TC8081

Atlantic Star
Pod Assembly
P/N 308106-00-15
TC8081
Cameron · P.O. Box 1212, Houston, Tx 77251-1212 · 713-939-2211 · http://www.c-a-m.com

All the information in this manual is the exclusive property of Cooper
Cameron Corporation, Cameron Division. Any reproduction or use of
the calculations, drawings, photographs, procedures, or instructions, ei-
ther expressed or implied, is forbidden without the expressed written
permission of Cameron or its authorized agent.
Initial Release 01
May 2006
Copyright © 2006 all rights reserved

by
Cooper Cameron Corporation, Cameron Division
TC8081 ii
PREFACE
The procedures included in this book are to be performed in conjunction
with the requirements and recommendations outlined in API Specifica-
tions. Any repairs to the equipment covered by this book should be done
by an authorized Cameron service representative. Cameron will not be
responsible for loss or expense resulting from any failure of equipment or
any damage to any property or death or injury to any person resulting in
whole or in part from repairs performed by other than authorized
Cameron personnel. Such unauthorized repairs shall also serve to termi-
nate any contractual or other warranty, if any, on the equipment and
may also result in equipment no longer meeting applicable require-
ments.
File copies of this manual are maintained. Revisions and/or additions will
be made as deemed necessary by Cameron. The drawings in this book are
not drawn to scale, but the dimensions shown are accurate.
This book covers Cameron products, which are products of Cooper

Cameron Corporation.
Cooper Cameron Corporation

Cameron Division
P.O. Box 1212
Houston, Texas 77251-1212
713-939-2211
http://www.coopercameron.com
TC8081 iii
TC8081 iv
Table Of Contents
Section 1 - Description
Section 2 - Operation
Section 3 - Maintenance
Section 4 - Troubleshooting
TC8081 v
TC8081 vi
Section 1
Description
I. Pod Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Part Number 308106-00-15
SK-7012 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
SK-308132-00-15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Control Pods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
TC8081 1-1
TC8081 1-2
Description : Pod Assembly
Part Number: 308106-00-15 Revision: 1
ITEM REV COMPONENT QTY UNIT DESCRIPTION

1 E01 107615 1 Ea Plate, Upper, Pod
2 H01 107616 1 Ea Pod Plate, Lower, Retractable Connectors
3 D01 107046 1 Ea Post, Support, Pod
4 2 307246-11 11 Ea Connector, Male, Double 1/4-Inch, Retractable
5 J04 307244-11 10 Ea Connector, Male, 1-In, Retractable, Sst
6 H02 307245-11 3 Ea Connector, Male, Retractable 1.5 In Sst
Valve,Piloted,1/4",4-Way 3-Pos,3000 Psi, Sst, Spring
7 L02 309068-01 10 Ea
Centered
Valve, Piloted Dual,1",3-Way,3000 Psi, Sst, W/Weld
8 A02 309932-04 4 Ea
Flange,
Valve, Piloted Dual,1-1/2",3-Way, 3000 Psi, Sst,
9 C03 309535-03 1 Ea
Spring Return
Regulator, 1-1/2" Sst Assembly- Hydraulic Pilot Op-
10 F08 309536-01 2 Ea
erated, 0-3000 Psi W.P.
11 F01 107005-01 2 Ea Bracket, Mounting, 1-1/2" Pressure Regulator
12 F01 107005-02 2 Ea Bracket, Mounting, 1-1/2" Pressure Regulator
Valve,Piloted,1-1/2",3-Way,3000 Psi Sst, Spring
13 C03 309535-02 1 Ea
Return.
Valve, Piloted Dual,1",3-Way,3000 Psi, Sst, Spring
14 A03 309932-03 1 Ea
Return
Elbow, 90 Deg Male 1-1/4 Npt X 1-1/4 Tbg
15 204890-11-07-22 4 Ea
Swagelok Sst 316
Tee, Tbg Male Run 1/4 Npt X 1/4 Tbg Swagelok Sst
16 204892-03-02-22 6 Ea
316
17 1 307651-02 3 Ea Lock, Pod Release Assembly, Hyd.
Elbow, 90 Deg Male 1/4 Npt X 1/4 Tbg Swagelok Sst
18 204890-03-02-22 30 Ea
316
19 1 107370 9 Ea Pin, Retaining, Pod Cover
Screw, Hex Hd Cap .500-13 X 1 Sst 316 /A193 Cl 1 Gr
20 702502-10-00-10 9 Ea
B8m B18.2.1
21 C01 107007 2 Ea Post, Mounting, Subsea Pod
Restrictor,1/4" Nptf X 1/4" Nptm, Orifice .046 Dia
22 D02 107800-01 4 Ea
(351 Lohm)
Tubing, Hydr., Sst 316/316l Dual Rated Seamless
23 2711865-24-13 10 Ft
1.500 X .120w Astm A213/A269
24 2711865-20-11 20 Ft
1.250 X .095w Astm A213/A269
25 2711865-06-07 50 Ft
0.375 X .035w Astm A213/A269
26 2711865-04-07 165 Ft
0.250 X .035w Astm A213/A269
TC8081 1-3

Tee, Tbg Male Branch ¼ Npt X 1/4 Tbg Swagelok
27 204893-03-02-22 48 Ea
Sst 316
Tee, Tbg Male Branch ¼ Npt X 3/8 Tbg Swagelok
28 204893-05-02-22 12 Ea
Sst 316
Connector, Tbg Male 1-1/4 Npt X 1-1/4 Tbg
29 204887-11-07-22 9 Ea
Swagelok Sst 316
30 706235 3 Ea Elbow, 90 Deg Braze/Weld 1-1/4 Tbg Sst 316
Nipple, Pipe-Regular 1/4 X 3.00lg 304 Sst Sch 80
31 201181 4 Ea
A312
32 702502-10-00-20 6 Ea
B8m B18.2.1
33 702502-16-00-20 12 Ea
B8m B18.2.1
Screw, Hex Hd Cap .625-11 X 1.5 Sst 316 / A193 Cl 1
34 702502-14-00-14 8 Ea
Gr B8m B18.2.1
Screw, Hex Hd Cap .375-16 X 0.625 Sst 316 / A193 Cl
35 702502-06-00-05 16 Ea
1 Gr B8m B18.2.1
36 204890-05-01-22 20 Ea
316
Washer, .500 Hel Spr Lock Sst 18-8 Regular Duty
37 702529-13-02 18 Ea
Ansi B18.21.1
38 702529-15-02 22 Ea
Ansi B18.21.1
39 702529-17-02 12 Ea
Ansi B18.21.1
Plug, Pipe-Threaded Hex Hd 1/4 Sst 316 / B16.11,
40 204800 10 Ea
8000 Psi Mawp
41 2710981-04 6 Ea Pipe Plug Hex Hd 1-1/4" Npt Nom, 316 Sst
42 2710981-02 1 Ea Pipe Plug Hex Hd 1-1/2" Npt Nom, 316 Sst
Screw, Hex Hd Cap .625-11 X 1.25 Sst 316 / A193 Cl
43 702502-14-00-12 14 Ea
1 Gr B8m B18.2.1
44 B01 107009-02 8 Ea Clip, Mounting, Pod Cover
U-Bolt, Round Bend .25 X 3.9 X 2.43 X 1.75 / Ifi Sst
45 203655-06-02 6 Ea
316
Accumulator, Hyd 30 Cu In 3000 Psi 3/4 Npt Port
46 704132 4 Ea Piston Type Viton Seals .001 Thk Exterior Electroless
Ni Pl
50 702505-02-00-24 16 Ea Screw, Soc Hd Cap .250-20 X 2.5 Sst 316
Manifold, 316 Ss, Three 1.5" Npt Ports “Rc” Subsea
51 A01 2186152-01 1 Ea
Pod
Valve,Piloted,1/4",4-Way 2-Pos,3000 Psi,Sst,(Unbal-
52 A01 309478-02 3 Ea
anced)
TC8081 1-4

