As you can see, we put together a good manual. But if you are reading this, you are way above our average customer in paying attention to your equipment, and maybe we won't be seeing you in our service shop anytime soon. After being in the power swivel service business over 20 years, we're sure that this manual is almost never used — unless maybe for wrapping fish or nailing up on the outhouse wall... People simply run equipment until it breaks. This is particularly true on the smaller sizes of power swivels which are used between a lot of rigs in the well servicing business. Many users think they are taking care of their equipment, but they’re not. Everyone understands the importance of changing engine oil, maybe because our dads always told us it was important...And it is important to change engine oil, but it’s EVEN MORE IMPORTANT to keep hydraulic oil clean. Engines actually handle contaminated oil much better than hydraulic systems. The clearances in engines are large and engine oil pressures are 75 psi or less, whereas hydraulic systems have extremely tight clearances and operate at pressures of 2500 to 5000 psi. Bottom line - If hydraulic oil is really maintained in a clean condition, the hydraulic system will outwear the engine ! We’re talking about hospital clean, not rig welder clean. This is the truth, but we didn’t say it’s easy to do. Outdoor, all-weather conditions, untrained people, pressure to cut costs, and pressure to get the next job done before doing maintenance all play a role. So — Are you really going to read this manual?NEHER XK-150 GENERAL DESCRIPTION POWER SWIVEL The XK-150 Power Swivel is a hydraulic-powered drilling tool which is capable of heavy well servicing work or medium-duty drilling. Lifting devices available include: elevator-type bail to fit 3 1/2” elevators, and Cobrahook™ link hooks which hook to the lower eyes of AP! 150 or 250 ton links. Link hooks allow mounting a wireline lubricator to the top of the power swivel for use in horizontal drilling. The XK-150 is rated at 12,000 FT-LB torque at 5000 PS! hydraulic pressure. Static load rating is 150 tons, and 100 rpm load rating is 127 tons. Its simple drive does not use gears. Instead, one rugged hollow shaft hydraulic motor drives the main stem directly through a splined hollow shaft. This special motor is designed to provide full swivel torque at maximum swivel speed. The fluid passage through the swivel has a 2-7/16" bore and a 4” Full Hole tool joint. HYDRAULIC POWER & CONTROL SYSTEM ‘The XK-150 power and control system includes a number of unique and practical features. Skid and trailer units are built oilfield rugged to take abuse. All components are arranged for easiest service, and are mounted above the floor for easy cleaning and corrosion prevention. Engine and tanks are bolted in place, so are easily removable. Air remote control panel includes controls for direction/speed control, throttle, engine kill (fuel shutoff), emergency kill (air shutoff), torque windup release, and a calibrated, liquid-flled stainless torque gauge. Panel faces are finished with permanently anodized, easy-to-read markings, Brake control is added when optional brake is ordered Maximum torque is set on the power unit at a torque box which includes a torque gauge identical to the gauge on the remote control panel. The torque box also has an anodized face with permanent markings showing the steps to follow to set maximum torque. Our power units use closed loop hydrostatic transmission hydraulics which allow the swivel to provide controlled torque from zero to maximum RPM. To control swivel speed, the hydraulic pump provides variable flow from zero to maximum. speed in both forward and reverse directions.XK POWER SWIVEL OPERATIONS AT A GLANCE (See Operation & Maintenance for full information) * JARRING THROUGH THE POWER SWIVEL WILL CAUSE EXPENSIVE DAMAGE ! * SETTING MAX TORQUE - The permanent instructions on the face of the torque setting box are: Back out adjustment. Close ball valve to set pressure against. Put engine to about half throttle. Move lever to right hand rotation, Adjust torque to desired setting. eae ey a Open ball valve and begin operations. * WHEN SWIVEL STOPS AT MAX TORQUE SETTING, come to Neutral, which will stop rotation and hold the pipe from spinning backward. (Do not throttle down because at low horsepower, the engine could die, after which the drill string, engine, and pump will spin backward due to the torque in the string.) Then, if there is much torque wind-up in the string, push the Torque Release button which will cause string wind-up to be safely backed out before picking up the string. * ENGINE KILL is the normal way to kill the engine which shuts off the fuel. Push and hold to kill. * EMERGENCY KILL shuts off the intake air, and is to be used only in an emergency condition, such as a natural gas engine runaway. Push once firmly and run like hell !Venture’: XK OPERATION | HOOKING UP QUICK-DISCONNECTS | If you can accept the inconvenience of handling the power swivel with THE BEST WAY TO HAVE the hoses connected, you will be LONG SYSTEM LIFE IS TO better off in the long run with less HAVE NO QD’S IN THE contamination in the system. We know this is difficult, but a few customers are somehow able to do it, and they usually have less trouble. SYSTEM! If the system is equipped with quick- disconnects, remove the dust caps and plugs and THOROUGHLY CLEAN each quick-disconnect half just before the connection is made. Use a spray can of WD-40 or diesel starting fluid with the small spray tube. The high velocity jet from the spray tube does a good job of cleaning. The rag in your back pocket won't do! IMPORTANT ! CLEAN EACH QUICK- DISCONNECT HALF THOROUGHLY BEFORE CONNECTING. XK Operations 1Each hose has a quick-disconnect with a check valve in each half which opens automatically when connected Connect the following hoses: High pressure hoses To prevent incorrect hookup, male and female coupling halves are reversed so hoses will only connect one way. Clean coupling threads are easily made up by hand, and face-to-face makeup should be checked through the viewing hole in the side of each coupling. Case drain hose is connected with a spring-loaded sleeve-type quick-disconnect. If this hose is not connected, the swivel incorporates a special patented pressure relief valve to prevent blowing a shaft seal and causing a major shut down for this mistake. This relief valve opens and discharges oil from the swivel to alarm people to stop and find the problem IMPORTANT ! Control hose umbilical to remote control panel All control hoses have quick- CONTAMINATION IN THE. disconnects, which are stamped HYDRAULIC FLUID ! with numbers matching the numbers on the back of this control panel. THE REASON MOST HYDRAULIC SYSTEMS FAIL IS | START UP * Check hydraulic fluid level and all other fluid levels. + Set FORWARD — REVERSE control to neutral. * Set THROTTLE control at SLOW to MEDIUM position. + Back off ADJUST MAXIMUM TORQUE SETTING control CCW. XK Operations 2* Start engine, keeping RPM low to medium. + Within a few seconds, the 600# charge pump gauge should read approximately 200-300 psi (Note: This