fee Gud “ah pert 1 he wey “ao (Ha 1 TITLE PAGE yl! of? te wie a gh e Je PAGE BREAK tO / 2. REVISION INFORMATION ge add t0r Sy s se A ae REVISION NUMBER I bate REVIEWERIS} 00 i ‘AUGUST 27, 2012 DICLAIMER Flo Draulic West has made every effort to ensure that this document cantains accurate and current information. This document is intended to be used in conjunction with a complete training program and on-site supervision. Fo Draulic West does not warrant or guarantee that the information contained herein is either complete or accurate in every respect. The reader hereby protects, indemnifies, and holds harmless Flo Draulic West together with its officers, employees, ‘and agents from and against all liability for personal injury, death, or property damage to any person arising directly or indirectly from this documents use by the reader of the information contained herein. “Specifications are subject to engineering and/or Improvement changes. CONTACT INFORMATION ct Ee ‘FD FLODRAULIC WEST 1008 — 16TH Ave Nisku, Alberta TSE OAS CANADA, Phone: (784 fo@flodraulic.com iS Visit us at www flodraulic.com COPYRIGHT INFORMATION All information contained within this technical manual is © copyright of Flo Draulic West, al rights reserved. It is a breach of copyright if this technical manual is copied or reproduced, in whole or part, using any means whatsoever, without the prior written approval of Flo Draulic West. reed li? anPAGE BREAK 3. TABLE OF CONTENTS PAGE BREAK / 4, ABOUT THIS DOCUMENT ‘The Flo Draulic Group is committed to exceed our customer's expectations by providing quality products, delivered on time, and followed-up with exceptional after-sales service. ‘The use of components different from those specified by Flo Draulic West may result in decreased system performance or failure. If trouble is encountered with the system, refer to the designated section of the manual for instructions on cleaning/repair or replacement of compromised components. The scope of material included in this manual may not apply to your Power Unit, Components and ‘Actuators, and information on more custom units may require obtaining service and application information from other sources. itis imperative that personnel involved in the installation, service and operation of the Power Unit, Components and Actuators be accustomed the operation of the equipment; the system capabilities and limitations. This document is a user manual for Hyduke Energy Services Inc. for the Hydraulic Power Unit systems, actuators, controls, and other equipment supplied by Flo Draulic West. PAGE BREAK Us. saver All personnel must be aware of the dangers related to the operation and maintenance of well se equipment, as wellas to sespecichazads The following are critical to well site safety: + the wearing of personal protective equipment (PP) + regular safety orientations + correct use and handing of liting equipment Hydraule Pressurised hyéralc systems store enery capable af exerting extreme force Serious injuries or even death can occur a result of improper use or mishandling of such equipment To minimize the dangers of equipment operation and maintenance: J « perform all required pre-start checks and inspections© + ensure that all lines and hoses are connected correcty to prevent any unintended operation of the equipment « shut down the equipment and release pressure from the system before performing any kind of maintenance or disconnecting any hydraulic lines «never use your hands to try andl detect a pinhole leak. Always use a piece of ‘wood or cardboard, and wear safety glasses face shield, or both Electrical a «Ensure that equipment and tools are properly grounded prior to startup and operations. + Never touch a tool and test equipment simultaneously. Stand on a dry wooden platform, a rubber mat, ora similar type of insulation when working on tools. Use grounding jumpers that are separate from the AC input