Nipple, Hex, 5300 Psi, 1" Npt, Sst Conn.: 1" Npt
53 619023-04-07 10 Ea
Nom. Press.: 5300 Psi / 360 Bar Material: Sst 316
Shipping Cover, Junction Box Plate For Pods And
54 A01 204678 1 Ea Hose Reels Marine & Petro Supply (Jack Porterfield
Die P/N 204-678) 486- 9426
Valve, Check, 1/4" Npt Female X 1/4" Npt Female,
55 2711402-01 3 Ea
6000 Psi, 316 Sst
Connector, Tbg Male 1-1/2 Npt X 1-1/2 Tbg
56 204887-12-08-22 6 Ea
Swagelok Sst 316
Connector, Tbg Male 1/4 Npt X 3/8 Tbg Swagelok
57 204887-05-02-22 20 Ea
Sst 316
58 204890-03-01-22 20 Ea
316
Pod Identification Letter B, Double Plex
59 A01 2020055-08-34 4 Ea
Materal,Black
Pod Identification Letter Y, Double Plex
60 A01 2020055-08-35 4 Ea
Materal,Black.
Screw, Hex Hd Cap .500-13 X 1.5 Sst 316 / A193 Cl 1
61 702502-10-00-14 12 Ea
Gr B8m B18.2.1
Tee, Tbg Male Branch 1/8 Npt X 1/4 Tbg Swagelok
62 204893-03-01-22 4 Ea
Sst 316
63 204897-03-00-22 4 Ea Tee, Union- Tubing 1/4 Tube Sst Swagelok
64 B01 106314 1 Ea Weldment, Lift Bracket, Pod
65 2725387-01 4 Ea Tee, Union, 3/8" Tubing, Stainless Steel
66 B01 107759 4 Ea Nipple, Special,1-1/2"
67 2710981-01 4 Ea Plug, Pipe Threaded, Hex Hd 1" Npt B16.11
68 B01 107387-01 1 Ea Bracket, Pod Assembly
69 B01 107387-02 1 Ea Bracket, Pod Assembly
Elbow, 90 D Union Soc Weld 1-1/2 Tbg Weld- Lok
70 203615 5 Ea
316 Sst
Elbow, 90 Deg Male 1-1/2 Npt X 1-1/2 Tbg
71 204890-12-08-22 3 Ea
Swagelok Sst 316
72 1 107113 1 Ea Retainer Plate, Junction Box, Est. Wt. 10.
Female Connector, 1", Hyd. Junction Box,4" X 11
73 A01 106309-03 1 Ea
5/8" 316l Sst
74 C02 105085 6 Ea Screw, Keeper Plate, Hyd. Junction Box, Sst
Quick Coupling, Socket ¼ Female Npt 316 Sst 3000
75 709249 46 Ea
Wp
Connector, Tbg Female ¼ Npt X 1/4 Tbg Swagelok
76 204888-03-02-22 45 Ea
Sst 316
Nipple, Pipe-Regular 1/4 X 2.00lg 304 Sst Sch 80
77 201641 45 Ea
A312
TC8081 1-5

Tee, Pipe- Threaded Female 4-Jan
78 202807 2 Ea
3000 Psi 316l Sst /B16.11
79 204887-03-02-22 5 Ea
Sst 316
80 700451 10 Ea Nipple, Pipe-Close ¼ Sst 316 Sch 80
81 204887-03-01-22 10 Ea
Sst 316
Plug, Pipe-Threaded Hex Hd Sst 316 6400 Psi /
82 704426 2 Ea
B16.11
Valve,Piloted,1/4",4-Way 2-Pos,3000 Psi,Spring Re-
84 H05 309069-05 1 Ea
turn, Sst,For Subsea Service
85 B01 108137-01 1 Ea Cover, Pod
86 B01 108137-02 1 Ea Cover, Pod
87 B01 108137-03 1 Ea Cover, Pod
88 B01 108137-04 1 Ea Cover, Pod
89 A01 111371-01 4 Ea Bracket, Mounting, Accumulator, 30 Cu-In
90 A01 111371-02 4 Ea Bracket, Mounting, Accumulator, 30 Cu-In
U-Bolt, Round Bend .250 X 8 X 3.00 X 1.00 /Ifi Sst
91 705422 8 Ea
316
Nut, Hvy Hex .250-20 Sst 316 Ansi B18.2.2/ A194 Gr
92 2709000-01-39 16 Ea
8m Ident & Pkg Per Dwg 2709000
0 E01 308132-00-15 1 Ea Flow Diagram Hyd. B.O.P. Control System
0 A01 SK-007012 1 Ea Pod Assembly
TC8081 1-6
TC8081 1-7
TC8081 1-8
TC8081 1-9
TC8081 1-10
TC8081 1-11
TC8081 1-12
TC8081 1-13
TC8081 1-14
CONTROL PODS
The Control Pods contain the valves that direct the hydraulic power fluid to
the various components for the operation of the blowout preventer stack.
The hydraulic fluid is supplied to the pods through the 1" lines in the Control
Hose Bundles and from the subsea accumulators. The pods contain pressure
regulators, three- way two-position and four-way three-position pilot oper-
ated valves.
There are two identical control Pods on each stack, color coded blue and yel-
low, and each pod can be independently lowered and retrieved.
TC8081 1-15
TC8081 1-16
Section 2
Operation
I. Install the Control Pods . . . . . . . . . . . . . . . . . . . . . . . . 2-3
II. Run the Stack and riser . . . . . . . . . . . . . . . . . . . . . . . . 2-5
III. Retrieve the Stack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
IV. Retrieve the Pod . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
V. Lower the Pod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
TC8081 2-1
TC8081 2-2
OPERATING PROCEDURES
I. INSTALL THE CONTROL PODS
A. Operate the following at the master hydraulic Control Panel.
1. Move the Operating Mode switch to LOCAL.
2. Move the BOP, the Annular Preventer, and the Ball Joint Regulator
Control Selectors to LOCAL.
3. Set the BOP, the annular Preventer, and the Ball joint regulators on
zero psi.
4. Move the Panel Pressure control switch to VENT.
B. Connect a Jumper hose to each reel.
C. Connect the reel hoses to the Control Pods. (Blue reel hose to Blue Pod;
Yellow reel hose to Yellow Pod.)
D. Set the control pods in place on the female baseplate.
E. Align the rotational pins on the baseplate with aligning holes in the
lower pod plate.
Note: The gap between the male housing and the female sockets is not more than
1/8 inch.
F. Operate the following at the Master Hydraulic Control Panel.
1. Move the Pod Connector Riser and Pod Connector Stack valves to
RETRACT, (Blue Pod and Yellow Pod)
Caution: All pod connectors must be in the RETRACT position before hydraulic
pressure is applied. Other stack functions must be in the center position.
2. Set the Panel Pressure on 2000 psi.
3. Move the Panel Pressure Control switch to OPEN.
TC8081 2-3
Note: Allow three minutes for the pressure to stabilize. Observe the panel pressure
at the Panel Pressure gauge.
4. Move the Pod Connector riser valve to EXTEND. (Blue Pod and Yellow
Pod)
Note: Allow five minutes for the connectors to fully extend.
5. Move the Pod Lock valves to LOCK. (Blue Pod and Yellow Pod)
Note: Allow one minute for locks to operate.
6. Move the Pod Selector valve to BLUE.
7. Observe the Flow Counter to ensure that the riser accumulators are
full.
8. Set the BOP regulator on 1500 psi.
9. Set the ball joint on 1000 psi.
10. Test thr riser functions of the Blue Pod according to rig procedures.
11. Move the Selector valve to YELLOW.
12. Test the riser functions of the Yellow Pod according to rig procedures.
G. Install the Riser Stab Assembly on the Blowout Preventer Stack.
1. Move the Stab Plate Locks to UNLOCK.
2. Move the Stab Plate Jacks to RAISE.
3. Install the Riser stab Assembly on the BOP Stack.
4. Ensure that the Riser Stab Assembly alignment pins are properly en-
gaged.
5. Move the Riser Connector to LATCH.
6. move the Stab Plate Jacks to LOWER.
7. Move the Stab Plate locks to LOCK.
H. Operate the following at the Master Hydraulic Control Panel.
1. Move the Pod Connectors Stack to EXTEND (Blue Pod and Yellow
Pod). Allow ten minutes for the connectors to fully extend.
TC8081 2-4
2. Test the stack functions of the Yellow Pod according to rig proce-
dures.
3. Move the Selector valve to BLUE.
4. Test the stack functions of the Blue Pod according to rig procedures.
II. RUN THE STACK AND RISER
A. Install the Control Pods and Riser Stab Assembly as outlined in Part I
above.
B. Operate the following at the Master Hydraulic Control Panel.
1. Set the BOP, the Annular Preventer, and the Ball joint regulators on
zero psi.
2. Move the Panel Pressure Control switch to VENT.
3. Set the Panel Pressure regulator on 1500 psi.
4. Move the Pod Lock valves to LOCK. (Blue Pod and Yellow Pod).
C. Disconnect the Jumper Hoses from the reels.
D. Operate the following at the Powered Hose Reel Panels.
1. Move the Stab Plate Jacks to LOWER.
2. Move the Stab Plate Locks to LOCK.
4. Move the Wellhead Connector to UNLATCH.
5. Move the Shear Ram to OPEN.
6. Move Ram #4 to OPEN.
7. Move the Retractable Connectors Stack to Extend.
8. Open the Pod Connectors and Pod Lock Actuator valve.
TC8081 2-5
Note: Set the controls on both reel panels identically.
E. Select one pod for control.
F. Operate the following at the Master Hydraulic Control Panel.
1. Move the Selector valve to the pod selected (Blue Pod or Yellow Pod).
G. Operate the following at the Reel Panel of the system selected.
1. Open the BOP Regulator valve.
2. Open the Panel Supply valve.
H. Lower the stack and riser according to rig procedures.
I. Operate the following at the Hose Reel Panel.
1. Move the Wellhead Connector to LATCH.
Caution: Ensure that the stack is in the proper position on the wellhead before
latching the wellhead connector.
2. Test the wellhead connection accoring to rig procedures.
3. Close the BOP Regulator valve.
4. Close the Panel Supply valve.
5. Move all the valves to the center position.
J. Unreel enough hose to allow for rig heave according to rig procedures.
K. Set the brakes and lock the reels in position.
L. Connect the Jumper hoses to the reels.
TC8081 2-6
M. Operate the following at the Master Hydraulic Control Panel.
1. Move all the valves to the desired positions for operation.
2. Set all hydraulic pressures to normal operating pressures according to