can take several nee eee Soe minutes on a new or repaired COME UP, SHUT DOWN AND system which has been cleaned CONSULT out, because it takes awhile for TROUBLESHOOTING the charge pump to refill the SECTION. hoses.) IMPORTANT ! Allow system to warm up long enough to warm reservoir oil temperature to at least 60° F. If outside temperature is very cold, this could take a while, or auxiliary heating could be required. Optional electric tank heaters are available, and may also be installed in the field. + System is now ready for setting maximum torque. SETTING MAXIMUM TORQUE (Instructions are also on the torque box.) Determine maximum torque allowable on drill string. Remember, this feature is intended to prevent twistoffs, so set maximum torque with consideration for drill string twistoff values. When operating torque reaches this preset maximum setting, the swivel will stop. MAXIMUM TORQUE SETTING should be backed out all the way CCW at the torque box. Leave the DIRECTION/SPEED control in neutral. Open throttle to medium engine RPM. Close the ball valve at the pump. XK Operations 3Venture + Push the FORWARD — REVERSE control lever to the full forward position. A low reading may appear on the torque gauge. + Now rotate ADJUST MAX TORQUE SETTING control clockwise until desired maximum torque shows on torque gauge. + Return FORWARD — REVERSE control lever to neutral. Notice the torque gauge drops to the original low level NOTE: Maximum torque is adjustable only in the right hand direction. In the left hand direction, the pressure limit is set by the system safety relief valve which is set at maximum pump pressure to provide maximum torque for breakout. THEREFORE, IF YOU MOVE THE PANEL LEVER IN THE REVERSE OR LH DIRECTION WITH THE BALL VALVE CLOSED, PRESSURE WILL QUICKLY GO TO MAXIMUM. * To check operation of torque controls, move the FORWARD — REVERSE control rapidly from neutral to the full forward position. The torque gauge reading should immediately rise to the torque previously set and hold this torque until the handle is returned to neutral. This procedure should repeat the same reading consistently. * Move FORWARD — REVERSE control back to neutral. « Open the ball valve. XK Operations 4» The power swivel is now ready for use. [ OPERATING SPEED OF ROTATION Always control swivel speed by adjusting the FORWARD — CHARGE PRESSURE IS REVERSE control (which adjusts JUST AS IMPORTANT TO pump displacement) as necessary YOUR HYDRAULIC PUMP while keeping engine RPM in the AS OIL PRESSURE IS TO medium range unless maximum YOUR ENGINE ! horsepower is needed at max engine rpm. This will result in best fuel economy, longer engine life, quieter operation, and longer pump - life. Never idle the engine when drilling with the swivel. We have seen people put the DIRECTION-SPEED handle in the max position (some people incorrectly think this is the “in gear” position), then adjust to a slow swivel speed with engine throttle. When torque comes up, the engine could die because it is not making enough HP at low rpm. Then the torque windup in the string would cause the engine & pump to spin backwards which will cause problems. + So keep an eye on the charge pressure gauge which should stay in the 200-300 psi range. If its reading should drop to a low level, immediately shut down and investigate. If you should hear any unusual noise from the pump or hydraulic system, look at this gauge reading. If the gauge fluctuates, this is a troubleshooting indicator. XK Operations 5HYDRAULIC FLUID (XK-250) Check hydraulic fluid level in reservoir before each startup CAUTION! and add fluid if level is low The XK-250 should only use an | RUNNING THE SYSTEM approved synthetic oil. Mobil WITH FILTERS DIRTY WILL SHC-526 or its equivalent is SHORTEN HYDRAULIC recommended. This oil is good | PUMP AND MOTOR LIFE ! for wide ranging temperature service from arctic to desert. Mobil SHC-526 has a pour point of -5OF or -42°C. HYDRAULIC FLUID (XK-90 & XK150) Check hydraulic fluid level in reservoir before each startup and add fiuid if level is low. Use only an approved high quality hydraulic fluid from a major oil company. Expensive, exotic oils are fine, but unnecessary. Changing filters regularly and oil at least twice a year is 1000 times more important than buying specialty oils. Unless you are in extreme temperature conditions, use AW-68 year round. For extremely cold conditions, use Mobil DTE 12M oil with a pour point of -48°C (-54°F). If outside the US, use Univis N-22 oil with a pour point of -54°C (-65°F). HYDRAULIC FLUID TEMPERATURE Temperature should never exceed 150° F, and will normally run much cooler. A hydraulic oil cooler is mounted ahead of the engine radiator. DURING TORQUE LIMITING When the drill string reaches the maximum preset torque during drilling, the swivel will stop but will continue to hold the torque windup already in the drill string. This sudden stop may be surprising, but is correct, and a twistoff may have been prevented. XK Operations 6WHEN THE SWIVEL STOPS AT THE TORQUE LIMIT: To release the torque in the drill string before picking up, simply pull the lever back to neutral, then push the torque release control button as required, allowing the drill string windup to back off safely. NOTE: The TORQUE gage is calibrated for safe use as a practical drilling tool. However, unlike a load cell on a tong, it does not measure torque directly but converts system pressure to torque, a common method used on power swivels and variables including efficiency, RPM, temperature, washpipe condition, mud pump pressure, etc. All affect the accuracy, but the gauge is calibrated so that inaccuracy occurs in the direction of safety against twistoffs. MAKING CONNECTIONS When the unit is used to makeup connections, do not run the swivel so fast that the connection shoulders out hard. The pressure compensated pump cannot react this fast and the connection may be over-torqued by the high- pressure spike, and this spike may damage the hydraulic system. Power swivels are not a substitute for tongs with torque indicators, and final makeup should always be done with tongs. BREAKING CONNECTIONS If the swivel is used to break out, keep the following in mind: * The breakout side of the hydraulic system has no adjustable torque control, so if the connection is made up tighter than the swivel’s maximum torque capability, the pressure will max out. As the unit ages and hoses degrade, this procedure will blow hoses, USE TONGS TO BREAK OUT, THEN SPIN OUT WITH THE SWIVEL! XK Operations 7XK MAINTENANCE { HYDRAULIC FILTERS & OIL | The XK power swivels require 10- IMPORTANT | micron filtration, which is a very fine degree of filtration typical for piston- THE REASON MOST type pumps and motors. This means HYDRAULIC SYSTEMS FAIL particles larger than 10 microns are 1S DIRT IN THE OIL! removed. Even particles this size are damaging to high pressure hydraulic equipment, and these particles are much smaller than the eye can see “S (see table), so a filter indicating a clogged condition will not necessarily have visible particles on its surface. Nonetheless, these particles must be removed to provide a long life hydraulic system, and