lines The following safety notices have been added to this manual, however these notices do not replace proper training on equipment or well site safety procedures. PAGE BREAK \/6. OVERALL SYSTEM DESCRIPTION ‘The equipment supplied by Flo Draulic West and as such the scope of this manual consists of the components contained in the following Hydraulic Schematics; 4 FW-S-11095 Top Drive and Rig Systems Hydraulic Power Unit FW-S-11085 ~ Rig Moving System a”? FW-S-) — Rig Mast, Drawworks, and Related Systems FW-S-12042 — Hydraulic Catwalk These schematics are referenced in the appropriate section of the operations manual and are contained in Appendix 1. PAGE BREAKPREPARATION FOR USE Unpacking and Checking _/ reform visual inspection for transport damage and contamination, All open ports on the Power Unit, Components and Actuators were plugged to prevent the entry of contamination. These plugs must not be removed until just before piping connections are to be made to the unit. v Report all damages and contamination immediately to carrier and send a copy to Flo Draulic West. Stovage - Short Ter Power Unit, Components and Actuators should be stored indoors, covered with plastic sheet, and all ports plugged. Storage - Long Term (Greater than 6 Months) Fill the reservoir on Power Unit to max capacity with clean hydraulic fluid to prevent the entry of moisture. INSTALLATION @_ Locating Power Units, Components and Actuators ¢/ Power Units should be installed indoors and in a dry environment with an ambient temperature of 15 C t0 38 C. Power Units, Components and Actuators can be installed outdoors if provisions were made for extreme temperature conditions. Blectrteat Electrical installation for the drive and controls is only to be carried out after the connection _/ specifications have been confirmed (available voltage, wattage, etc). Verily that the all electrical components (refer to component nametag or other service information in this manual for operating voltage and ratings) match the facilty power source available. if necessary, connect the coolant supply Check the correct direction of rotation ofthe pumps before switching on. (Pum gheveled Howe od befene ds GP Simoiy ana Return Connect all piping and hose between the Power Unit, Components and Actuators. Line sizes should be determined based on cil flow, operating pressure and allowable pressure drop between the Power Unit, Components and Actuators. With installations, the longer lines are to be flushed through. Inspect the reservoir for debris and if necessary, clean before opening and filing. Also check that the avactecfe- hydraulic fluid has not been contaminated wth water, The eservoir must be filed with the appropiate hydraulic fluid, and above all, that its viscosity is correct. Wherever possible, always use filing device which incorporates a special filter. The type of fluid must be compatible with the seals used on the Power Unit, Components and Actuators, and must comply with the recommendations of the manufactures of the component parts. Hist & baal are ¢ bypliacen seq wat enteryGE coupling Alignment The pump/motor shaft alignment should be checked before start-up using the coupling installation Instructions provided in appendices of this manual. If re-alignment is required, the motor mounting bolts should be loosened, and shims inserted. If the pump/motor assembly has been mounted with a bell-housing, the only check required is to verify that the coupling halves have adequate clearance, and that the coupling set-screws are tight. A slot is provided in the bell housing for this purpose. START UP PROCEDURE 1. Open any ball or gate valve (if applicable) located in the pumnp suction line 7 2. gill the pump housing by pouring the oil into the pump case drain port {in the case of piston- type pumps) 3, Adjust the system relief valve and/or pump pressure compensator so that pressure willbe near zero during the