rig procedures.
3. Move the Panel Pressure Control valve to OPEN.
N. The Control System is ready for drilling operations.
III. RETRIEVE THE STACK
A. Operate the following at the Master Hydraulic Control Panel.
1. Set the BOP, the Annular Preventer, and the Ball Joint regulators on
zero psi.
Note: Allow two minutes for signal hoses to bleed to zero psi.
2. Move the Panel Pressure Control switch to VENT.
3. Set the Panel Pressure regulator on 1500 psi.
4. Ensure that the Riser Connector and Wellhead Connector valves are
on LATCH and the Pod Connectors Stack is on EXTEND.
B. Disconnect the Jumper Hoses from the reels.
C. Operate the following at the Powered Hose Reel Panels.
1. Move the stab plate jacks to LOWER.
2. Move the Stab Plate Locks to LOCK.
4. Move the Wellhead Connector to LATCH.
5. Move the Shear Ram valve to OPEN.
6. Move Ram #4 to OPEN.
TC8081 2-7
7. Move the Retractable Connectors Stack to EXTEND.
8. Open the Pod Connectors and Pod Lock Actuator valve.
Note: Set the controls on both reel panels identically.
D. Select one pod for control.
E. Operate the following at the Master Hydraulic Control Panel.
1. Move the Selector valve to the pod selected (Blue Pod or Yellow Pod).
F. Operate the following at the reel panel of the pod selected.
1. Open the BOP Regulator valve.
2. Open the Panel Supply valve.
3. Move the Wellhead connector valve to UNLATCH.
G. Raise the stack and riser according to rig procedures.
H. Operate the following at the Reel Panel.
1. Close the BOP Regulator valve.
2. Close the Panel Supply valve.
3. Move all the valves to the center position.
I. Connect the Jumpers Hoses to the Hose Reeld.
J. The stack is ready for operation from the Master Hydraulic Control Panel.
TC8081 2-8
IV. RETRIEVE THE POD
A. Operate the following at the Master Hydraulic Control Panel.
1. Move the Pod Selector to the controlling pod.
2. For the pod being retrieved only:
a. Turn off the air supply to the panel valves for the hydraulic pod
connectors (riser and stack).
b. Move the Pod Connectors Stack hydraulic valve to RETRACT.
c. Move the Pod Connectors Riser hydraulic valve to RETRACT.
Note: Allow 15 minutes for the connectors to retract.
d. Move the Pod Lock valve to UNLOCK.
B. Disconnect the Jumper hose from the reel of the pod to be retrieved.
C. Raise the pod.
V. LOWER THE POD
A. The Pod Connectors Stack and the Pod Connectors Riser must be re-
tracted.
1. If the connectors have been extended, apply 2000 to 3000 psi hydrau-
lic pressure to control lines 31 and 34 at the reel.
2. Apply the same amount of hydraulic pressure to line 37.
3. After the connectors retract, reduce pressure from line 37, then re-
duce pressure from lines 31 and 34.
B. Set all hydraulic pressures to zero.
TC8081 2-9
C. Disconnect the jumper hose from the hose reel.
D. Lower the pod and stop it on the female baseplate.
1. Inspect the pod with the subsea TV camera, if available.
E. Lock the Pod Locks.
F. Connect the jumper hose to the hose reel.
G. Set the hydraulic regulatros to their normal operating pressures.
H. Extend the Pod Connectors Stack and Pod Connectors Riser.
Note: Allow 15 minutes for the connectors to fully extend.
I. The Pod is ready to test according to rig procedures.
TC8081 2-10
Section 3
Maintenance
¼" Double Retractable Connector - Male Half. . . . . . . . . . . . . . 3-3
Part Number 307246-11
1" Retractable Connector . . . . . . . . . . . . . . . . . . . . . . . . 3-11

1½" Retractable Connector - Male Half . . . . . . . . . . . . . . . . . 3-18

¼" Four-Way Three-Position valve - Spring Centered . . . . . . . . . 3-24

1½" Three-Way Two-Position Valve (Dual Valve Assembly) . . . . . . 3-33

1½" Three-Way Piloted Valve w/Spring Return. . . . . . . . . . . . . 3-34

1½" Hydraulic Regulator . . . . . . . . . . . . . . . . . . . . . . . . 3-43

1" Three-Way Piloted Dual Valve w/Spring Return . . . . . . . . . . . 3-54


1" Three-Way Two Position Piloted Valve w/Spring Return . . . . . . 3-55


1“ Three-Way Piloted Dual Valve . . . . . . . . . . . . . . . . . . . . 3-69

¼" Four-Way Piloted Valve . . . . . . . . . . . . . . . . . . . . . . . 3-73

¼" Four-Way Two Position Piloted Valve w/Spring Return . . . . . . 3-77

TC8081 3-1
TC8081 3-2
Description: Connector, Male, Double 1/4-Inch, Retractable
Part Number: 307246-11 Revision: 02

Housing Subassy, Connector, Male, 1/4 And 1-Inch
1 A03 309507-01 1 Ea
Retractable, Sst
Stab Guides W/End Cap Ass’y, For 1/4" Double Ret.
2 B02 309509-01 1 Ea
Conn, Model “A”, Sst Version
Stab W/ Guide, 1/4" Double Ret. Connector, Model
3 2 111372 1 Ea
“A”, Sst
5 A01 111378-01 2 Ea Sleeve, 1/4" Retractable Conn., Sst, Model “A”
Gland Nut, 1/4" & 1" Double Ret. Connector, Sst Ver-
6 B01 111350 1 Ea
sion, Models “A” And “B”
Backing Ring, 1/4" Double Ret. Connector, Model
7 A01 111340-01 2 Ea
“B”, Sst Version
Seal “Blow Proof” For 1" Retract-Able Connector
8 E02 111441-02 4 Ea
(2.250 Od X 1.750 Id X .250)
Retaining Ring, Truarc- Ext For 3.250 Od Sst Basic Se-
10 203511 1 Ea
ries
Retaining Ring, Truarc- Int For 3.250 Id Sst Basic Se-
11 203510 1 Ea
ries
Seal Ring, 1.875id X 2.250od X .188 W/2 Backup
12 204842 1 Ea
Rings Std Mat Piston Seal
O Ring, Size As-568-224 1.734 Id X .139 W 90d
13 702645-22-41 1 Ea
/Ms-1078 Nitrile Pkg And Qual /Ciw 702645
14 702645-23-61 1 Ea
Seal Ring, .500id X .750od X .125 W/ 2 Backup Rings
15 204865 2 Ea
Std Mat
16 A01 107469 4 Ea Bearing, Thrust
18 705437 1 Ea Pin, Cotter Sst .094 X 1.5 Extended Prong Sq Cut
End Cap, Stab, 1/4" & 1" Ret. Connector, Model “A”
19 B01 111376-01 1 Ea
& “B”
Seal Ring, 2.625id X 3.000od X .188 Mal’l Nitrile 4115
20 204843 1 Ea 70 Durometer W/Backup Rings Mat’l Nylon B001 Pis-
ton Seal
21 705436 1 Ea
ries
Retaining Ring, Spirolox- Int For .750 Id Sst 302 Hvy
22 041008-00-75-52 2 Ea
Duty Dp Grv
27 A02 107130-46-99-01 1 Ea Tag, Obs Use 2020055-07-88
28 202117 2 Ea Screw, Drive-Rnd Hd Type U #4 X.188 Sst
Packing Retrainer 1/4" Double Ret. Connector Model
0 111356 1 Ea
“A” & “B” Sst Ver.
0 A01 307246 1 Ea Double Connector 1/4" Npt
Repair Kit, Hydraulic Connector,1/4" Double, Male,
0 1 307246-11-99 1 Ea
Retractable
0 A01 307570-01 1 Ea Stab, Test, 1/4" Double Male Conn.
TC8081 3-3
Description: Repair Kit, Hydraulic Connector, 1/4" Double, Male, Retractable
Part Number: 307246-11-99 Revision: C07