such filter elements are NOT CLEANABLE !!! Attempting to clean such elements will only worsen the situation, and there is no substitute for changing filter elements when required. This hydraulic motor is very rugged and extremely high quality, and is also the reason no gears are required. Like other piston-type equipment, this motor is subject to contamination damage, and is also VERY EXPENSIVE. Pay attention to filter indicators, but there is no substitute for changing filters and oil in a regular manner! Such a schedule should be worked out according to the number of jobs, time since last change, etc. Every 500 hours, or at least once a year, or more frequently if heavily used or water contamination is suspected, the reservoir must be cleaned out and refilled with new hydraulic oil, along with a complete filter change. Hoses should be blown out at this time. XK-150 MaintenanceNenture = "Group Take a look at the following table. It is a dramatic illustration of the sizes of very small substances, and the sizes that must be FILLING RESERVOIR The best way to transfer fluid from a drum is with a transfer pump through a filter having a 1 to 10 micron rating. This is important, filtered out, FILTRATION DIAMETER, oe DIAMETER, REQUIREMENTS MICRONS eee! INCHES 100 Grain of Table Salt 70 Human Hair 7 Lower Limit of Human 7 ue pe | vieinitity - ee Vane-type motors on the Pie Neer el Petia 25 White Blood Cells 0.001 larger than 25 microns filtered out. | Piston-type pumps on all XK's, & motors on the XK- 160 & 250 need all 10 Talcum Powder 0.0004 particles larger than 10 microns filtered out J al eee 8 Red Blood Cells, 0.0003 2 Bacteria (Average) 0.00008 because even new hydraulic oil in sealed drums contains surprisingly high levels of contaminants invisible to the eye, which are still large enough to cause damage. HYDRAULIC FLUID TEMPERATURE Temperature should never exceed 150° F and will normally run much cooler, FLUID CHANGE The complete contents of the system should be changed at least every year or 500 hours of operation, whichever comes first. At this time the reservoir should be opened and thoroughly cleaned, and the XK-150 Maintenance vVenturi hoses should be blown out. But use common sense — If it gets dirty, change the oil & filters and clean out the tank! And remember, if the oil gets visibly dirty, then the filters have probably not been changed regularly. OIL TYPE The XK-250 should only use an approved synthetic oil. Mobil SHC- 526 or its equivalent is recommended. This oil is good for wide ranging temperature service from arctic to desert Mobil SHC-526 has a pour point of -50F or -42°C. INSTRUCTIONS FOR REPACKING WASHPIPE PACKING CARTRIDGE CARTRIDGE REMOVAL * Unscrew upper and lower packing nuts by hammering on lugs (LEFT HAND THREADS) * Move lower packing nut and upper packing nut toward each other until complete assembly can be removed from swivel CARTRIDGE TEARDOWN (See drawing after this section) * Slip lower packing nut off washpipe and remove grease fitting Back off holding screw several turns. Remove packing and spacer rings from packing nut. * Remove packing rings and O-rings from spacers and thoroughly clean grease and mud from spacers and inside of upper and lower packing nuts. + Inspect all parts for excessive wear, corrosion, and washout. Examine upper packing nut ring for excessive wear in slots. Examine washpipe and replace if worn or grooved. XK-150 Maintenance 3CARTRIDGE ASSEMBLY Install a new packing ring in bronze upper packing nut ring. Completely fill the cavity between packing lip and spacer with waterproof, heavy duty grease. Slip upper packing nut over washpipe and upper packing nut ring. * Install new packing in bronze spacer rings. Hand-pack grease into inside cavity formed by each packing lip and spacer. Arrange spacers as shown in drawing and again hand pack grease into all inside cavities. * Carefully drop packing assembly into the lower packing nut. * Push lower packing nut assembly over washpipe until it is flush with end of washpipe. Carefully install O-rings in the dovetail grooves in the top and bottom bronze rings ¢ Pick up entire washpipe and packing cartridge assembly and insert into space between stem and gooseneck. ¢ Grease threads and screw on both left hand packing nuts and hammer until nuts stop turning at metal-to-metal contact. (Note: if desired, this cartridge may be installed upside down to allow greasing while rotating.) * Complete the lubrication with a few shots from a grease gun. * Screw in the locking set screws against the plastic plugs to lock the nuts in place. XK-150 Maintenance 4| POWER SWIVEL REBUILDING ] SWIVEL EVALUATION BEFORE TEARDOWN * The magnetic drain plug should be inspected to evaluate the level of bearing wear. A small amount of very fine metal particles may be OK, but a large amount of metal on the plug means substantial wear has occurred and should be inspected by teardown. * Bearing oil should be inspected for cleanliness and water content. A low oil level is cause for concern, and substantial water in the oil signals bigger problems inside. + End play is not as important in XK’s as in gear-driven power swivels, but should still be noted. By carefully lifting and lowering the swivel weight on and off the stem against the floor, it is easy to see unacceptable upward shaft movement in the washpipe packing nut. Correct end play is .004” - 010” which is easily measurable with a dial indicator. Excessive end play may indicate other problems inside. SWIVEL TEARDOWN INSTRUCTIONS The XK Power Swivels are precision made units with close tolerances and fine surface finishes. Particularly with this piston-type hydraulic equipment, special care must be used to prevent contamination of internal parts with any foreign material. Keep in mind the hydraulic filters are designed to remove damaging particles so fine they cannot be seen by the human eye. For these reasons, only skilled mechanics working in a clean, well-lit, and well-equipped shop should be used for major repairs. XK-150 Maintenance 5Nenture: XK-150 TEARDOWN AS FOLLOWS USING ASSEMBLY DRAWING & PARTS LIST + For easiest teardown, support the swivel vertically in a fixture with the bail supported horizontally. Group + Remove drain plug and drain oil * Remove hydraulic motor manifolds with swivel joints and quick- disconnects. + Remove hydraulic motor using a bar-type puller across the end of the stem with two long all-thread rods. + Hammer LH packing nuts loose and remove complete washpipe and packing cartridge assembly + Remove gooseneck from bonnet + Remove bonnet. Carefully slide the seal protector up off the shaft. « Remove top cover plate. + Remove seals and O-ring from cover plate. Lift the shaft assembly with the main thrust bearing straight up and out of the swivel body. XK-150 Teardown 1INSPECTION Carefully clean and inspect all parts to determine if replacement or repair is required. All O-rings, gaskets, and seals should be replaced, Bearings may be reused if they spin smooth and free, and no looseness, pitting, or other damage Nenture Group: MAGNAFLUX ! Every year, or any time excessive load has been put on the swivel, it should be completely