intial stat, Set the directional control valves to thei at-rest position ‘ 4, Charge the accumulators to theirspeciied pre-charge pressures. Boo? 5. ‘Ram the pump motor once, to verify correct pump rotation. If the oy incorrect, reverse ‘two (2) of the three (3) motor leads, and recheck the rotation, we A hand Boma, fo eed, 6. Run the pump motor (3) to (6) timedjto prime the pump and allow the pump to run several minutes at e70 pressure. Check the piping for any leaks and correct immediately. SAeetAger. “L7, Bleed the system at the load lines, as far as possible at the highest points. Operate the directional control valves and allow the loads to move in and out a number of times. Adjust the load slowly. Increase the setting of the pressure control valves and/or pressure compensators, Bleeding has been completed correctly when no more foam appears in the reservoir, when all load movernents are smooth and free from jerks, and when no abnormal noises are present. -8. Continue increasing pressure until normal operating pressure is obtained, and recheck system for leaks. Lock adjustment screws in place. if the system has a pressure compensated pump and 2 relief valve, adjust the relief valve approximately 10% higher than the compensator so that excessive heat is not generated by the relief valve. 49, During the start-up sequence, all filters should be monitored closely. Replace any filter elements immediately, as soon as they begin to go into by-pass as indicated on visual indicator. 710. After the entire system has been wetted with fluid, check the hydraulic fluid level and top it off after bleeding has been completed, /11, Observe the operating temperature of the machine and verify that the cooling equipment (if applicable) is operating correctly. After it has been running at full load for a number of hours,the final operating temperature should not have risen above 70 degrees C. If it has, ascertain the cause, check the cooling equipment. 12. Check and repair fitting leaks after the installation has been running for a number of hours. 13. Clean the filters (or replacing filter elements) within the first few hours of operation,GENERAL MAINTENANCE Typical maintenance must include several different types of operations that may be performed in any number of sequences depending on well conditions, operating environment, ora variety of other contributing factors. These are only guidelines, however, and all tems may not apply to every Hydraulic Power Unit, Components and Actuators. Procedures outline typical maintenance events that can be modified as required to meet the operator's preferences, the objectives of the operators, as well as the specific industrial conditions Maintenance Procedure. a zg & z 3 i = Hydraulic Reservoir We.“ ‘Check fluid level v Monitor fluid temperature Y Check for leaks y Tate Tuidsomple ae change uid a ae ses ining & Ftings ‘Check for leaks Vv System Fens Monitor contamination indicators, V Replace Element Vv 4 Suction Strainers clean strainer 0 Y ume/Motor Couplings CCheck alignment (noise) qv v Pressure and Fow Valves Check settings 20 Y[v[qv Signal Elements upon of ie lnieaeiahas 2 lille Eos Cylinder(s) heck the piston rod ecraper rings v [4Clean and grease the suspension points v v ‘Maintenance Procedure als i z 3 2 3 Wouning Hardware Ties and hen aed) 100 Accumtr Check charge pressure 10 y a COMPONENTS See component literature in appendices. RECOMMENDED SPARE PARTS Spare filter elements should be purchased with the Power Unit, Components and Actuators, and be available during the start-up operation. Other spare parts may be required, and are a function of the duty cycle of the hydraulic system, operation environment, and acceptable downtime of the equipment. It is recommended that spare parts for the system be in stock (on hand) to reduce downtime in the case of component failure. PREVENTIVE MAINTENANCE, ‘© Check/adjust settings, remove, repair