Seal “Blow Proof” For 1" Retract-
8 E02 111441-02 4 Ea Able Connector (2.250 Od X 1.750 Id X
.250)
Retaining Ring, Truarc- Ext For 3.250 Od
10 203511 1 Ea
Sst Basic Series
Retaining Ring, Truarc- Int For 3.250 Id Sst
11 203510 1 Ea
Basic Series
Seal Ring, 1.875id X 2.250od X .188 W/2
12 204842 1 Ea Backup Rings Std Mat Piston
Seal
O Ring, Size As-568-224 1.734 Id X.139 W
13 702645-22-41 1 Ea 90d /Ms-1078 Nitrile Pkg And Qual /Ciw
702645
702645
Seal Ring, .500id X .750od X .125W/ 2
15 204865 2 Ea
Backup Rings Std Mat
16 A01 107469 4 Ea Bearing,Thrust
Pin, Cotter Sst .094 X 1.5 Extended Prong
18 705437 1 Ea
Sq Cut
Seal Ring, 2.625id X 3.000od X .188Mal’l
20 204843 1 Ea Nitrile 4115 70 DurometerW/Backup Rings
Mat’l Nylon B001Piston Seal
Retaining Ring, Truarc- Ext For2.000 Od Sst
21 705436 1 Ea
Basic Series
Retaining Ring, Spirolox- Int For .750 Id Sst
22 041008-00-75- 52 2 Ea
302 Hvy Duty Dp Grv
23 702645-33-41 1 Ea 90d /Ms-1078 Nitrile Pkg And Qual
/Cameron 702645
O Ring, Size As-568-016 .614 Id X.070 W
24 702645-01-61 2 Ea 90d /Ms-1078 Nitrile Pkg And Qual
/Cameron 702645
Back-Up Ring, Size 016 .643 Id X.749 Od
25 704168 2 Ea
Nitrile Parbak 8 Series
0 A01 307246 1 Ea Double Connector 1/4" Npt
TC8081 3-4
TC8081 3-5
TC8081 3-6
I. ¼" DOUBLE RETRACTABLE CONNECTOR
P/N 307246-11
INSPECTION AND MAINTENANCE
A. Special Instructions
1. Read the procedure carefully before beginning.
2. Gather the tools and materials required.
3. Follow the procedure step-by-step in numerical order.
4. Refer to the assembly drawing while following the procedure. The

item numbers in the procedure refer to the item numbers on the as-
sembly drawing.
5. If a part requires replacement, replace the part from the repair kit. if
the repair kit does not contain the part, order the part from Cameron.
The item number of each part referred to in the procedure refers to
the item number on the parts list or the repair kit parts list. The part
number is opposite the item number.
B. Special Tools or materials Required
1. Cameron Repair Kit P/N 307246-11-99
2. Lubriplate lubricant or light waterproof grease.
3. Nonexplosive degreasing solvent.
C. Packing Replacement Procedure
1. Turn off the hydraulic supply to the connector assembly.
2. Extend the connector by applying air or hydraulic pressure to the

EXTEND port in the connector housing (item1).
3. Loosen the set screws (items 6), and remove the gland nut (item 4)
from the stab (item 3).
Caution: Do not allow the stab to rotate. Rotation will damage the end cap exten-
sion tubes.
4. Remove the set screws (items 170 from the sleeves (items 5).
TC8081 3-7
5. Remove the packings (items 8), the backing rings (items 7), the sleeves
(items 5), and the lock ring (item 9) from the stab (item 3).
6. Install the backing rings and the new packings onto the stab.
7. Install the set screws (items 17) into the sleeves.
Important: Ensure that the flow holes in the sleeves are installed over the ports in
the stab.
8. Install the gland nut (item 4) onto the stab (item 3).
sion tubes.
9. Tighten the set screws (items 6) in the gland nut.
10. Retract the connector by applying air or hydraulic pressure to the

RETRACT port in the upper housing (item 1).
D. Disassembly Procedure
1. turn off the hydraulic supply to the connector assembly, including the
EXTEND and RETRACT ports.
2. Bleed off the hydraulic pressure from the connector assembly, includ-
ing the EXTEND and RETRACT ports.
3. Disconnect the hydraulic lines from the end cap. (item2) of the con-
nector assembly.
Important: If the end cap has a valve connected to it, disconnect the hydraulic pip-
ing from the valve assembly. Leave the valve connected to the end cap.
4. Remove the snap ring (item 11) from the connector housing (item 1).
5. Remove the end cap (item 2) and the stab (item 3) from the connector
housing by carefully driving the stab out of the housing or by carefully
applying hydraulic pressure through the RETRACT port.
6. Remove the end cap from the stab.
7. Remove the screws (items 20) and the washers (items 21) from the
stab end plate (item 19).
8. Remove the end plate and the thrust bearings (items 18) from the
stab.
TC8081 3-8
from the stab.
10. Remove the set screws (items 17) from the sleeves (items 5).
11. Remove the packing (item 8), the backing rings (items 7), the sleeves
(items 5), and the lock ring (item 9) from the stab.
E. Inspection Procedure
1. Clean and inspect the "O" rings (items 14 and 15) and the backing
rings (items 16). Replace the "O" rings or backing rings that have nicks
or cuts.
2. Clean and inspect the "T" rings (items 12 and 13). Replace the "T"
rings that have nicks or cuts.
3. Clean the remaining parts.
F. Assembly Procedure
1. Lubricate all parts thoroughly with Lubriplate or light waterproof

grease.
2. Install the new packings (items 8), the sleeves (items 5), and the back-
ing rings (items 7) onto the stab.
3. Install the set screws (items 17) into the backing rings.
4. Install the gland nut (item 4) onto the stab.
5. Tighten the set screws (items 6) on the gland nut.
sion tubes.
6. Install the thrust bearings (items 18) into the stab.
7. Install the end plate (item 19) onto the stab with the screws (items 20)
and the washers (items 21).
Important: Endure that the hole in the end plate marked "U" is over the hole in
the stab marked "U".
8. Install the end cap (item 2) onto the stab.
TC8081 3-9
Important: Be sure to insert the end cap tube sample "U" into the hole stamped
"U" in the stab.
9. Install the stab and the end cap into the connector housing (item 1).
10. Install the snap ring (Item 11) into the connector housing.
11. Connect the hydraulic lines to the end cap (item 2) of the connector
assembly.
Important: If the end cap has a valve connected to it, connect the hydraulic piping
to the valve assembly.
12. Turn on the hydraulic supply to the connector assembly.
13. Inspect the connector assembly for leaks and proper operation.
TC8081 3-10
Description: Connector, Male, 1-In, Retractable, Sst
Part Number: 307244-11 Revision: J04

Housing Subassy, Connector, Male, 1/4 And 1-Inch
1 A03 309507-01 1 Ea
Retractable, Sst
Stab Guide With End Cap Ass’y, For 1" Retractable
2 A02 309508-01 1 Ea
Connector, Model “A” Sst Version
Stab W/Guide, 1 In. Retractable Connector, Sst
3 B01 111361 1 Ea
Version, Model “A”
Gland Nut, 1/4" & 1" Double Ret. Connector, Sst
6 B01 111350 1 Ea
Version, Models “A” And “B”
Seal “Blow Proof” For 1" Retract-Able Connector
7 E02 111441-02 2 Ea
(2.250 Od X 1.750 Id X .250)
Retaining Ring, Truarc- Ext For 3.250 Od Sst Basic
8 203511 1 Ea
Series
9 702640-22-41 1 Ea /Ms-1004 Nitrile Pkg And Qual /Ciw 702640 Obs, Use
702645-22-41
Seal Ring, 2.625id X 3.000od X .188 Mal’l Nitrile 4115
10 204843 1 Ea 70 Durometer W/Backup Rings Mat’l Nylon B001
Piston Seal
Seal Ring, 1.250id X 1.500od X .125 wW/ 2 Backup
11 204866 1 Ea
Rings Std Mat
12 C01 107253 2 Ea Bearing,Thrust,1" Retractable Conn.
13 203510 1 Ea Retaining Ring, Truarc- Int For 3.250 Id Sst Basic Series
14 702645-23-61 1 Ea
Retaining Ring, Truarc- Ext For 2.000 Od Sst Basic
15 705436 1 Ea
Series
16 A03 106877 1 Ea Sleeve, 1", Retractable Connector
17 203742 1 Ea Pin, Roll -.125 X .500 Sst
End Cap, Stab, 1/4" & 1" Ret. Connector, Model “A”
18 B01 111376-01 1 Ea
& “B”
Retaining Ring, Spirolox- Int For 1.500 Id Sst 302 Hvy
19 041008-01-50-52 1 Ea
Duty Dp Grv
Screw, Drive-Rnd Hd Type U #4 X.188
20 202117 2 Ea
Sst Ansi B18.6.4
Seal Ring, 1.875id X 2.250od X .188 w/2 Backup Rings
24 204842 1 Ea
Std Mat Piston Seal
27 A02 107130-46-99-01 1 Ea Tag, Obs Use 2020055-07-88
0 307244 1 Ea Retractable Connector 1" Npt
Repair Kit, Hydraulic Connector,1", Male, Retractable,
0 C07 307244-11-99 1 Ea
Model “A” And “B”
0 C02 307569-01 1 Ea Stab, Test, 1" Male Connector, Models “A” And “B”
TC8081 3-11
Description: Repair Kit, Hydraulic Connector,1", Male, Retractable, Model “A” And B