disassembled, stripped of paint, and all load carrying parts should is evident. be magnafluxed for cracks. REASSEMBLY Reassembly is basically done in reverse order of disassembly, paying extreme attention to cleanliness and proper fits between mating parts. This is not engine mechanic clean, this is hospital clean! Any burrs or sharp edges must be carefully removed. Particularly, the shaft must be filed and buffed smooth and free of any raised tong marks because the hollow motor shaft must pass freely over these surfaces at assembly. If the seal surfaces in the upper shaft seal area and the motor shaft seal areas are tracked or damaged, replace the wear rings to renew these seal surfaces. Lubricate all parts with hydraulic oil before assembling, except where certain items are noted to require special lubrication. «Install the link hooks (or bail) and bail pins. * Set the body into a suitable support fixture for assembly. « Pre-fit the main thrust bearing lower race into the bearing pocket of the swivel body to be sure of a correct fit. Remove the race. + Heat the upper shaft bearing in an oven and drop into place on the shaft, seating against the shoulder. « Install the main thrust bearing upper race. XK-150 Teardown 2Venture: Group Set main thrust bearing cage and lower race over the shaft down against the upper race. Do not install rollers yet. + Tum the shaft assembly upright and hang it vertically + Lower the shaft assembly down thru the swivel body until thrust bearing seats in the body « Install the upper shaft bearing outer race in the bore of the top cover. * Install the top cover with O-ring and estimated thickness of shims * Check the shaft end play with a dial indicator and a hydraulic jack to determine the shim thickness required to give .004” - .010” end play. * Correct end play with shimming if necessary « Install seals and snap ring in top cover with top seal lip facing up and bottom seal, lip facing down. * Pack the top of the upper seal with grease, and use a grease gun to grease between the seals. * Slide the seal protector down over the shaft until it contacts the bonnet flange. + Bolt the bonnet down to the top cover. + Install the gooseneck on top of the bonnet, and tighten the top plug. + Install the washpipe packing cartridge assembly. Note: If desired, this cartridge may be installed “upside down” to allow the packing to be greased during rotation + Swing the swivel to a “stem up” position and lock safely in position K-150 Teardown 3Venture 1'Group- Install hydraulic motor after applying “Never-Seez” to spline. Install motor manifolds with O-rings, and tighten manifold bolts fully. Fully tighten hydraulic motor mounting bolts. Install cartridge valves if removed from the manifold. Fill swivel with 85W — 140 gear lube unless special oil is required for an extreme environment. VERY IMPORTANT ! Before startup, completely fill the motor case with hydraulic oil. E | POWER UNIT PUMP This is a piston-type variable displacement pump. It has infinitely variable speeds, is air shifted, and automatically unloads in neutral. It has a small piggy-back pump used for hose reel and winch power options. HOSE REEL Our special “ugly gear drive’ triple hose reel uses brutally rugged flame cut gears, eliminating the need for motorcycle chains or a lubricated gear box. The high pressure sealing is done with readily available “Chiksan-style” swivel joints, while the low pressure case drain sealing uses our long-life, corrosion-protected rotating union which we call the D-block assembly because of it's shape. XK-150 TeardownVenture “Group! CONTROL PANEL All parts of this remote air control panel are aluminum, stainless, or brass for corrosion protection, and the permanently anodized markings are easily readable after 20 years of sun and weather. Panel fasteners are assembled with Loc-tite and self-locking nuts, and the Loc-tite should be redone when replacing components. TORQUE BOX Replacing the valve is easily done through the front panel without opening the box. When replacing the torque gauge, always use a backup wrench on the wrench flats to tighten the plumbing connections, or the new gauge WILL BE DAMAGED ! See photos and drawings in the drawing section. XK-180 Teardown 5XK-150/250 HIGH PRESSURE HYDRAULIC FILTERS FIELD SERVICE AND INSPECTION Si a ~— - XK-250 “A” SIDE 4 HIGH PRESSURE FILTERS ARE INSTALLED, 2. ON EACH SIDE OF DOUBLE PUMPS XK-150 PUMP CONFIGURATION 2 HIGH PRESSURE FILTERS ARE INSTALLED, 1 ON EACH SIDE OF DOUBLE PUMPSTHE BASICS Contamination Indicator Filter Head Filter Element. Each high pressure filter includes a reverse flow bypass valve assembly built into its head. This valve allows filtration in the forward direction, filter bypass in the forward direction when the element is clogged, and filter element bypass in the reverse direction. To indicate clement change is necessary (before it bypasses in the forward direction) the contamination indicator (above) pops up and a red band is visible. HY-M This diagram (left) indicates the hydraulic schematic of the Reverse Flow Bypass Valve. This is the actual valve (right) removed from the filter head.INSPECTING THE REVERSE FLOW BYPASS THE FILTER HEAD Remove the filter element from the filter head (above left) and then the bottom of the Reverse Flow Bypass Valve is visible (above right) for inspection and removal. To check the normal forward flow function, place your finger into the center and push in. This should be a smooth easy operation that requires only two to three (2-3) pounds of pressure to open. Pushing in this direction will allow you to check the light spring in the upper half of the valve. If the seat does not move, is missing, or will not return to the normally closed position by itself then there is something wrong with the valve assembly and it needs to be removed and replaced. (See ‘Removal Procedures’ in the following section)On the top of the filter head, remove the Contamination Indicator and look into the hole. (below) *CAUTION* There may be head pressure from the long hoses going up into the derrick. In this case, we recommend disconnecting the high pressure lines from the unit to the derrick at the quick disconnects. This will eliminate head pressure and minimize loss of fluid at the pump. Place a CLEAN screwdriver or punch into the top of the filter and press down on the center of the Reverse Fl This will take considerably more force to push down than the bottom side as it requires approx 50 ~ 60 Ibs. to open. Pushing on the Reverse Flow Bypass Valve in this direction will check the forward flow, filter bypass function. The valve stem should move freely at this 50 ~ 60 Ib. load. This also allows you to see that the top of the valve is in place and not broken.REMOVING THE REVERSE FLOW BYPASS VALVE ‘This procedure requires the use of a special tool that can be made from a piece of 2” ID schedule 80 pipe 4-6 inches long and ground down on one end to form two prongs opposite cach other. (below) pra *NOTE* While this tool can be fabricated in the field it is still imperative that any tools used on the hydraulic system are clean!Insert tool into the slots on the bottom of the Rever (counter-clockwise) Visually inspect the valve and replace if there is any damage or parts that will not move freely.