or replace valves, pumps or other components that are running hot. Follow your equipment owner's manual in appendices. ‘© Break in new components gradually. New components typically have tight tolerances that expand at different rates, and may be prone to seize with excessive thermal expansion. + Start 2 cold pump oF motor on hot oil by running long enough to draw the hot oil into component. Allow a few minutes to equalize the temperature in all the components part. Repeat until the temperature on the outside ofthe component equals that on the piping + Remove dit and dust from equipment. Dirt will prevent the hydraulic system from getting rid of the heat + Check and change the ol! more frequent in hot climates Y periodically siphoning an oll sample from the reservoir, and comparing it with a sample of clean, new oll Oil that has been running too hot will look darker and feel thinner than new oil. It will also smell burned. Chances are, it will contain more contaminants, because hot oil leads to accelerated wear of component parts.TROUBLESHOOTING Dirty ail Components not properly cleaned after servicing Inadequate screening infill pipe. Air breather left off. (No air breather provided... inadequate unit provided... insufficient protection of air breather.) Tank not properly gasketed. Pipe lines not properly covered while servicing machine, Improper tank baffles not providing settling basin for heavy materials. Filter dirty or ruptured. Foaming oit Return of tank line not below fluid level Broken pipe, line left out between a bulkhead coupling and the bottom of the tank. Inadequate baffles in reservoir. © Fluid contaminated with incompatible foreign matter. ‘© Suction leak to pump aerating oll. © Lack of antifoaming additives. fsture in alls * Cooling coils not below fluid level. * Cold water lines fastened directly ‘against hot tank causing condensation within tanks. ‘© Soluble oll solution splashing into poorly gasketed tanks causing condensation within tank. ‘© Moisture in cans used to replace fluid in tanks. © Extreme temperature differential in certain geographical locations, © Drain not provided at lowest point in tank to remove water collected over possibly long operating periods.ting of system ng Pump © Variable pump controls defective ‘© Excessive rotational speed ‘© Efficiency reduction due to wear Hose/Piping Pressure filter blocked © Line ID undersized causing frictional resistance Pressure Valves, © Flow too high Valve undersized # Pressure setting too high # Response time too long, Flow Control Valves + Flow set too low + Faulty valve Directional Control Valves © High leakage * Spool sticking Fluid * Viscosity (too low) causing excessive leakages * Viscosity (too high) causing excessive flow resistance Foaming fluid Actuators (Motors/Cylinders) + Efficiency losses due to wear Internal friction © Internal leakage Cooler © Water shut off or heat exchanger clogged Reservoir © Reservoir assembled without baffling or sufficient baffling ‘Sized too small Other + Ambient temperature is too high Thermostat set too highExcessive noise Suction Line + Foaming fluid + Suction filter clogged or sized too small Actuators * Line blocked, leaking, ID too small or ‘* Wear of running surfaces too many bends ‘i Pump * Rotating too fast * Max. pressure exceeded = Seal leakage ‘© Control system oscillating Hose/Pi . + 1D too smal + Return fier blocked Pressure Valves © Valve worn or not closing properly (chatter) Incorrect design Flow Control Valves * Valve oscillates and may cause other control valves to oscillate Directional Control Valves + Defective solenoid or voltage too low causing valve to chatter = Contamination or excessive wear Excessive flow through valve Fluid * Cavitation Problems - Fluid level too low or viscosity too high = Contamination causing damage or blockages Check compatibility of fluid being pumped against manufactures recommendations. Aeration