV OF AN-936-B416 1 7
X X X FLAT POINT SET SCREW #10-32 3 1 6
X X X FLAT HEAD SET SCREW # 5-40 3 3 5
X X X RETAINER 10-407-7 1 4
X X X GASKET 10-450-28 1 3
X X X INLET VALVE ASSY 3 10-450-29 1 2
X X X OUTLET VALVE ASSY 3 10-450-30 1 1
-15 -20 -30 DESCRIPTION PART NO. NO. REQ ITEM NO.
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

Page 45
 HYDRAULIC ASSEMBLIES 10-550-10 AND 1
-15, -20 & -30
9

10

PARTS LIST 10-550-10 AND 10A*

-15, -20 & -30
— — X “O” RING TEFLON 1 3 6227-6 1 15
— X — ıı ıı ıı ıı 6227-8 1 15
X — — ıı ıı ıı ıı 6227-9 1 15
— — X PLATE 3 10-450-40-16 1 14
— X — ıı ıı 10-450-40-10 1 14
X — — ıı ıı 10-450-40-8 1 14
— — X PISTON & CYL ASSY 2 10-550-11-30 1 13
— X — ıı ıı ıı 10-550-11-20 1 13
X — — ıı ıı ıı 10-550-11-15 1 13
— — X “O” RING 2 6227-6 1 12
— X — ıı ıı 6227-8 1 12
X — — ıı ıı 6227-9 1 12
— — X BACKUP MS28782-6 2 11
— X — ıı ıı MS28782-8 2 11
X — — ıı ıı MS28782-9 2 11
X X X “O” RING 2 6227-11 2 10
X X X BUMPER-PISTON 10-450-51 1 9
X X X RETAINER-BUMPER 10-450-58 1 8
X X X WASHER COMM EQUIV OF AN-936-B416 1 7
X X X FLAT POINT SET SCREW #10-32 3 1 6
X X X FLAT HEAD SET SCREW # 5-40 3 3 5
X X X RETAINER 10-407-7 1 4
X X X GASKET 10-450-28 1 3
X X X INLET VALVE ASSY 3 10-450-29 1 2
X X X OUTLET VALVE ASSY 3 10-450-30 1 1
-15 -20 -30 DESCRIPTION PART NO. NO. REQ ITEM NO.
10-550-10- __

Page 48 *10A MODELS ARE FOR USE WITH SPECIAL FLUIDS

Page 56
 TYPICAL INSTALLATION

GAUGE

FILTER OILER
AIR SUPPLY AIR EXHAUST
SHUT OFF AIR GAUGE
VALVE REGULATOR
FLUID PRESSURE
OUTLET
FILTER
FLUID
SUPPLY
FLUID OFF VALVE

USE 10-550-11A, 10-450-23A, 10-450-24A, 10-450-29A AND

5 10-450-30A ON 10-550-26A ASSYS.

STANDARD MODELS DO NOT HAVE BLEED HOLES, PLATE,

4 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 assem-
bly 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 writ-
ten 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.

Page 52
 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 #RRT-
93, 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
Page 56
 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 T3 Energy Services T3 Energy Services T3 Energy Services T3 Oilco Energy Services
Pressure Control Equipment Pressure Control Equipment Pressure Control Equipment Pressure Control Equipment Pressure Control Equipment
Service Center Manufacturing Center Service Center Manufacturing & Service Center Manufacturing & Service Center
103 Venture Blvd. 9768 East Main St. 14710 Cypress N. Houston 119 E. Interstate Drive 2303A 8th Street
Houma, LA 70360 Houma, LA 70363 Cypress, TX 77429 Jennings, LA 70546 Nisku, Alberta T9E 7Z3
Phone: (985) 851-3160 Phone: (985) 851-2020 Phone: (832) 237-0561 Phone: (337) 824-6000 Phone: 780-955-2210
Fax: (985) 851-5102 Fax: (985) 868-5913 Fax: (832) 237-0546 Fax: (337) 824-7042 Fax: 780-955-7504
E-Mail: pcgsales@t3energy.com E-Mail: pcgsales@t3energy.com E-Mail: pcgsales@t3energy.com E-Mail: pcgsales@t3energy.com E-Mail: pcgsales@t3energy.com