*NOTE* When installing (or reinstalling) a Reverse Flow Bypass Valve it is important that the threads of the Reverse Flow Bypass Valve be installed with Loc-Tite 545 or equivalent. *IMPORTANT* Use only Stauff manufactured filter elements in these filter housings as an off brand filter WILL NOT BE COMPATIBLE. and may come apart in the system. Any damage to the hydraulic swivel or pumps traced back to incorreet filter elements WILL NOT be warranted by Venturetech.6901 Alabonson Road Houston, Texas 77088 Phone: (713) 895-8700 Fax: (713) 895-8720 XK-250 FIELD UPDATE PROCEDURE REPLACING BALL ASSEMBLY IN KOBELT AIR CONTROL MODULES. BEFORE STARTING THIS PROCEDURE, REMOVE AIR INLET TO KOBELT CONTROL HEAD! 1 Remove air lines from air control modules and remove modules from Kobelt control head 2. Remove the two screws on the top of the air module. 3. Pull out the ball valve assembly and replace it with a modified, welded assembly FAPOWER SWIVEL MANUALS\Service & field update procedures\Xk-250 FIELD UPDATE PROCEDURE - AIR MODULES doc6901 Alabonson Road Houston, Texas 77088 Phone: (713) 895-8700 Fax: (713) 895-8720 4. Before reassembly insure all parts are accounted for including: washer, spring, ball valve assembly, cover and screws, 5. _ Install washer into body. Make sure it seats around the raised lip in the bottom of the cavity. 6. __ Install ball valve assembly into the valve. Watch your seals and make sure they do not catch or tear. The ball valve assembly must move freely inside the cavity! FAPOWER SWIVEL MANUALS\Service & field update procedures\XK-250 FIELD UPDATE, PROCEDURE - AIR MODULES.doci 6901 Alabonson Road Houston, Texas 77088 Phone: (713) 895-8700 Fax: (713) 895-8720 7. Install spring 8. _ Install cap and screws. Reinstall onto Kobelt control and connect air lines. TEST THE ACTION OF THE VALVE SEVERAL TIMES TO INSURE THAT IT 1S NOT STICKING OR DRAGGING BEFORE INSTALLING! FAPOWER SWIVEL MANUALS\Service & field update procedures\XK-250 FIELD UPDATE, PROCEDURE - AIR MODULES, docGENERAL ADJUSTMENTS FOR VARIABLE PRESSURE CONTROL HEAD CHROME 2-HANDLE 4-AIR FWD, REV, THROTTLE, KILL. P/N 6332 For prolonged life, Venturetech requires an air filter/lubricator/regulator placed inline before the control panel. Max output pressure to Control Head set to 120 psi. Failure to install this eritical device will VOID any warranty to the Valve Modules. In the event that it becomes necessary to adjust the variable speed Fwd, Rev, ‘Throttle, Kill valve that is located in or next to the Drillers Console, please follow the directions below in the order they are presented to attempt to correct the issue. Adjustment No. 1 — This set serew can be adjusted to preload a valve to a minimum. starting pressure. Venturetech preloads these set screws at 0 psi minimum. That means that when the control lever is in the neutral position, no air will pass through the valve -NOTE- If the swivel rotates either direction when the control lever is in neutral, this could be an indication of a maladjustment at this set screw. A quick check will be to remove the output air line QD for the Forward (#1) or Reverse (#2) and check for air leaking out of the male QD in the control panel. Adjustment No. 2 ~ This set screw must be adjusted to coincide with the adjusting serew at the bottom (Adjustment No. 1) . If the pressure range needs to be increased, the serew can be turned downwards (towards the valve). If the valve responds too slow to the mechanical movement of the handle, the slack can also be taken up with bottom set serew (Adjustment No. 1). -NOTE- Symptoms of this problem can be engine/swivel speed not going to max at the full forward/reverse position of the handle. Delayed response in engine speed up or forward/reverse due to a gap between this set screw and the top of the air control module. Adjustment No. 3 - These two set screws with jam nuts provide maximum handle travel stop which will result in maximum output pressure limitation. For example, if adjustment No.1 and 2 have been correctly made to establish a minimum pressure (0 psi in the neutral position for Venturetech controls), the maximum pressure can now be set with these stop screws. Adjustment screw No. 3 should only be used for minor pressure adjustments. -NOTE- Venturetech control heads have a max air output of 60 psi. This is factory set via a spring inside the Valve Module. No mater how many adjustments are made to this control head, the max psi output will always be 60 psiAdjustment No, 4 ~ Adjustable nylon friction with spring and set serew. The set sorew can be set to obtain the desired drag on the handle to avoid creeping. Adjustment No.5 ~ Adjustable detent with stainless steel plunger, spring and set screw. This adjustment can he set to provide the required feel of the detent (Neutral position), If these steps do not correct the valve, it may be necessary to repair/replace one or more of the Valve Modules. Removing the Valve Module from the Control Valve Assembly. 1, Open the Driller’s Panel to gain access to the underside of the valve, (If using a Venturetech Control Panel, turn the box over.) 2. Locate the four (4) Valve Modules (P/N 5684-1) underneath the Contro! Handles and remove the two (2) Allen head screws that mount the Valve Module to the Control Head. Each Valve Module corresponds to one function of the valve, so be sure to remove the correct Valve Module for the function that is not working properly. It will be located directly under the Handle position of the fault. For example, if the Forward direction is not responding correctly, the Valve Module will be the front/top left. 3. Install a new module. Make sure the O-ring seals (2) are in place. Tighten the Allen head screws. Test for correct function, To rebuild the Valve Module remove the four (4) Phillips head screws from the bottom half of the Valve Module and replace the Diaphragm, “U” Cup, and O-ring, (Seal Kit PIN 3238). Any other parts can be ordered from Venturetech by referencing DWG 5684 and providing the corresponding eight (8) digit P/N.CHROME 2-HANDLE VALV at COMPLETE PART # 6332 * === ADJUSTMENT # 5 AIR VALVE mmm MODULE R PART # 5684-1 ==== ADJUSTMENT # 1Venturetech Customer Parts List Assy P/N: 8343 1/10/2008 Revised: 10/6/2009 Page 10f 3 Created: Description: XK-150 BASIC POWER SWIVEL ee 1 Qty Part# Description =. 4 1 6080 XK-150 BEARING HOUSING 2 1 a 6316 HOUSING COVER, XK-150 - = 3 1 4860 a MAIN THRUST BEAR BEARING 7 2 4 6141 —_ UPPER STEM BEARING oO —_ 5 1 2 = WASHPIPE & PACKING CARTRIDGE 6 6 HO-SIB-1IXS HEX HEAD CAP SCREW, 5/8"-11 X 3" LONG, GRADE 5, PLATED 7 32 LW-t/2HC LOCKWASHER, 1/2" HIGH COLLAR 8 1 7529 4/8" NPT GREASE FITTING 9 1 6170-279 O-RING 2-279 BUNA-N 70 DURO 10, 2 _ HO-518-11%2. 