of fluid in reservoir (return lines above fluid level.) Worn or sticking vanes (vane type pur).PAGE BREAK 7. RIG HPU — FW-S-11095 OVERALL DESCRIPTION ‘The HPU consists of a 400 HP AC motor driving a 24.6 cu.in./rev Denison P24 Gold Cup pump and a SO HP AC motor driving a 90cc Sauer Danfoss piston pump and a 1.61 cu.in./rev Permco vane pump. The pumps circulate hydraulic fluid from a common reservoir and while the rig hydraulics can be operated with the top drive pump offline, the top drive most be operated with both electric motors drive the pumps on the HPU. The Denison top drive pump supplies fluid to the closed loop Warrior 25014 top drive motor and is controlled by the Top Drive Operator's Console. The Sauer Danfoss pump supplies fluid to the open. loop, closed center system feeding the control valves located in the rig system, The Permco vane pump circulates hydraulic fluid from the reservoir to a heat exchanger and filters to provide cooling and filtration independent of what functions are being used. 1. KIDNEY LOOP AND RIG PUMP SYSTEM 2. PRE-OPERATIONS CHECKLIST i. Ensure hydraulic reservoir is filled to operational level with correct fluid li, Ensure that the suction ball valves for the piston and vane pump are open iii, Ensure that all hydraulic connections are completely engaged, paying close attention to hydraulic quick couplers b. OPERATIONS i. Engage the 50 HP AC motor via the motor control switch located (LOCATION!) The vane pump pressure can be monitored at the gauge ‘mounted on the pump output. The piston pump will energize the closed center system with a constant 3000PSI pressure which can fluctuate depending on which functions are being used li. The temperature switch located on the vane pump output will control the AC motor for the heat exchanger in response to elevated hydraulic fluid temperatures. MAINTENANCE i. Replace hydraulic fluid at 0" operational hours. Ti, Replace hydraulic fiters at» operational hours or when a restriction indicator detects high differential pressure. ili, See OEM information for component specific maintenance requirements. 2, TOP DRIVE PUMP SYSTEM ‘2. PRE-OPERATIONS CHECKLIST i. Ensure hydraulic reservoir is filled to operational level with correct fluid li, Ensure that the suction bal valves for the piston pump are openil, Ensure that all hydraulic connections are completely engaged, paying close attention to hydraulic quick couplers iv. Ensure all settings for the Warrior 250H14 Top Drive are adjusted as per the Warrior OEM operations manual b. OPERATIONS i. Once the Denison P24 pump is engaged, the pressure and flow demands for the top drive will dictate how the pump operates. The safety systems controlled by the Warrior Controls will destroke the pump if the OEM programming detects a fault, however the user can monitor pressures and filter restrictions on the live gauges on the HPU. ji, Operations of the Warrior top drive and its control and safety systems are contained in the Warrior OEM literature. ¢. MAINTENANCE i. Replace hydraulic fluid at 0°! operational hours. ii, Replace hydraulic filters at 100% operational hours or when a restriction indicator detects high differential pressure. il, See OEM information for component specific maintenance requirements. HYDRAULIC SYSTEM SPECIFICATIONS Tope sips c nig Systems Supply Pressure Rig Systems Relief Setting Kidney Loop Supply Pressure Kidney Loop Relief Setting : Reservoir Capacity gallon“ oil SAEXXW Temperature Minimum Starting ELECTRICAL SYSTEM SPECIFICATIONS Top Drive Electric Motor 400 HP, 600 VAC, 1750 RPM, TEFC Rig Systems Electric Motor SO HP, 600 VAC, 1750 RPM, TEFC Cooler Motor HP, 1750 RPM, 3 PHASE, 600 VAC EQUIPMENT LIST ~TOP DRIVE HPUMAKE PART # DESCRIPTION ‘QUANTITY DENISON P24S-2RIE-SAZ-800-280 ‘GOLD CUP PUMP 7 PERMCO T6Cl-B28-3ROO-C1 VANE PUMP (ON P245) z MAGNALOY $4001 802F PUMP/MOTOR MOUNT 7 MAGNALOY 180031228 ‘COUPLING 7 MAGNALOY 1180020016 