Seal “Blow Proof” For 1" Retract- Able Connec-
7 E02 111441-02 2 Ea
tor (2.250 Od X 1.750 Id X .250)
Retaining Ring, Truarc- Ext For 3.250 Od Sst Ba-
8 203511 1 Ea
sic Series
9 702640-22-41 1 Ea /Ms-1004 Nitrile Pkg And Qual /Ciw 702640 Obs,
Use 702645-22-41
Seal Ring, 2.625id X 3.000od X .188 Mal’l Nitrile
10 204843 1 Ea 4115 70 Durometer W/Backup Rings Mat’l Nylon
B001 Piston Seal
Seal Ring, 1.250id X 1.500od X .125 W/ 2 Backup
11 204866 1 Ea
Rings Std Mat
Retaining Ring, Truarc- Int For 3.250 Id Sst Basic
13 203510 1 Ea
Series
14 702645-23-61 1 Ea
Retaining Ring, Truarc- Ext For 2.000 Od Sst Ba-
15 705436 1 Ea
sic Series
Retaining Ring, Spirolox- Int For 1.500 Id Sst 302
19 041008-01-50-52 1 Ea
Hvy Duty Dp Grv
21 702640-02-51 1 Ea
Back-Up Ring, Size 025 1.205 Id X 1.311 Od
22 042000-00-25 1 Ea
Nitrile Parbak 8 Series
23 702645-33-41 1 Ea /Ms-1078 Nitrile Pkg And Qual / Cameron
702645
Seal Ring, 1.875id X 2.250od X .188 W/2 Backup
24 204842 1 Ea
Rings Std Mat Piston Seal
TC8081 3-12
TC8081 3-13
TC8081 3-14
II. 1" RETRACTABLE CONNECTOR
P/N 307244-11

sembly drawing.
5. If a part requires replacement, replace the part from the repair kit. If
B. Special Tools or Materials Required.
1. Cameron Repair Kit, P/N 307244-11-99.
C. Packing Replacement Procedure.

EXTEND port of the housing (item 1).
3. Loosen the set screws (items 6) and the gland nut (item 4) from the
stab (item 3).
4. Remove the packings (items 7) and the sleeve (item 5) from the stab.
5. Install the sleeve and the new packings onto the stab.
TC8081 3-15

RETRACT port of the housing (item 1).
1. Turn off the hydraulic supply to the connector assembly, including the
3. Disconnect the hydraulic line from the end cap (item 2) of the connec-
tor assembly.
4. Remove the snap ring (item 13) from the connector housing (item 1).
5. Remove the end cap (item 2) and the stab (item 3) from the connector
housing by carefully driving the stab out of the housing or by carefully
applying hydraulic pressure through the retract port.
6. Remove the end cap from the stab.
7. Loosen the set screws (items 6), and remove the gland nut (item 4).
8. Remove the lower packing (item 7), the sleeve (item 5), and the upper
packing (item 7) from the stab.
1. Clean and inspect the "O" ring (item 11) and the backing ring (item
14). Replace the "O" ring or the backing ring if wither one has nicks
or cuts.
2. Clean and inspect the "T" rings (items 9, 10, and 12). Replace the "T"
TC8081 3-16
1. Lubricate all parts thoroughly with the Lubriplate lubricant or the

light waterproof grease.
2. Install the sleeve (item 5) and the new packing (items 7) onto the stab
(item 3).
5. Install the end cap (item 2) onto the stab.
6. Install the stab and the end cap into the connector housing (item 1).
7. Install the snap ring (item 13) into the connector housing.
8. Connect the hydraulic line to the end cap (item 2) of the connector as-
sembly.
TC8081 3-17
Description: Connector, Male, Retractable 1.5 In Sst
Part Number: 307245-11 Revision: H02

Housing Subassy, Connector, Male, 1-1/2 Inch, Re-
1 A01 309510-01 1 Ea
tractable, Sst
Stab Guide With End Cap Ass’y For 1-1/2" Retract-
2 A01 309511-01 1 Ea
able Connector, Model A, Sst Version
Stab With Guide, 1-1/2 Retractable
3 B01 111384 1 Ea
Connector, Model “A”, Sst Version
End Cap/Stab, 1-1/2 Retractable Connector, Model
6 B01 111382-01 1 Ea
“A”, Sst Version
Nut, Gland, 1-1/2" Retractable Connector, Model
7 A01 111352 1 Ea
“B”
8 A03 106883 1 Ea Sleeve, Retractable Connector
9 203742 1 Ea Pin, Roll -.125 X .500 Sst
11 A01 112553-01 1 Ea Retaining Ring, Internal,1-1/2",Ret Connector
Retaining Ring, Spirolox-Int For 2.375 Id Sst 302 Hvy
12 041008-02-37-52 1 Ea
Duty Dp Grv
13 705452 1 Ea
ries
14 204860 1 Ea
Ring Std Mat
15 A01 108210 2 Ea Bearing, Thrust
16 204845 1 Ea
Rings Std Mat
O Ring, Size 232 2.734 Id X .139 W 6230-10 70d
17 006230-10-01-70 1 Ea
/Ps-4-200 Obs Use 702640-23-21
O Ring, Size 246 4.484 Id X .139 W 6230-24 70d
19 200037 1 Ea
/Ps-4-205 Obs Use 702640-24-61
Seal Ring, 2.875id X 3.250od X .188 w/ 2 Backup
22 204844 1 Ea
Rings Std Mat
Seal “Blow Proof” For 1-1/2" Re- Tractable Connec-
23 E02 111441-03 2 Ea
tor (3.250 Od X 2.750 X .250)
24 204847 1 Ea Pin, Cotter-Sst .094 X 1.75 Extended Prong Sq Cut
Retaining Ring, External-Supercedes P/N 203513 Re-
25 A01 111623-02 1 Ea
tractable Conn
26 A02 107130-46-99-01 1 Ea Tag, Obs Use 2020055-07-88
Repair Kit, Hydraulic Conn, 1-1/2", Male, Retract-
0 1 307245-11-99 1 Ea
able, Model “A”
0 A01 307568-01 1 Ea Stab, Test, 1-1/2" Male Connector
TC8081 3-18
Description: Repair Kit, Hydraulic Conn, 1-1/2", Male, Retractable, Model “A”

11 A01 112553-01 1 Ea Retaining Ring, Internal,1-1/2",Ret Connector
Retaining Ring, Spirolox- Int For 2.375 Id Sst
12 041008-02-37-52 1 Ea
302 Hvy Duty Dp Grv
Retaining Ring, Truarc- Ext For 3.000 Od Sst
13 705452 1 Ea
Basic Series
Seal Ring, 2.000id X 2.375od X .188 w/ 2
14 204860 1 Ea
Backup Ring Std Mat
16 204845 1 Ea
17 702645-23-21 1 Ea
0 Ring, Size As-568-344 3.850 Id X .210 W 90d
18 702645-34-41 1 Ea
19 702645-24-61 1 Ea
20 702645-13-61 1 Ea
21 042000-01-36 1 Ea
Nitrile Parbak 8-Series
22 204844 1 Ea
Seal “Blow Proof” For 1-1/2" Re- Tractable
23 E02 111441-03 2 Ea
Connector (3.250 Od X 2.750 X .250)
Pin, Cotter-Sst .094 X 1.75 Extended Prong Sq
24 204847 1 Ea
Cut Ansi B18.8.1
Retaining Ring, External-Supercedes P/N
25 A01 111623-02 1 Ea
203513 Retractable Conn
TC8081 3-19
TC8081 3-20
III. 1½" RETRACTABLE CONNECTOR
P/N 307245-11
2. Gather to tools and materials required.

sembly drawing.
B. Special Tools or Materials Required
1. Cameron Repair Kit, P/N 307245-11-99.
C. Packing Replacement Procedure

EXTEND port of the housing (item 1).
from the stab (item 3).
4. Remove the packings (items 7) and the sleeve (item 5) from the stab.
5. Install the sleeve (item 5) and the new packings (items 7) onto the stab
(item 3).
TC8081 3-21
7. Tighten the set screws (items 6) in the gland nut.