75 HEX CAP, 5/8"-11 X 2 3/4" LONG - 1) 18287 CIL FILLER PLUG, 9/4" NPT, FOR RELIEF VENT 1 6245 FILLER PLUG RELIEF FITTING 7 13 1 6187 “UPPER ‘STEM SEAL, INNER 14 1 6188 a UPPER STEM SEAL, OUTER: 81 «6189,=SSSSCRETAVNER RING, STAINLESS a 16 1 6184 7 SHIM SET, PLASTIC COLOR-CODED = 7 1 16HPSON-S: PLUG, #16 SAE ST THREAD, SOC HD, 1" STEEL 22 1 6082 : UPPER ‘STEM SEAL WEAR, RING, HARDFACE OVERLAYED 23 1 9076 a ‘STEM, XK 50 FINISH MACHINE, FINAL GRINDING 24 6 : H-5/8-11%2 25 ; HEX CAP, 5/8"-11 X 2%" LONG. 25 7 16 7 LW-5/8 LOCKWASHER, 5/8" - “1 631 BONNET - 1 9414 : GOOSENECK, MACHINING, XK-150 1 5604 = NPT HEX PLUG 29 16 7601 HEX CAP, 6/8-11 x 6-1/2" LONG, GR. 8 - TORQUE TO CORRECT SPEC 30 1 7023 HYDRAULIC MOTOR, 12,000 FT-LBS, XK-160_Venturetech Customer Parts List een Ces Created:11/10/2006 Revised: 10/6/2009 Page 2 of 3 Description: XK-150 BASIC POWER SWIVEL a Qty Part# Description 32 7 SC-5/8-11X2.25 SOC HD., 5/8-11 x2 1/4 LONG, GR. 8 8 SC-1/2-13X3 SOC CAP, %4"-13 X 3" LONG. 1 e176 SEAL PROTECTOR 36 1 6170-281 O-RING, 2-281, BUNA-N 70 DURO SPACER BLOCK, FOR RELIEF VALVE MANIFOLD. RELIEF VALVE MANIFOLD, 1-1/2" NPT OUTLETS EACH END. HOSV MANIFOLD, XK-150 & XK-250 METRIC FLAT WASHER FOR HAGGLUNDS SWIVEL JOINT, 1-1/2"760/6K PIPE NIPPLE, 1-1/2" SCH, 160 x 3", A-106B NPT THD'D, BOTH ENDS. 8000 QD COUPLER FEMALE HALF 43 1 8507 ala! 1 8506 1-1/2" - 5000 QD NIPPLE MALE HALF 47 1 30187 1" SNAPTITE QD, NIPPLE MALE HALF 60 1 7951 UPPER PULLBACK BRACKET, XK-150 “1 9098, | _XK-150 HOSE SAFETY CABLE ASSEMBLY - 64 1 st60 SAFETY CABLE BRACKET, XK-150 : 55 2 HC-5/8-11X3.25 HEX HEAD CAP SCREW, 5/6"-11 X 3.25" LONG, GRADE 5, PLATED 56 1 9184 HOSE CLAMP ASSEMBLY, 1" 0. HOSE 87 2 9156 HOSE CLAMP ASSEMBLY, 1-1/2" LD. HOSE “st 9192 "BOLT SHACKLE, BOLTTYPE ‘60 1 9075 44" QD NIPPLE COUPLER - GEAR OIL FILLER/ BAIL PIN PULLER 6 1 9815 GEAR OIL SAMPLER FITTING 63 1 3276 4B FLG, 1"- 3K, OR x FP 90° _ aa 1 9000 PIPE NIPPLE, 1" SCH. 160 x 3", A-1068 NPT THD'D. BOTH ENDS. 64 3.912 ORING — 7 66 16 © SC-1/2-13X4,00 SOC CAP, 1/2-13 X 4" LONGVe h rts List Assy PIN: 8343 ‘enturetech Customer Parts List Created: 11/10/2006 Revised: 10/6/2009 Page 3 of 3 Description: XK-150 BASIC POWER SWIVEL n Qty Part# Description er i e319 SWIVEL HOSV CARTRIDGE, 75 PSI SHIFT PRESSURE 68 1 6170-208 O-RING, 2-206, BUNAN7ODURO. 69 6 6170-222 O-RING, 2-222 BUNA-N 70 DURO 70 1 8323 ORIFICE FITTING, 1/16 NPT WITH 093 ORIFICE - n 2 7381 RELIEF VALVE CARTRIDGE, 100 GPM, SET AT 5500 PSI 72 a LW-5IBHC LOCKWASHER, 5/8" HIGH COLLAR 73 1 9734 OIL SAMPLING VALVEVenturetech Customer Parts List Created: 11/3/2008 Revised: 10/6/2009 Page 1 of 2 Description: HYDRAULIC MOTOR, 12,000 FT-LBS, XK-150 SK Te ™P}]§9{V.—ewwvrwrvH______——_ 1 Qty Patt Description Assy PIN: = 7023 1 1 6104 50 HYDRAULIC MOTOR ASSY, AS PURCHASED 2 - 6283 MOTOR PORT HOUSING - : 2 6000 ===SCCASOMO ROTOR, SPLINED 4 1 6006 : MOTOR COVER PLATE 7 1 eats SEAL RETAINER, FOR MOTOR COVER PLATE. a + 6170-269 — O-RING, 2-269, BUNA-N 70 DURO Z 7 7 6 ‘SC-3/8-16X1 SOC CAP, 3/8"-16 X 1" LONG ee 8 —_ LOCKWASHER, 3/8" HIGH COLLAR 9 BOLTED RING FOR END OF HOLLOW SHAFT 12 = PPS STYLE SEAL, 7.289 X 8. 288/827 X 304 c 13-2 64B1-4004.0 O-RING, 400MM X40MM 2 ‘SC-3/8-16X3.5 SOC CAP, 3/8"-16 X 3%" LONG a : 16 1 AGHPSON-S PLUG, #16 SAE ST THREAD, SOC HD, 1" STEEL 17 1 9790 CASE RELIEF VALVE ELBOW 18 : 1 6428 7 : MOTOR SEAL CARRIER WITH SNAP RING GROOVE AND O-RING 7 GROOVES ON OD 19 1 - 9859-210-3.0 a O-RING 210mm X 3.0mm 90 DURO VITON 20 2 7 9859-162-3. oO O-RING 162mm X 3.0mm 90 DURO VITON 24 5 9450 12 X SOMM LG., SOCKET HEAD CAP SCREW WITH VIBRATITE 23 4 9742 MODEL "B" 160 PSI MOTOR CASE RELIEF VALVE, ‘ASSEMBLY - 24 1 7801 SNAP RING, INCLUDED WITH MOTOR AS PURCHASED: 25 1 7967 7 SEAL RETAINER RING 26 2 7844 - WEAR RING, AS PURCHASED: “a 7 1 6420-113 O-RING 2-113 VITON 75 DURO _— 1 3-916 O-RING OO a 2% 1 76 ABFLG,1"-3K, ORK FPO" 30 1 8270 1" PIPE PLUG.Assy PIN: Description: 1 Qty 34 2 32 1 Venturetech Customer Parts List 7023 Created: 11/3/2008 Revised: 10/6/2009 Page 2 of 2 HYDRAULIC MOTOR, 12,000 FT-LBS, XK-150 Part Description 667 PLUG, 1/4" BSP SOCKET HEAD, WITH SEAL 6170-250 O-RING 2-260, BUNA-N 70 DUROAssy PIN: 6142 Venturetech Customer Parts List Created: Revised: 12/2/2003 Page 1 of 1 Description: WASHPIPE & PACKING CARTRIDGE a Qly Parti Description 1 4 6094 ‘WASHPIPE, XK-150 & XK-250 4 6092 WASHPIPE HOLDING NUT 3 + 6098 WASHPIPE PACKING NUT 4 4 6096 WASHPIPE HOLDING RING 5 16099 =—SSCWLANTERNRING 1 : “SPACER RING : : 1 "BOTTOM RING NPT GREASE FITTING 8 1 6100 PACKING SET, XK-150 AND XK-250 10 2 6170-242 O-RING, 2-242 BUNA-N 70 DURO “ 6 6tts 1A" x 112" LONG SS - 6 1356-1 PLASTIC PACKING NUT RETAINER, FOR THDVenturetech Customer Parts List Assy PIN: Created: 7/6/2009 —_—Revised: 9/9/2009 Page 1 of 1 Description: 160 PSI MOTOR CASE RELIEF VALVE, ASSEMBLY om ty Description 1 + 9745 MODEL "B" MOTOR CASE RELIEF VALVE, PLUG MOTOR CASE RELIEF VALVE, CAGE 2 1 9744 MODEL 3 1 9743 MODEL "B' MOTOR CASE RELIEF VALVE, POPPET 4 1 9844 SPRING, MOTOR CASE RELIEF VALVE, 160 PSI O-RING 6 1 9842 SEAL, MOTOR CASE RELIEF VALVEVenturetech Customer Parts List Assy PIN: = 7805 Created:7/7/2004 Revised: 1/19/2009 Page 1 of 1 Desct ion: DISC BRAKE ASSEMBLY, XK-150 a Qty Patt Description 1 1 8396 BRAKE HUB LOCK RING, XK-160 2 1 7768 DISC BRAKE HOUSING BRAKE HUB, XK-150 DISC BRAKE BLADDER 5 1 ‘SPACER, HUB, XK-150 BRAKE “6 12 HEX HEAD cap SCREW, 5/8-11UNO, SPECIAL 7 + e402 XK-160 DISC BRAKE CARTRIDGE 7 8 4 8300 SQUARE KEY, 1/2"x 1/2" x 2-1/2" LG. a 9 - 1 9578 LOWER SEAL, WEATHER EXCLUSION _ 2 12 1 7769 — O-RING ADAPTER FITTING, v2" NPT 13 - - 6170-213 - O-RING, 2-213 BUNA-N 70 DURO a : © 6 a 12X 65MM LG., SOCKET HEAD CAP SCREW WITH VIBRA-TITE 16 c 1 8265 7 O-RING, 10.500 1.D. x .070 CS, BUNA-N, 70 DURO 7 4 - 9454 1/2-13 X 1-1/4" LG., SOCKET HEAD CAP SCREW WITH VIBRA-TITE 18 1 "6452 PUSH PLATE, DISC BRAKE, NON-SLOTTED HALF - 7 - 19 12 LW-5/8 LOCKWASHER, 5/8" = 20 1 "8091 - "HYD HOSE ASSY, 3/8" (2-WIRE) x 23" LG., FIX x FIX “at 7 1 2501-06-08 3/8" M-JIC X 1/2" M-NPT, 90° ELBOW “22 1 ; 2404-06-08 3/8" M-JIC X 1/2" M-NPT, REDUCER “23 4 8804 QUICK EXHAUST AIR VALVE, 3/8" QE3 —- 24 4 5404-06-06 3/8" MANPT X 3/8" M-NPT HEX NIPPLE 7 ae 25 4 8808 : 7 QUICK EXHAUST VALVE MOUNT FOR ALL BRAKES 26 2 5602-06-06 3/8" M-NPT X 3/8" F-NPT, 90° STREET ELBOWVenturetech Customer Parts List Assy PIN: 8402 Created: 4/12/2006 Revised: 10/23/2008 Page 1 of 1 Description: XK-150 DISC BRAKE CARTRIDGE Qty Patt Description 1 1 8372 COVER, BRAKE HOUSING, XK-250 & XK-150 200 4 7163 PUSH PLATE, XK-160 DISC BRAKE = 3 5 8827 METAL DISC, XK BRAKE 4 6 ~ 8721 - FRICTION DISC WITH ALUMINUM CENTER PLATE 5 5 7704 WAVE SPRING 6 2 HC-3/8-16%3.75 HEX CAP SCREW 3-8-16UNC X 3-3/4 LONG.Venturetech Customer Parts List Assy PIN: — 9038 Created: 10/12/2007 Revised: 4/1/2008 Page 1of 3. Description: XK-150 WITH CAT C-9 POWER UNIT, LESS SKID & CONTROL. PANEL tem Qty Part# Description o 0 872 GENERAL ARRANGEMENT XK-150 OFFSHORE SKID ° 0 7687 GENERAL ARRANGEMENT DRAWING, XK-150 SKID 0 o XK-150 SKID ASSEMBLY DRAWING SHOWING COMPONENT LOCATIONS, 4 1 7514 CATERPILLAR C9 ACERT ATAAC INDUSTRIAL ENGINE, C/W AIR COMPRESSOR, RADIATOR & CAC (NO CONTROL PANEL) 4 0 e440 CAT C-9 COMPLETE ENGINE PACKAGE INCL MOUNTS, RADIATOR, FAN, INSTRUMENT PANEL, AIR SHUTDOWN 6 1 7525 HYDRAULIC PUMP, MANUAL CONTROL, "A" THRU-DRIVE 7 1 807 OIL COOLER WITH BYPASS, 25" X 36" CORE, 1-1/2" O-RING PORTS HOSE REEL ASSY, XK-150 SKID XK-150 SWIVEL RACK WITH AIR TANK, FOR SKID MOUNTING. BALL VALVE, 1-1/2".5000 HL-PRESS FILTER ASSEMBLEY, 160 GPM, REVERSE FLOW BYPASS TYPE 8 1 2468 XK-150 DUAL TANK ASSEMBLY, 110 GALLON/110 GALLON 14 1 6745 4-WAY VALVE, 2000#, DOUBLE SPOOL 15 150-8127 GALLONS OF AW-68 HYDRAULIC OIL eo 8 wT ‘GALLONS OF COOLANTIANTIFREEZE 47 1 6313-2 ee PRESSURE GAGE, 160#, SS, LIQUID FILLED, CENTER MOUNT a7 a 1 6313-1 PRESSURE GAGE, 160#, SS, LIQUID FILLED, BOTTOM MOUNT 19 4 8482 AUXILIARY PUMP FOR REEL & WINCH. 