COUPLING 1 MAGNALOY wig708 INSERT T ‘ea00P26¢ “400 HP ELECTRIC MOTOR 1 STAUFF 3FO70Gi08-TU/B/V/2 PRESSURE FILTER 2 STAUEF SE070GI08 REPLACEMENT ELELMENT 10 MICRON | - “ANCHOR HDT CHECK VALVE T - PRESSURE SWITCH 200 PSI 1 STAUFF STAS-010-8-P3-U-LT8 ‘ACCUMULATOR 1 GALLON 2 HEDLAND R2084-ASCIB C/W FESS7-A5, FLOW METER 85 GPM, 4-20MA, #16 | 2 ona. HYDRAFORCE _| SF20-23-207- N26 SOLENOID VALVE T FLO BRAULIC | FW-M-6082 CUSTOM HOT OlL SHUTTLE 7 west ‘SUN HYDRAULICS | DSIH-XHN ‘SHUTTLE VALVE T ‘SUN HYDRAULICS | RPICLNN RELIEF VALVE 7 ‘STAUFF '5PG-63-03005 PRESSURE GAUGE 3 ‘STAUFF '5°G-63-60005 PRESSURE GAUGE 2 ‘STAUFF '3PG-63-30005 PRESSURE GAUGE z 91305739) PRESSURE TRANSOUCER 0-300 PSI 4-20 | 2 MA 913057 130 PRESSURE TRANSDUCER 0-1000 PSI4-20 | 2 MA yoi3057 134 PRESSURE TRANSOUCER 0-3000 PSI4-20 | 1 MA STAUFF ‘SMK20-7/16 UNF VE TEST POINT, 2 HAWE Pav a-a3/G24 PROPORTIONAL PRESSURE RELIEF 24) 1 voc ‘SUN HYDRAULICS | OTDA-MHN-GAH/S-224 “SOLENOID VALVE 24 VDC 2 ‘01080 DIA ORIFICE FITTING 2 HAWE ACAO-1/4 ‘ACCUMULATOR 40CC r ‘SUN HYDRAULICS | RDDA-LAN-FAI/S RELIEF VALVE T ‘STAUFF ‘SFB00GIOB-TG/RIE/2 PRESSURE ALTER 4 ‘STAUFF SE3006108 REPLACEMENT ELEMENT 10 MICRON MAKE PART # DESCRIPTION QUANTITY, INSERTA IGFT-AG224-NIS ‘CHECK VALVE 35 PST 2FLODRAULIE WEST | FW W 608s ‘CUSTOM TEE MANIFOLD Ie FLODRAULIC WEST | FW-M O84 CUSTOM 1 5°CD62 ADAPTER ATES [12 INSERTA BEB GANS TAIL VAIVE i INSERT CASON TNSERTA CARER VANE 15 FT iz STAVE $F00GI08TGMTETE PRESSURE FCTER Iz TAU 3e3006%08 REPLACEMENT ELEMENT IO MICRON [2 RI72NTRNUTASSUPATE [TEMPERATURE TRANSDUCER 420 WA [4 SON FYORATUIGS | FOEALANICNT PRESSURE COMPENSATED FLOW] 1 CONTROL | SON RVORATIICS | PPB TANTRCL PRESSURE REDUCING/RELEVING VANE [T SON HYORADUIS | DRAR-MCN WFO-DB8 SOLENOID VALVE (VENT FOR PVFEIAN | 7 — | STAFF TAS OE UTE ‘ACCUMULATORS GNION i ANCHOR cmai7 CHECK VANE iB SUN HYORAUIIGS| RPGC LWN-CENN RELEFVAWWE i ANCHOR wer? CHEERVANVE iB PESTO STADE TIECTRIC MOTORSOHP6OOWAE | WAGHAIOY COURLNS T SAUER FaROBOCIS2E2ONNNBRBDATNNNNN | PSTON PUMP9OCE i PeAMCO PTEEMBO8-3ROO CA VANE PUMP i ANCHOR GH6-27 CHECK VANE iT SUN HVORAUUGS | RPECLAN-EI RFLIFF AVE z SAU 396-63 -03005 PRESSURE GAUGE r NASON TAC 120R/HR TEMPERATURE SWITCH TOF i THERMAL B01 260026 COOLER 600 t TRANSFER ANCHOR Cae GHEEKVANEGS PSIROOTER DASH] T STAUFE aFSB0GI08/UNU7E RETURN FLTER o STAVE aETSOGIOB REPLACEMENT EERENT IO CRON [1 ‘STAUFF ‘RFO7OG10B/U/M/G RETURN FILTER & STAUFE AEOTOGIOB BEPLACEMENT ELEMENT z SUCTION BALL VALVE i SUCTION BAIL VALVE i SUCTION BAILVAIVE i sa SGSS0TSADIADIS DESSICANT BREATHER z TAU SNADSABSTIZ SIGHTLEVEL GAUGE Z Wika S50E0R006Ge R31. 90A00 TEMPERATURE GAUGE THEAWOWEL [1 DRAIN BALL VAGVE i wuRPAY iit TOW LEVEL SwircH T8, MOVING SYSTEM ~ FW-S-11085 (OVERALL DESCRIPTION ‘The rig moving system consists of an HPU, control valves, aHetronic radio system, and hydraulic cylinders. The HPU is located 9.81/00) and consists of @ 30 HP AC motor driving a mult-outlet HAWE pump. Two custom Flo Draulic West manifolds contro fluid flow, pressure, andthe cylinder soft- advance feature. The six HAWE directional control valves feature electric and manual operation —the Hetronic radio controls the valves under normal operating conditions while the manual operation can be used in emergencies, a. HPU a. PRE-OPERATIONS CHECKLIST i. Ensure hydraulic reservoir is filled to operational level with correct fluid li, Ensure that the suction ball valves for the piston pump are open ii, Ensure that all hydraulic connections are completely engaged, paying close attention to hydraulic quick couplers. iv, Ensure that the rigs ready to be moved and that all personnel and equipment are in safe locations. b. OPERATIONS |. Once the electric motor is running and the pump is supplying oll to the system, ‘the Hetronic radio is used to control the lift, side shift, and travel cylinders. To move the rig, the lift cylinders are extended to lift the rig from the matting, Once