RETRACT port of the housing (item 1).
1. Turn off the hydraulic supply to the connector assembly, including the
3. Disconnect the hydraulic line from the end cap (item 2) of the connec-
tor assembly.
4. Loosen the set screw (item 13) in the connector housing (item 1).
5. Unscrew the end cap (item 2) from the connector housing (item 1).
6. Remove the stab (item 3) from the connector housing by carefully

driving the stab out of the housing or by carefully applying hydraulic
pressure to the retract port.
7. Loosen the set screws (items 6) and remove the gland nut (item 4)
from the stab.
8. Remove the lower packing (item 7), the sleeve (item 5), and the upper
packing (item 7) from the stab.
1. Clean and inspect the "O" ring (item 11) and the backing ring (item
14). Replace the "O" ring or the backing ring if either one has nicks or
cuts.
2. Clean and inspect the "T" rings (items 9, 10, and 12). Replace the "T"
TC8081 3-22
1. Install the sleeve (item 5) and the new packing (item 7) onto the stab
(item 3).
3. Tighten the set screw (items 6) on the gland nut.
4. Install the stab into the connector housing (item 1).
5. Install the end cap (item 2) into the connector housing.
6. Tighten the set screw (item 13) in the connector housing.
7. Connect the hydraulic line to the end cap (item 2) of the connector as-
sembly.
TC8081 3-23
Description: Valve,Piloted,1/4",4-Way 3-Pos,3000 psi, sst, Spring Centered
Part Number: 309068-01 Revision: L02

1 B02 110462 1 Ea Body Valve, 2" X 2" X 6" Long
Dual Cylinder Head, 2.000" Sq X 1.500 X .500 Cyl.
2 B02 110463 1 Ea
Dia
3 C02 110464 1 Ea Cylinder Head, 2.000" Sq X 1.5 Dia X .750 Dia.
4 D01 110465 1 Ea Flange Inlet 2" X 2" X 1/4" Npt Sst
5 C01 110466 1 Ea Flange Outlet-Dual Ports, 2" Sq X 1/4" Npt.
6 B02 110467 1 Ea Piston, Spring Centering, .938 Id X 5.5 Long.
Plate-Seal Outlet Dual Port .187 Holes X 1.87 Dia
7 E02 105641 1 Ea
.474 Thk.
8 F02 105423 1 Ea Plate-Inlet Seal,1.75 Dia X 0.47 Thk X .250 Dia Hole
9 A02 108132-01 2 Ea Ring Seal,.50 Id X .60 Thk (17-4 Ph
10 B01 108162 1 Ea Spring, 0.59 Od X 0.75 Fl X 25# Ld.
11 C01 106615 1 Ea Spring, 0.938 Id X 2.75 Lg X 0.244 Dia. Wire
12 B01 106616 2 Ea Thrust Washer, .935 Id X 1.438 Od X 1.25 Thk
Retaining Ring, Truarc- Int For 1.500 Id Sst Basic Se-
13 200238 1 Ea
ries
Retaining Ring, Truarc- Ext For .875 Od Sst Basic Se-
14 203347 1 Ea
ries
O Ring, Size As-568-218 1.234 Id X .139 W 90d /
15 702645-21-81 1 Ea
Ms-1078 Nitrile Pkg And Qual /Ciw 702645
O Ring, Size As-568-210 .734 Id X .139 W 70d /
16 702640-21-02 1 Ea
17 702645-11-62 2 Ea
Ms-1082 Nitrile Pkg And Qual /Cameron 702645
18 702640-11-31 1 Ea
19 702640-11-11 2 Ea
20 702640-11-22 1 Ea
21 702640-12-81 1 Ea
Screw, Soc Hd Cap .250-20 X 1.25 Sst 316 /A193 /
22 702505-02-00-12 4 Ea
Ansi B18.3
Screw, Soc Hd Cap .250-20 X 0.875 Sst 316 / A193
23 702505-02-00-07 4 Ea
/Ansi B18.3
25 702640-12-71 1 Ea
Back-Up Ring, Size 116 .765 Id X .935 Od Nitrile
26 200132 2 Ea
Parbak 8 Series
29 203657 1 Ea O Ring, Size 029 1.489 Id X .070 W 70d Buna-N
Screw, Drive-Rnd Hd Type U #4 X.188 Sst Ansi
30 202117 2 Ea
B18.6.4
TC8081 3-24
Description: Valve,Piloted,1/4",4-Way 3-Pos,3000 psi, sst, Spring Centered
Part Number: 309068-01 Revision: L02

31 A02 107130-46-99-01 1 Ea Tag, Obs Use 2020055-07-88
32 B03 110493 1 Ea Pin, Dowel, .250" Od, Sst
Valve, 1/4" 4-Way 3-Position Valve Spring Centered,
0 E01 309068 1 Ea
3000 Psi Sst
Repair Kit,Valve,1/4",4-Way, 3-Pos, 3000 Psi, Hyd Pi-
0 H02 309068-99 1 Ea
lot, Spring Center
TC8081 3-25
Description: Repair Kit,Valve,1/4",4-Way, 3-Pos, 3000 Psi,Hyd Pilot,Spring Center

Plate-Seal Outlet Dual Port .187 Holes X 1.87 Dia
7 E02 105641 1 Ea
.474 Thk.
Plate-Inlet Seal,1.75 Dia X 0.47 Thk X .250 Dia
8 F02 105423 1 Ea
Hole
11 C01 106615 1 Ea Spring, 0.938 Id X 2.75 Lg X 0.244 Dia. Wire
Retaining Ring, Truarc- Int For 1.500 Id Sst Basic
13 200238 1 Ea
Series
Retaining Ring, Truarc- Ext For .875 Od Sst Basic
14 203347 1 Ea
Series
15 702645-21-81 1 Ea
O Ring, Size As-568-210 .734 Id X .139 W 70d
16 702640-21-02 1 Ea
17 702645-11-62 2 Ea
/Ms-1082 Nitrile Pkg And Qual / Cameron 702645
18 702640-11-31 1 Ea
19 702640-11-11 2 Ea
20 702640-11-22 1 Ea
O Ring, Size As-568-128 1.487 Id X
21 702640-12-81 1 Ea .103 W 90d /Ms-1004 Nitrile Pkg And Qual / Ciw
702640
25 702640-12-71 1 Ea
Back-Up Ring, Size 116 .765 Id X .935 Od Nitrile
26 200132 2 Ea
Parbak 8 Series
29 203657 1 Ea O Ring, Size 029 1.489 Id X .070 W 70d Buna-N
TC8081 3-26
TC8081 3-27
TC8081 3-28
IV. ¼" FOUR-WAY THREE-POSITION VALVE - SPRING CENTERED
P/N 309068-01
4. Refer to the assembly drawing while following the procedure. the

sembly drawing.
The item number of each part referred to the in the procedure refers
to the item number on the parts list or the repair kit parts list. The
part number is opposite the item number.
B. Special tools or Materials Required
1. Cameron Repair Kit, P/N 309068-99.
Important: Be sure that the solvent is not so strong that it removes the blue coat-
ing on the valve assembly.
C. Disassembly Procedure
1. Turn off the hydraulic supply to the valve assembly.
2. Bleed off the hydraulic pressure from the valve assembly.
3. Disconnect the hydraulic piping from the valve assembly. It is not nec-
essary to remove the pipe fittings from the valve assembly.
4. Take the valve assembly to a work bench or suitable area where there
is room to work.
TC8081 3-29
5. Remove the cap screws (items 22) from the inlet flange (item 4).
6. Remove the inlet flange from the valve assembly.
7. Remove the inlet seal plate (item 8) from the valve assembly. To pry
the seal plate loose, insert the sharp edge of a knife blade under the
edge of the seal plate.
8. Remove the inlet seal ring (item 9) and spring (item 10) from the valve
assembly.
9. Remove the cap screws (items 28) from the outlet flange (item 5).
10. Remove the outlet flange from the valve assembly.
11. Remove the outlet seal plate (item 7). To pry the seal plate loose, in-
sert the sharp edge of a knife blade under the edge of the seal plate.
12. Remove the outlet seal ring (item 9) from the valve assembly.
13. Remove the cap screws (item 27 from the end flange (item 2).
14. Remove the flange from the valve assembly.
15. Remove the cap screws (items 23) from the end flange (item 3).
16. Remove the flange from the valve assembly.
D. Inspection Procedure
1. Remove the "O" ring (item 200 from the piston (item 6).
2. Install the new "O" ring (item 20) onto the piston.
3. Remove the "O" rings (items 15 and 16) from the end flange (item 3).
4. Clean the end flange.
5. Install the new "O" rings (items 15 and 16) onto the end flange.
6. Remove the "O" ring (item 21) from the end flange (item 2).
7. Clean the end flange.
8. Install the new "O" ring (item 21) onto the end flange.
9. Remove the "O" rings (items 17) and the back-up rings (items 26) from
the seal rings (items 9).
TC8081 3-30
10. Clean and inspect the seal rings. Replace seal rings if the polished, slid-
ing surface has scratches or pits.
11. Install the new "O" rings (items 17) and the new back-up rings (items
26) onto the seal rings.
12. Remove the "O" ring (item 25) from the inlet seal plate.
13. Clean and inspect the inlet seal plate. Replace the seal plate if the pol-
ished surface has scratches or pits.
14. Install the new "O" ring (item 25) onto the inlet seal plate.
15. Remove the "O" ring (item 18) from the inlet flange (item 4).
16. Clean the inlet flange.
17. Install the new "O" ring (item 18) onto the inlet flange.
18. Remove the "O" ring (item 29) from the outlet seal plate (item 7).
19. Clean and inspect the outlet seal plate. Replace the seal plate if the
polished surface has scratches or pits.
20. Install the new "O" ring (item 29) onto the outlet seal plate.
21. Remove the "O" rings (items 19) from the outlet flange (item 5).
22. Clean the outlet flange.
23. Install the new "O" rings (items 19) onto the outlet flange.
24. Clean the body (item 1) of the valve assembly.
E. Assembly Procedure