20 1 7982 HOSE HOOKUP DRAWING, ‘XK1: 150 SKID DUAL 110 GAL. TANK a 24 1 7620 CHARGE PUMP FILTER ADAPTER ASSY FOR 250 PUMPS 22 1 4659 SPIN-ON FILTER ELEMENT, 10 MICRON TANK MOUNTING POST, 3-1/2" TALL, TAPPED 3/4”-10 1-1/2" THERMAL BYPASS VALVE ASSY FOR 8107 OIL COOLER 26 1 4313 8D BATTERYParts List Assy PIN: 9038 Venturetech Customer Parts Lis' Created: 10/12/2007 Revised: 4/1/2009 Page 2 of 3 Description: XK-150 WITH CAT C-9 POWER UNIT, LESS SKID & CONTROL PANEL Hem Qty __Part# Description a 1 3895 RED POSITIVE BATTERY CABLE, CUT TO LENGTH, CRIMP ON POSITIVE CLAMP AND CORRECT EYE FOR STARTER TERMINAL rr BLACK NEGATIVE BATTERY CABLE, CUT TO LENGTH, CRIMP ON POSITIVE CLAMP AND CORRECT EYE FOR STARTER TERMINAL 29 1 aati 8D BATTERY RACK oe 1 777 HYDRAULIC WINCH, 2000 LB PULL. 7 32 1 7522 GOFT OF WINCH CABLE WITH SWAGED-ONHOOK 3 soe 4B FLG, 1%"-6K, OR X FP 90" 33 1 6987—————«~PIPE NIPPLE, 1-1/2" SCH. 160 x 4", A-1068 NPT THOD. BOTH ENDS. 6 1 6976 CONTROL PANEL STAND, ALUMINUM 3-LEG HIGH STABILITY TYPE, FOR XK PANELS, ‘TORQUE CONTROL BOX ASSEMBLY, WITH HYDRAULIC TORQUE GAGE, XK-150 HOSE KIT, XK-150 SKID, 250 PUMP, INCLUDING WINCH “ 1 8596 HOSE KIT, TO ADD WINCH TO XK-160 SKID 43 1 6244 AIRLINE FILTER/REGULATORILUBRICATOR, MODULAR TYPE 44 4 7940 | 41/2" 60" HIGH PRESSURE HOSE 45 2 3036-24-328 ADAPTER, 1-1/2" MJ X2"MP, STRAIGHT 468 2 3040-24-248 ADAPTER, 1%" MJ-1%" FP, STRAIGHT a4 7942 TDRAINHOSE,103FT(2WIRE) 49 1 6149 AIR CONTROL UMBILICAL, 7/1, 50 FT. 50 1 5069 11-HOLE TERMINATION PLATE FOR #1 & #0 FLYWHEEL HOUSING. 52 1 6608 AIR STROKER KIT, 90/250 53 2 7517 TORQUE ARM SPUD, XK-160 1 7425 FLATTED ROUND BAR FOR MOUNTING CONTROL PANEL STAND. ON DECK CHARGE PRESSURE GAGE, 0-600#, BOTTOM MOUNT es 2 7654 GAGE MOUNT TO HIGH PRESSURE FILTER 59 1 6869 TOOL BOX, CARBON STEELte Parts List Assy PIN: 9038 Venturetech Customer Parts Lis' Created: 10/12/2007 Revised: 4/1/2009 Page 3 of 3 Description: XK-150 WITH CAT C-9 POWER UNIT, LESS SKID & CONTROL PANEL vem Qty Parti# Description 7” 1 8436 PRESSURE SWITCH FOR ENGINE FUEL KILL, SWITCHES AT 20 PSI 2 1 8370 90-250 PUMP BLOCK ELBOW ASSY WITH HOSV, RELIEF VALVE, & TORQUE RELEASE VALVE, INCL BOLTS & LOCKWASHERS 8126 PUMP CASE PRESSURE RELIEF VALVE 8108 PUMP BLOCK ELBOW ASSY, INCL BOLTS & LOCKWASHERS, 75 2 6403 SWIVEL RETAINING PIN & CHAIN, 1" DIA X 10" GRIP, FOR USE ONLY WITH ELEVATOR BAIL 76 1 8384 SWIVEL RETAINING PIN & CHAIN, 1" DIA X 11 3/8" GRIP 76 1 6410 SWIVEL RETAINING PIN & CHAIN, DIAX 8 1/2" GRIP RADIATOR PROTECTION PLATE. OIL DRIP RAIL, SEAL WELDED, INCL DRAINS 143 1 ese7 CASE PRESSURE GAGE, 100 PSI 1g 158537 AIR RELIEF POPOFF VALVE, 7 145 1 8991 HYD. HOSE ASSY. 3/8" (2-WIRE) x 23" LG., FAX x FIX = 146 1-42"- 5000 QD COUPLER FEMALE HALF - 147 "4472" 8900 QD NIPPLE MALE HALF cae © _XKe150 CROSSOVER SUB, 4" FH BOX x 3-1/2" IF PIN 149 + 8651 LUBE OIL PUMP AND HOSE 150 + 9525 STAINLESS STEEL NAME TAG 151 2 9537 CHARGE PRESSURE GAGE MOUNTING BRACKET WELDMENTVenturetech Customer Parts List Assy P/N: 8468 Created: 5/31/2006 Revised: 6/11/2008 Page 1 of f Description: XK-150 DUAL TANK ASSEMBLY, 110 GALLON/110 GALLON “a Qty Part# Description 1 1 e402 DUAL 110 GALLON HYD RESERVOIR AND DIESEL TANK FABRICATION 2 2 5192 SUCTION STRAINER MAGNETIC, 1%" NPT WITH BYPASS 3 2 6495 RETURN DIFFUSER O41 8694-02400-2 PIPE, 1-1/4" SCH, 40, ALUMINUM, 6069-76 x 24" LG THD BOTH ENDS — "8891-023 50-2 PIPE, 1-1/4" SCH. 40, ALUMINUM, 6063-T6 x 23-1/2" LG THD BOTH ENDS: 6 1 8895-024. 00-2 7 "PIPE, 1412" SCH. 40, ALUMINUM, 6063-16 x2 MLG THD BOTH ENDS 8 8890-025.00-2 _ ‘PIPE, SCH. 40, ALUMINUM, 6063-T6 x 25" LG THD BOTH ENDS. 8 2 8886-035.001 PIPE, 1/2" SCH. 40, ALUMINUM, 6062-76 X 25" LG., THD. ONE END 10 1 8888-018.00-1 PIPE, 1/2" SCH 40, ‘ALUMINUM, 6063-T8 x 18 LG THD ONE, END 11 1 8823 " NPT 300#, BLACK CAST IRON a 2 8822 STREET ELL, 1-1/4" NPT 300#, BLACK CAST IRON 8 1 8821 STREET ELL, 1" NPT 300#, BLACK CAST IRON 14 3 8819 STREET ELL, 1/2" NPT 300#, BLACK CAST IRON 15 1 9335-1-1/2X1-1/4 BUSHING, HEX, 4-1/2" M-NPT X 1-1/4" F-NPT, BLACK CAST IRON DIESEL TANK CAP 16 1 3419 7 2 4348 CLEANOUT COVER, 18° i 18 2 6791 "TANK COVER SCREW “19 2 6170-216 O-RING, 2-216, BUNA-N 70 DURO 20 2 8818 PIPE PLUG, 2" NPT, BLACK CAST IRON a 2 8817 PIPE PLUG, 1-1/2" NPT, BLACK CAST IRON ro FILLER-BREATHER, 3 PSI 34 9335-1-1/4X1 BUSHING, HEX, 1-1/4" M-NPT X 1" F-NPT, BLACK CAST IRON 24 1 49 MOUNT BAR, TORQUE BOX TO TANK TOP > 1 8269 FLUID LEVEL & TEMP GAUGE, 15" CONTROL PANEL STORAGE MOUNT ON TANK, 26 1 7433Venturetech Customer Parts List Assy P/N: 8364 Created: 3/9/2006 Revised: 7/28/2010 Page 1 of 1 Description: HYDRAULIC TANK ASSEMBLY, XK-150 TRAILER FENDER MOUNT tem Qty Part # Description 1 1 8479 HYDRAULIC TANK FABRICATION, XK-150 TRAILER FENDER MOUNT 2 1 891-011.00-2 PIPE, 1-1/4" SCH. 40 ALUMINUM, 6083-T6 X 11" LG., THD. BOTH ENDS 3 1 5192 SUCTION STRAINER MAGNETIC, 1%" NPT WITH BYPASS 4 1 8816 PIPE PLUG, 1-1/4" N.P.T., BLACK CAST IRON, 6 1 8888-011.00-1 PIPE, 1/2" SCH. 40 ALIMINUM, 6063-T6 x 11" LG, THD ONE END. 7 1 e819 STREET ELL, 1/2" NPT 300#, BLACK CAST IRON 8 2 5404-24-24 4-1/2" M-NPT X 1-1/2" M-NPT HEX NIPPLE ve 1 8607-008.60-2 —_~PIPE, 1-1/4" SCH. 40 ALUMINUM, 6069-76 x6-172"LG, THD BOTH ENDS 10 1 6495 RETURN DIFFUSER " + 8890-011.00-1 PIPE, 1" SCH 40, ALUMINUM, 6063-T6 x 11" LG.,THD ONE END 1 8821 STREET ELL, 1" NPT 300#, BLACK CAST IRON 13 1 8823 STREET ELL, 1-1/2" NPT 300#, BLACK CAST IRON. 6 1 7149 MOUNT BAR, TORQUE BOX TO TANK TOP. 6 1 7433 CONTROL PANEL STORAGE MOUNT ON TANK, 7 1 8617 FILLER BREATHER STRAINER, 5 PSI S/S, CHROME CAP, FOR TRAILER TANKS CLEANOUT COVER, 18” 19 2 6791 TANK COVER SCREW 20 2 6170-216 O-RING, 2-216, BUNA-N 70 DURO 24 1 8818 PIPE PLUG, 2 NPT, BLACK CAST IRON 22 1 8817 PIPE PLUG, 1-1/2" NPT, BLACK CAST IRON 23 1 8269 FLUID LEVEL & TEMP GAUGE, 15"Venturetech Customer Parts List Assy PIN: 8363 Created: 3/9/2006 _—_—Revised: 6/10/2008 Page 1 of 1 Description: DIESEL TANK ASSEMBLY, XK-150 TRAILER “tem Qty Part# Description 1 1 8486 DIESEL TANK FABRICATION, XK-150 TRAILER 2 1 4348 CLEANOUT COVER, 18" 3 1 671 TANK COVER SCREW 4 1 6170-216 O-RING, 2.216, BUNA-N 70 DURO 5 1 8818 PIPE PLUG, 2" NPT, BLACK CAST IRON. 6 1 8817 PIPE PLUG, 1-112" NPT, BLACK GAST IRON 7 1 3819 2" DIESEL TANK GAP 8 2 8819 STREET ELL, 1/2" NPT 300#, BLACK CAST IRON 9 2 8888-014.75-1 PIPE, 1/2” SCH. 40, ALUMINUM, 6063-T6 X 14-3/4" LG., THD. ONE ENDte ist Assy PIN: 7481 Venturetech Customer Parts Lis Created: 8/21/2003 Revised: 8/29/2008 Page 1 of 1 Description: D-BLOCK ASSEMBLY m Qty Part# Description 1 1 7418 D-BLOCK, ELECTROLESS NICKEL PLATED, MASK BOLT HOLES AXLE WEAR SLEEVE, ELECTROLESS NICKEL PLATED 3 3 SC-3/8-16X0.76SS__ SOC CAP, 3/8-16UNC X 3/4 LG. STAINLESS STEEL RETAINING RING 2 6441 SPLIT NYLON BUSHING FOR D-t BLOCK BEARING 6 - 2 6502 a SEAL, HIGH PRESSURE TEFLON _ _ - 8 + 6170-154 ‘ORRING, 2-164 70 DURO BUNAN : “a + 6170-153 O-RING, 2.16370 DURO BUNAN a 10 1 6170-142 (O-RING 2-142 70 DURO BUNA-NVenturetech Customer Parts List Assy PIN: 8249 Created: 10/18/2005 Revised: 11/27/2006 Page 1 of 1 Description: 1-1/2" THERMAL BYPASS VALVE ASSY FOR 8107 OIL COOLER m Qty Part# Description 0 0 7918 THERMAL BYPASS VALVE ASSEMBLY DRAWING. 