up, the travel cylinders are retracted to move the rig the distance of their stroke ~ 72". To change the direction of the rig travel, use the side shift cylinders ‘to adjust the position of the walking pads when the pads are off the rig matting, and the rigs resting on the mat MAINTENANCE iL Replace hydraulic fluid at 120% operational hours ii Replace hydraulic fiers at \* operational hours or when a restriction indicator detects high cifferential pressure il, See OEM information for component specific maintenance requirements 2. CYLINDERS a. PRE-OPERATIONS CHECKLIST i. Ensure that all hydraulic connections and quick couplers are engaged il, Ensure that all pins and support components are fixed and in good operating condition il, Ensure that ifthe hydraulic supply lines to any cylinder were opened for repair, orifany cylinder was removed and repairs, thatthe cylinder and lines are properly purged of all air b. OPERATIONS i. Ensure that there are no noises or apparent mechanical binding o failures during routine operations V3 c. MAINTENANCE Routinely inspect eylinders for damage and noticeable differences in performance between other cylinders. Repair as needed. CONTROL VALVES a. PRE-OPERATIONS CHECKLIST 1. Ensure all electrical connections to solenoids are connected and wiring is not damaged. Ji, Ensure that all manual control handles are installed and can be accessed, b. OPERATIONS i. The directional control valves will function in sequence according to the Hetronic Radio System, ji, Incase of a radio system failure, the individual valves can be manually actuated to allow the rig to be moved, In this case extreme caution must be exerciseand your Flo Draulic West representative must be notified to provide support. MAINTENANCE i. See OEM information for component specific maintenance requirements. HETRONIC RADIO SYSYTEM a. PRE-OPERATIONS CHECKLIST iL Ensure that the radio system is fully charged and communicating with the b. OPERATIONS i. While inspecting the cylinders in question, go through all functions before attempting to move rig Extend and retract cylinders through a range of travel before any force is exerted that would move the rig—ensure that the radio signals are being communicated to the cylinders, c.-MAINTENANCE i. Fully charge battery packs when not in use, il, See OEM information for component specific maintenance requirements. HYDRAULIC SYSTEM SPECIFICATIONS : = Pressure Relief Setting (SUN Relief) 3400PSI : 3 “i Minimum StartingELECTRICAL SYSTEM SPECIFICATIONS Electric Motor 30 HP, 600 VAC, 1750 RPM, TEFC EQUIPMENT LIST — MOVING SYSTEM MARE Paar DESCRIPTION uaniiy E2667 30-1805 305? HECTIC MOTOR T MAGNALOY ‘M28486100M PUMP/MOTOR MOUNT = as Twacnaioy | macoa2ais COUPLING r agNALOY | abOB008 COUPLING r ‘wagnaioy | warau RSET 7 HAWE R11,8-11,8-11,8-11,8-11,8-11,8 | RADIAL PISTON PUMP iE FO DRAUUC WEST | FE aD CUSTOM WANIFOLD i SUN HYDRAULICS | DWOALAN/77O2B4 DIRECTIONAL VALVE DV 2 SUN TVDRAULICS | CORON caviry PLUG i SUN HYDRAULICS] ADBACN RELEFVALVE ¢ WE ew28087 DIRECTIONAL VAIVE 12 WE ew a089 DIRECTIONAL VALVE r AWE ew28100 DiRECTIONAL VALVE i HAWE FW-2-8098 DIRECTIONAL VALVE 12 FO DRAULC WEST | PM BDET @USTOM MANIFOLD if SUN HYORALLIES | CxDAEN CHECK WAIVE 0 SOW HYDRAUINGS | OWDRLANTIORE@ SOLENOID VANE I SON HYORAULNGS | RBAELAN AELEF VALVE iz SON HYORAUINGS | CBCA LAN WED DUAL COUNTERBATANGE VALVE [a eOH05 CHLNDER 6” BORE KE" STROKE XSF ROD [6 PeiO 078 ‘CHLNDER IO" BORE XE” STROKE XG? ROD [6 PC60351 ‘CYLINDER 6” BORE X 72” STROKEX 4” ROD | 2 oa SoFTIS ITD RETURN FLTER HEAD tt ‘STAUFF ‘SF6731-MG RETURN FILTER ELEMENT [2 ‘STAUFF c-20 RETURN FILTER INDICATOR 7 ‘STAUFF - ‘SGB-90-03 & TBA-O75 ‘TANK BREATHER 1 STALE SNAREEBE TID TANKSIGHT GAUGE t STALFF 3evi70245 SUCTION ANIL VALVE BYORACONTROL | SvMOsKo8 SELECTOR if HETAONE S0BFaa36 TRANSWITTERRECETVER a CaPae SATAN UGK COUPLER FRGIZ-SAE-L/RF ‘ue courieR Tae M ‘QUICK COUPLER CAP WOGEF ‘QUICK COUPLER PLUG10. CATWALK ~ FW-5-12042 OVERALL DESCRIPTION ‘The hydraulically operated catwalk consists of an HPU, directional control valves, a skate motor, and a series of hydraulic cylinders. A 50 HP AC motor drives a 75cc Linde pump that provides the fluid power to the two directional control valves, One 8-Bank Hydrocontrol valve controls the 8 levelling cylinders for the catwalk. The 7-Bank HAWE valve controls the skate motor and the 6 index and kicker cylinders. The HPU also has @ 1.54 cu.in./rev gear pump for a kidney loop cooling and filtration circuit. 