grease.
2. Install the end flange (item 3) onto the valve assembly with the cap
screws (items 23).
3. Install the end flange (item 2) onto the valve assembly with the cap
screws (items 27).
4. Install the outlet seal ring (item 9) into the valve assembly.
5. Install the outlet seal plate into the valve assembly by pushing the
seal plate into position by hand.
TC8081 3-31
6. Install the outlet flange (item 5) onto the valve assembly with the cap
screws (items 28).
7. Install the inlet seal ring (item 9) and new spring (item 10) into the
valve assembly.
8. Install the inlet seal plate (item 8) into the valve assembly by pushing
the seal plate into position by hand.
9. Install the inlet flange (item 4) onto the valve assembly with the cap
screws (items 22).
10. Reinstall the valve assembly.
11. Turn on the hydraulic supply to the valve assembly.
12. Inspect the valve for leaks and proper operation.
TC8081 3-32
Description: Valve, Piloted Dual,1-1/2",3-Way, 3000 psi, sst, Spring Return
Note: For Surface Application See Optional Items On B.O.M. 309535-01
(Preferred Valve Is 309915-12)
Part Number: 309535-03 Revision: C03

17 702640-22-81 2 Ea /Ms-1004 Nitrile Pkg And Qual /Ciw 702640
Valve,Piloted,1-1/2",3-Way,3000 Psi,Sst, Spring Return
33 1 309535-01 2 Ea Note: For Surface Application Use Optional Items Per
B.O.M. (Preferred Valve Is 309915-05)
Manifold, 1.5" Npt, 303 Stainless For Mounting Two
35 A02 111483-01 1 Ea 1.5" Subsea Valves
Screw, Cap, 5/8-11 X 5-1/2" Lg., Socket Head, 316 Sst
37 C01 111417-02 4 Ea W/Full Thread Length
Nut, Hvy Hex .625-11 Sst Ident & Pkg Per Dwg
38 2709000-07-39 4 Ea 2709000
39 A01 107130-24-58-01 1 Ea Tag, Final Assy, 1.5 X 2.5, Metal
40 202117 4 Ea Screw, Drive-Rnd Hd Type U #4 X.188 Sst Ansi B18.6.4
Valve 1-1/2" Sst Assembly-Pilot Operated Spring Re-
0 B01 309535 1 Ea turn 3-Way 3000 psi Wp
Repair Kit, Valve, 1-1/2", 3-Way, Sst, 3000 Psi, Hyd Pi-
0 J03 309535-01-99 1 Ea lot, Spring Return, Basic Ass’y
TC8081 3-33
Description: Valve,Piloted,1-1/2",3-Way,3000 Psi,Sst, Spring Return Note: For Surface
Application Use Optional Items Per B.O.M. (Preferred Valve Is 309915-05)

1 G01 111481-01 1 Ea Body, Valve Sst 1-1/2" Npt , 4" Sq X 8" Long
2 G01 107068 1 Ea Slide, 1-1/2 In. Valve
3 A01 111454-01 1 Ea Pilot End Cap/Stem, Sst
4 702645-12-81 2 Ea
/Ms-1078 Nitrile Pkg and Qual /Ciw 702645
5 A01 107061-01 2 Ea Ring,Seal,1.375 Dia, Type 17-4 Ph Sst
6 C01 107066 2 Ea Spring, 1.65 Od X 0.68 Lg
7 H01 107063 1 Ea Plate-Outlet Seal
9 A01 111474-01 1 Ea Flange Outlet, Sst 4 X 4 X 1.5" Npt
10 G01 107062 1 Ea Plate Blind Seal 3.5 Dia
11 B01 111472-01 1 Ea Flange Blind Seal, Sst 4"X4"X1.5"
12 D01 110004 1 Ea Spring, 1.87 Od X 5.5 Lg
13 D01 111480-01 1 Ea End Cap Inlet, Sst 4" Sq X 2.75 Lg. X 1.38 I.D.
14 702645-23-61 3 Ea
15 702645-12-91 1 Ea
16 702645-23-21 1 Ea
17 702645-22-81 1 Ea
18 702645-23-41 1 Ea
19 702645-23-01 1 Ea
Screw, Soc Hd Cap .500-13 X 2.25 Sst 316 /A193
20 702505-10-00-22 4 Ea
/Ansi B18.3
21 702505-14-00-12 4 Ea
/Ansi B18.3
22 702505-10-00-24 4 Ea
/Ansi B18.3
Screw, Soc Hd Cap #10-24 X 1.25 Sst 18-8 Ansi
23 203987 2 Ea
B18.3
24 D01 107830 2 Ea Round Retainer Ring
Tag, “Caution, Spring Is Compressed
25 A01 107130-29-71-01 1 Ea Use Two Jacking Screws (Provided) to Remove
and Install Spring", 1.25 X 3.5
26 202117 6 Ea
B18.6.4
TC8081 3-34

27 A02 107130-46-99-01 1 Ea Tag, Obs Use 2020055-07-88
Valve, Relief-Manual 1/8m Npt Sst 4000 Psi
28 705671 1 Ea
Purge Type
Screw, .38-16 X 1.25 Lg. Brass, Hex Hd. Full
31 A02 110060 2 Ea
Length Thd. Make From 704043
32 704042 2 Ea Nut, Hex Jam .375-16 Brass Ansi B18.2.2
33 042000-02-36 2 Ea
Nitrile Parbak 8-Series
Valve 1-1/2" Sst Assembly-Pilot Operated Spring
100 B01 309535 1 Ea
Return 3-Way 3000 Psi Wp
Repair Kit, Valve, 1-1/2", 3-Way, Sst, 3000 Psi,
95 J03 309535-01-99 1 Ea
Hyd Pilot, Spring Return, Basic Ass’y
Flange, Blind Sst For 1-1/2" Valve for Surface
96 A01 2020436 1 Ea
Use
Flange, Return 1-1/2" Npt Sst For 1-1/2" Valve
97 A01 2020437 1 Ea
for Surface Use
98 702645-12-51 1 Ea
/Ms-1078 Nitrile Pkg and Qual /Cameron 702645
O-Ring, Size AS-568-131 1.674 ID X .103 W 90D
99 702645-13-11 1 Ea
/MS-1078 Nitrile Pkg and Qual /CC 702645
TC8081 3-35
Description: Repair Kit, Valve, 1-1/2", 3-Way
Part Number: 309535-01-99 Revision: J03

4 702640-12-81 2 Ea
14 702645-23-61 3 Ea
15 702640-12-91 1 Ea
16 702640-23-21 1 Ea
17 702640-22-81 2 Ea
18 702640-23-41 1 Ea
19 702645-23-01 1 Ea
Back-Up Ring, Size 236 3.256 Id X 3.492 Od Nitrile
33 042000-02-36 2 Ea
Parbak 8-Series
98 702640-12-51 1 Ea
99 702640-13-11 1 Ea
TC8081 3-36
TC8081 3-37
TC8081 3-38
V. 1½" THREE-WAY TWO-POSITION VALVE
(DUAL VALVE ASSEMBLY)
P/N 309535-03
1. Repair the valve assembly in place.
2. Repair only one valve at a time.