1 1 8109 90 DEGREE ELBOW, 1-1/2MB X 1-1/2" MB 2 1 ati0 TEE, 1-1/2"MB RUN X 1-1/2MJ O-RING RUN & BRANCH 3 1 ttt THERMOSTATIC VALVE, 1-1/2" O-RING PORTS 4 1 atts ADAPTER, 1-1/2"MB X SPECIAL 1-1/2" SLIP IN TUBE CONNECTION FLARED TUBE AND NUT, FOR 6107 OIL COOLER 14 O-RING, 2-222 BUNA-N 70 DURO 3-924 O-RING, BUNA-N 70 DUROVenturetech Customer Parts List Assy PIN: — 6606 Created: 1/24/2001 Revised: 7/2/2009 Page 1 of 1 Description: AIR STROKER KIT, 90/250 a Qty Part # Description 1 1 8170 BRACKET, AIR STROKER, TILTED SUNSTRAND 90/250 2 1 3406-4 PUMP STROKING CYLINDER, 10-60 PSI 3 1 8187-7F ROD EYE, 7/16" FEMALE 4 3 HC-8MMX25 HEX CAP, 8MM X 25MM LONG 5 1 HC-3/8-16X1.75 6 1 HC-7/16-14x1.25 7 1 NLN-3/8-16 NYLOC NUT 3/8” x 18UNC GRS Zn PLATED 8 1 Lw7e LOCKWASHER, 7/16” 9 1 7249 MODIFIED PUMP LEVERVenturetech Customer Parts List Assy PIN: 8864 12/2007 Revised: 6/12/2008 Page 1 of 1 Description: TORQUE CONTROL BOX ASSEMBLY, WITH HYDRAULIC TORQUE GAGE, XK-150 Item Qty Part# Description Created: 0 0 8861 TORQUE CONTROL BOX ASSEMBLY LESS TORQUE GAGE, —XK- 90, XK-150 & XK-250 1 1 8154 TORQUE BOX FRONT PLATE, STAINLESS. 2 1 6004 TORQUE GAUGE ASSEMBLY, XK-150, 12000 FT-LBS @ 5000 PSI 3 (8 9276-#6-32-0,50SS__ SCREW, PHILLIPS, OVAL, COUNTERSUNK HEAD, NO. 6-32UNC X 1/2" LONG, STAINLESS STEEL 4 3 NLN-#6-328S NYLOC NUT #6 X 32UNC SS 7 5 2 FW.5I16SS FLAT WASHER, 6/16", SS 6 4 9305-114-20 STEEL NLN-1/4-208S NYLOC NUT 4/4" x 20UNC SS 8 1 6500-06-06 3/8" M-JIC X 3/8" F-JIC, 90° SWIVEL ELBOW 9 1 7255.06.04 ——=—«ADAPTER, 3/8" COMPRESSION TUBE X 1/4" FEMALE NPT ¥ 4 8161 TORQUE CONTROL BOX, FABRICATION 38 7460 BULKHEAD FITTING, 3/8" COMP. TUBE X 3/6" MJ ROUND TUBING, 3/8" DIA. X 049" WALL THICKNESS X 31” LONG, STAINLESS STEEL 12 1 9330-3/8x31 8 1 8209 TORQUE BOX INLINE FILTER, 50 MICRON, 1/4°FP x 1/4°FP “wt Tae PVCTRIM,CLIPON - 16 1 7318-06-06 3/8"COMPRESSION TUBE (FLARELESS) X 3/8" M-ORB 16 i 5086 CARTRIDGE, MAX TORQUE SETTING v7 2 HC-SI16-18X.75SS__ HEX CAP, 5/16"-18 X 3/4 LONG STAINLESS 18 1 7518-06-06 ADAPTER, SODEG, 3/8 COMP. TUBE X 3/8 MALE BOSS 04 7318-06-06 318°COMPRESSION TUBE (FLARELESS) X 3/8” M-ORB - 20 1 6HPSON-S PLUG, #6 SAE ST. THREAD, SOC. HD., STEEL 24 1 e210 VALVE BODY FOR TORQUE BOX CARTRIDGE, ar) TWO-PIECE KNOBKIT, 9/824.Venturetech Customer Parts List Created:8/8/2005 Revised: 9/18/2008 Page 1 of 2 Description: XK-150, AIRCONTROL PANEL ASSEMBLY, WITH BRAKE a Qty __—Part# Description Assy PIN: 8168 0 0 6928 XK-150, & 250 REMOTE AIR CONTROL PANEL ASSEMBLY, WITH. BRAKE 1 1 e153 BOX, STAINLESS, REMOTE PANEL 2 1 6004 TORQUE GAUGE ASSEMBLY, XK-150, 12000 FT-LBS @ 5000 PSI 3 1 20481 (QD, %'-8500 MALE HYDRAULIC FITTING 4 1 27889 QD, %'-6500 AD DUST CAP, 5 1 8159 ENGRAVED PANEL W/ HANDLEBAR CUTOUTS, 6 3 9276-#6-32-0.508S __ SCREW, PHILLIPS, OVAL, COUNTERSUNK HEAD, NO. 6-32UNC X 1/2" LONG, STAINLESS STEEL 7 3 NUN-#6-328S, NYLOC NUT #6 X 32UNC SS 8 3 6873 PUSHBUTTON ASSY, RED 9 1 6332 PUSHBUTTON VALVE MOUNTING BLOCK, FOR CONTROL PANEL 8072 4 1 6870 PUSHBUTTON VALVE FOR BRAKE, DETENTED, NOT INCLUDING AIR PILOT OPERATOR “2 + 6962 AIR PILOT OPERATOR FOR BRAKE PUSHBUTTON RETURN 13 1—6956.=—=—SSS—CSSTAINLESS TUBING PROTECTOR RAIL FOR XK-180 PANEL 14 3 4275 ~~ NYCOIL, 4/4" TUBE X 1/4" NPT, MALE SWIVEL RUN TEE "57144" 15 2 SC-1/4-20X0.75SS _ SOC CAP, 1/4-20 X 3/4 LONG, STAINLESS STEEL 16 48 NUN-/4-2088 NYLOC NUT 14"x20UNCSS “7 4 SC-1/4-20X0.63SS SOC CAP, 1/4-20X 5/8 LONG, STAINLESS STEEL - 18 1 iis AIR SHUTTLE VALVE, 1/8" NPT _ 19 2 HC-1/4-20X2 1/288 HEX CAP, 14".20 X 214" LONG STAINLESS, 20 6 —-HO-4/4-20X1.25S8 HEX CAP, 1/4-20UNC X 1-1/4" LONG, STAINLESS STEEL 24 1 JNGI6-1088 —_JAMINUT, 3/4 X 10UNG, STAINLESS STEEL WASHER, 3/4" TYPE B, NARROW, STAINLESS STEEL 23 1 6934 PANEL HOLE PLUG 24 2 6898 PUSHBUTTON VALVE, AIR,Venturetech Customer Parts List Created: 8/8/2005 Revised: 9/18/2008 Page 2 of 2 Description: XK-150, AIR CONTROL PANEL ASSEMBLY, WITH BRAKE eee m Qty Part# Description OT Assy P/N: 8168 25 4 9305-5/16-18X1.00SS SCREW, PHILLIPS, PAN HEAD, 5/16-18NC X 1" LONG, STAINLESS STEEL 28 “740 MOUNTING BRACKET ASSEMBLY, REMOTE PANEL TO STAND, XK- 90 & XK-150 a1 (88 SAFETYPIN —- 28 1 5058 12" OF 1/8" STRAIGHT LINK PLATED CHAIN “m2 4369—SSCSPLITRING, 188" 30 4 NLN-5/16-18SS_ NYLOG NUT 5/16" x +8UNC ss — - ci 8 19308-1/4-20X1 25SS_ screw, PHILLIPS, PAN HEAD, 1/4-20NC X 1-1/4" LONG, STAINLESS: @ 17613. = CAIRMANIFOLD FOR CONTROL PANEL 33 3 9138 PIPE PLUG, SOC HEX, 1/4" NPT STAINLESS STEEL 34 4 4279 NYCOIL, 1/8" MP, SWIVEL ELL **"57942"* i 1 e469 1/4" ASSORTED COLORED POLYURETHANE TUBING FOR CONTROL, PANEL, 10’ LONG 36 1 217 QUICK EXHAUST AIR VALVE, 1/4" SQE2 a7 1 8404-04-04 4/4" M-NPT X 1/4" M-NPT HEX NIPPLE 38 1 6337 NYCOIL, 4/4" TUBE X 1 NPT, MALE SWIVEL BRANCH TEE ses72aqt 39 8 54307 OD, %MALEAIR FITTING —_ a 40 1404-02-02 118" MANPT X 1/8" M.NPT HEX NIPPLE 41 1 8886 CNYCOIL, 4/4” TUBE X 1/0" NPT, MALE SWIVEL BRANCH TEE wp7242"0" 42 1 5502-02-02 1/8" M-NPT X 1/8" F-NPT, 90° STREET ELBOW 43 4 4273 NYCOIL 1/4" MP, STRAIGHT "™""56844""*" 44 4 42m7 NYCOIL 1/4" MP, SWIVEL ELL ***57944**** 4 Fw4toss FLAT WASHER, #10 STAINLESS STEEL 4 NLN-10-328S NYLOC NUT, #10-32UNF STAINLESS STEEL a7 4 9276-#10-32-0.75SS SCREW, PHILLIPS, OVAL, NO. 10-32 UNC X 2/4" LONG, STAINLESS STEELVenturetech Customer Parts List Assy PIN: = 9143 Created: 12/14/2007 Revised: 12/20/2007 Page 1 of 1 Description: LONG TORQUE ARM ASSEMBLY, XK-150, VK, 3.5, , WITH SELF- LUBRICATING ROLLING SHEAVES item Qty Part Description ° Oo stat TORQUE ARM ASSEMBLY LONG TORQUE ARM WELDMENT, XK-150, VK, 3.5 2 2 9183 SHEAVE, SELF-LUBRICATING MATERIAL, TORQUE ARM 4 1 7529 1/8" NPT GREASE FITTING 5 2 9187-.13-2.00 COTPN 1/8" DIA. x 2" LG. ZINC PLATED 6 2 HN-3/4-10 HEX NUT 3/4-10UNC GR-8 Zn PLATED 7 1 3300 TORQUE ARM RETAINER PIN ASSY, 1" DIA X 4" GRIPXK-150 Troubleshooting SYMPTOMS No torque or low torque Starts to turn, then stops and torques up to torque box setting No charge pressure Delayed reaction going into forward or reverse XK-150 Troubleshooting Adjust torque at torque box up to desired maximum. Swivel motor relief valves not set or set too low. Adjust setting using procedure in maintenance section. Quick-Disconnect check valves could close if snap ring comes loose. Replace QD. (Remove check valves in QD to finish a job). « New hoses not full of oil yet. Wait several minutes with engine idling. « Pump not turning — drive spline could be sheared « Bad gauge * Bad pump Water in air system. Blow water out of pump actuator and lines. Keep water separator drained. Low air pressure— should be set to 90 psi minimum.TORQUE BOX CARTRIDGE REPLACEMENT Use a 3/32” Allen wrench to loosen the set screw. After loosening, turn the knob counter-clock wise to remove. Use a small pry bar or screwdriver to pull off locking knob.Use a 7/8” deep socket to unscrew the valve from the valve body. Remove PIN 5086 cartridge from the torque box.