1 pu PRE-OPERATIONS CHECKLIST Rahs Ensure hydraulic reservoir is filed to operational level with correct fluid Ensure that the suction ball valves for the piston pump and gear pump are open Ensure that all hydraulic connections are completely engaged, paying close attention to hydraulic quick couplers b. OPERATIONS i. Once the HPU is running, the actuator demand will determine fluid flow ji, Ensure that the pressure and return filter restriction indicators are not showing a clogged filter. IF'so, shut down the system and replace the filter in question, MAINTENANCEi. Replace hydraulic fluid at 9%» operational hours. ii, Replace hydraulic filters at 00% operational hours or when a restriction indicator detects high differential pressure. li, See QEM information for component specific maintenance requirements 2. JACKING DIRECTIONAL CONTROL VALVES a. PRE-OPERATIONS CHECKLIST i. Ensure that all manual control handles are installed and can be accessed b. OPERATIONS |. Extend or retract cylinders to level the catwalk as per manufacturer's specifications. MAINTENANCE i. See OEM information for component specific maintenance requirements. 3. CATWALK FUNCTION DIRECTIONAL CONTROL VALVES @, PRE-OPERATIONS CHECKLIST 1. Ensure all electrical connections to solenoids are connected and wiring is not damaged, li, Ensure that all manual control handles are installed and can be accessed b. OPERATIONS |. Extend or retract the ODS and DS kicker and index cylinders to handle pipe as per the catwalk manufacturer's specifications. li, Actuate the skate motor to handle pipe as per the catwalk manufacturer's specifications. MAINTENANCE i. See OEM information for component specific maintenance requirements. HYDRAULIC SYSTEM SPECIFICATIONS system Supply Pressure ye system Pressure Rel Setting . Kidney Loop Supply ressure Kidney Loop Pressure Rei Setting Reservar Cpacy gallon ol £ Temperature Minimum Staring ELECTRICAL SYSTEM SPECIFICATIONSElectric Motor Cooler Motor 50 HP, 460 VAC, 1750 RPM, TEFC XX HP, 1750 RPM, 3 PHASE, 460 VAC EQUIPMENT LIST - MOVING SYSTEM MAKE PART # DESCRIPTION (QUANTITY PEC 326TC-50-1804 ‘SOHP ELECTRIC MOTOR I MAGNALOY azaa72c ~_| PUMP/MOTOR MOUNT 1 MAGNALOY 50020816 ‘COUPLER 1 MAGNALOY MMSOOATAI2C COURIER 7 WAGNALOY MS70N INSERT 1 UNDE {630AWO0077A 7SCC PISTON PUMP 1 26010-RZE 1.54 CUIN, PUMP 1 STAUFF S0F-2215.25-.1.0 DUAL ELEMENT RETURN FILTERHEAD | 1 STAUFF SF6731- MG FILTER ELEMENT z STAUFF cr20 RESTRICTION INDICATOR 7 THERMAL BOL3023 ‘OIL COOLER [z “TRANSFER, SUN HYDRAULICS | RPGCLAN-CAL RELIEF VALVE Tt STAUFF RV20-75 CHECK VALE Te STAUFF ‘SFO7OGIOB-TU/BNI2 PRESSURE ALTER Tt STAUFF NDV-I2N NEEDLE VALVE fe SUN HYDRAULICS | RPGCLAN-CEM RELIEF VALVE ig ‘STAUF ‘SPG-63-3000° “3000°SI GAUGE 2 ‘STAUFF CSHI6-T 6S CHECK VALVE a ‘STAUF ‘SPG-63-10005 {100051 GAUGE i ‘SUN HYDRAULICS | C8GG-LIN-VIM COUNTERBALANCE VALVE {2 FD WEST FW-D-6020 (114-1034- | SKATE ASSEMBLY Tt (006 /25¢F2-66-1-175/20G6-1) | AWE FW-53-20133 DIRECTIONAL VALVE ASSEMBLY 1 CCOUNTERBALANCE VALVE 3 DIRECTIONAL VALVE 1 ‘woo2A-001{04A0108) i STAUFF '568-90-08 BREATHER 1 NASON HTACA2ORR TEMPERATURE SWITCH Ia NASON HTACABOR/HR TEMPERATURE SWITCH 1 MURPHY war LOW LEVEL SWITCH ia ‘STAUFE ‘SNK254V0012,— LEVEL SWITCH iH ta STAUFF ‘2Bvi20328, 2 BALL VAWWE T STAUFF 2BvL20268 1 BALL VALVE T11. APPENDIX 2 FD WEST SCHEMATICS 12, APPENDIX 2 (OEM INFORMATION AND LITERATURE