sembly drawing.
B. Special tools or Materials Required
1. Cameron Repair Kit, P/N 309535-01-99
TC8081 3-39
3. Disconnect the hydraulic piping from the valve needing repair. it is
not necessary to remove the pipe fittings from the valve.
4. Remove the valve from the manifold (item 31) by removing the cap
screws (items 32).
5. Take the valve to a work bench or suitable area where there is room
to work.
6. Remove the cap screws (items 20) from the blind seal flange (item 11)
of the valve.
7. Remove the blind seal flange from the valve.
8. Remove the blind seal plate (item 10) from the valve by prying under
the edge of each seal plate with the sharp edge of a knife blade.
9. Remove the seal ring (item 5) and the spring (item 6) from the valve.
10. Remove the cap screws (items 22) from the outlet flange (item 9) of
the valve.
11. Remove the outlet flange from the valve.
12. Remove the outlet seal plate (item 7) from the valve by prying under
the edge of the seal plate with the sharp edge of a knife blade.
13. Remove the seal ring (item 5) and the spring (item 6) from the valve.
14. Remove the cap screws (items 23) from the inlet end cap (item 13).
Important: The inlet end cap is under spring pressure. Hold the end cap and valve
body firmly as you remove the cap screws to prevent the end cap from
flying off.
15. Remove the inlet end cap from the valve.
16. Remove the slide (item 2) from the valve. Remove only if necessary.
17. Remove the cap screws (item 21) from the pilot end cap (item 3).
18. Remove the pilot end cap from the valve.
1. Remove the "O" ring (item 15) from the outlet flange (item 9).
2. Clean the outlet flange.
TC8081 3-40
3. Install the new "O" ring (item 15) onto the outlet flange.
4. Remove the "O" rings (items 14) from the outlet seal plate (item 7)
and the blind seal plate (item 10) of the valve.
5. Clean and inspect the seal plates. Replace a seal plate if the polished
surface has scratches or shows excessive wear.
6. Install the new "O" rings (items 14) onto the seal plates.
7. Remove the "O" ring (item 4) from each seal ring (item 5).
8. Clean and inspect the seal rings. Replace a seal ring if the polished,
sliding surface has scratches or pits.
9. Install the new "O" rings (items 4) onto the seal rings.
10. Remove the "O" ring (item 17) from the slide (item 2).
11. Clean and inspect the slice. Replace the slide if the seal ring bore or
the contact surfaces have scratches or show excessive wear.
12. Install the new "O" ring (item 17) onto the slide.
13. Remove the "O" ring (item 16) from the pilot end cap (item 3).
14. Clean the pilot end cap.
15. Install the new "O" ring (item 16) onto the pilot end cap.
16. Remove the "O" ring (items 14, 17, and 19) from the inlet end cap
(item 13).
17. Clean the inlet end cap.
18. Install the new "O" rings (items 14, 17, and 19) onto the inlet end cap.
19. Clean and inspect the body (item 1) of the valve. Replace the body if
the blue coating on the bore where the "O" ring's seal has scratches,
flaking, or pits.
1. Lubricate all parts thoroughly with the Lubriplate lubricant or the

light waterproof grease.
TC8081 3-41
2. install the pilot end cap (item 3) onto the valve with the cap screws
(items 21).
3. Install the slide (item 2) and the spring (item 12) into the valve.
4. Adjust the antirotation guides for a clearance of 0.005 inch with the
valve slide guide surface perpendicular to the plane of the seal plates.
Refer to the assembly drawing.
5. Install the inlet end cap (item 13) onto the valve with the cap screws
(items 23).
6. Install the seal rings (items 5) and the spring (item 6) into the valve.
7. install the blind seal plate (item 10) onto the valve by pushing the seal
plate into position by hand.
Important: Do not hammer the seal plate into position. The seal plate is brittle and
may break.
8. Install the blind seal flange (item 11) onto the valve with the cap
screws (items 20).
9. Install the outlet seal plate (item 7) onto the valve by pushing the seal
plate into position by hand.
Important: Install the outlet seal plate so that the port is near the inlet end of the
valve assembly.
10. Install the outlet flange (item 9) onto the valve with the cap screws
(items 22).
11. Install the valve onto the manifold (item 31) with the cap screws
(items 32).
13. Inspect the repaired valve for leaks and proper operation.
TC8081 3-42
Description: Regulator, 1½“ sst Assembly - Hydraulic Pilot Operated, 0-3000 psi WP
Part Number: 309536-01 Revision: F08

Piston,-Regulating, For 1½“ Model ”Dp" Regulator,
1 D01 107085 1 Ea
C/S
2 A01 111470-01 1 Ea Pilot End Cap, Sst 4" Sq X 2.5 Long X 1/4" Npt
3 C01 107087 1 Ea Bushing
4 702645-22-81 2 Ea
5 702645-23-11 1 Ea
/Ms-1078 Nitrile Pkg And Qual /Cot 702645
6 702645-23-01 4 Ea
7 C01 111589-01 2 Ea Plate Inlet Seal,1½ Model Dp Reg
9 702645-12-31 2 Ea
/Ms-1078 Nitrile Pkg And Qual /Cameron 702645
11 D01 111475-01 2 Ea Flange, Inlet Seal Stainless Steel, 1¼ Npt
12 203794 1 Ea Retaining Ring, Truarc- Int for 2.750 Id Sst Basic Series
13 C02 107090 1 Ea Bushing, Internal Feed, 1.500" Mode L Dp Regulator
14 A02 111482-01 1 Ea Body Main, Sst 1½“ Model Dp Reg
15 702505-10-00-20 8 Ea Screw, Soc Hd Cap .500-13 X 2 Sst 316
16 702529-13-02 8 Ea Washer, .500 Hel Spr Lock Sst 18-8 Regular Duty
17 702645-22-41 2 Ea
18 702645-11-91 2 Ea
19 A01 110370-01 2 Ea Ring, Seal, Inlet, 1.5" Dp Reg, 17-4 Ph Sst
20 A04 112386-02 2 Ea Plate, Exhaust Seal,1½ For 1½” Dual Pilot Regulator
21 D02 107089 1 Ea Piston-Relief, For 1½“ Model Dp Regulator, C.S
22 E01 111476-01 2 Ea Flange, Relief, 1½”Sst Regulator (½“ Npt Port)
23 702645-21-61 3 Ea
24 702529-15-02 16 Ea Washer, .625 Hel Spr Lock Sst 18-8 Regular Duty
26 A01 107093 1 Ea Bushing, Relief Pilot, 1½” Reg
Screw, Soc Hd Cap .625-11 X 1.75 Sst 316 / A193 /Ansi
27 702505-14-00-16 4 Ea
B18.3
28 203795 1 Ea Plug, Pipe-Threaded Hex Hd 4-Mar Sst
29 A03 107160 1 Ea Spring,Exhaust Return Od.700"
30 A01 111469-01 1 Ea Relief End Cap Sst 4" Sq X 1" Thk. ¼“ Npt
31 B02 110369 1 Ea Spring, Inlet Seal, 1½” Hyd. Pressure Regulator
32 A02 107097 1 Ea Spring,Releif Seal 1½“ Model Dp. Regulator
33 702645-11-61 2 Ea
TC8081 3-43
Description: Regulator, 1½“ sst Assembly - Hydraulic Pilot Operated, 0-3000 psi WP
Part Number: 309536-01 Revision: F08

34 B01 107091-01 2 Ea Ring,Seal,Relief,1.50" Model Dp Reg Type17- 4 Ph Sst
35 702528-06-03 1 Ea Washer, .250 Flat Type A Sst 18-8 .281 X .625 X .065
36 A02 107945 1 Ea Spring, 0.410 Od X 2½ Lg X 0.072 Wire, 302 Sst
37 705671 1 Ea Valve, Relief-Manual m Npt Sst 4000 Psi Purge Type
38 A02 107130-46-99-01 1 Ea Tag, Obs Use 2020055-07-88
Regulator, 1½” Sst Assembly- Hydraulic Pilot Oper-
0 C01 309536 1 Ea
ated, 0-3000 Psi W.P.
Repair Kit, Pressure Regulator,1½ Npt, Hydraulic Pi-
0 A01 309536-90 1 Ea
lot,1:1 Ratio,3000 Psig Input With Ceramic Seal Plate
Repair Kit, Pressure Regulator,1½ Npt, Hydraulic Pi-
0 D05 309536-99 1 Ea
lot,1:1 Ratio, 3000 Psig Input
TC8081 3-44
Description: Repair Kit, Pressure Regulator,1-1/2 Npt, Hydraulic Pilot,1:1 Ratio, 3000 Psig
Part Number: 309536-90 Revision: A01

4 702645-22-81 2 Ea
5 702645-23-11 1 Ea
/Ms-1078 Nitrile Pkg And Qual /Cot 702645
6 702645-23-01 4 Ea
7 C01 111589-01 2 Ea Plate Inlet Seal,1-1/2 Model Dp Reg
9 702645-12-31 2 Ea /Ms-1078 Nitrile Pkg And Qual /Cameron
702645
Retaining Ring, Truarc- Int For 2.750 Id Sst Ba-
12 203794 1 Ea
sic Series
17 702645-22-41 2 Ea
/Ms-1078 Nitrile Pkg And Qual / Ciw 702645
702645
20 B03 112386-01 2 Ea Plate, Exhaust Seal, 1-1/2 Model Dp Regulator
23 702645-21-61 3 Ea
29 A03 107160 1 Ea Spring, Exhaust Return Od.700"
Spring, Inlet Seal, 1-1/2" Hyd. Pressure Regula-
31 B02 110369 1 Ea
tor
32 A02 107097 1 Ea Spring,Releif Seal 1-1/2" Model Dp. Regulator
702645
Ring,Seal,Relief,1.50" Model Dp Reg Type17-4
34 B01 107091-01 2 Ea
Ph Sst
Washer, .250 Flat Type A Sst 18-8 .281 X .625 X
35 702528-06-03 1 Ea
.065 Ansi B18.22.1
Spring, 0.410 Od X 2-1/2 Lg X 0.072 Wire, 302
36 A02 107945 1 Ea
Sst
Regulator, 1-1/2" Sst Assembly- Hydraulic Pilot
0 C01 309536 1 Ea
Operated, 0-3000 Psi W.P.
TC8081 3-45
Description: Repair Kit, Pressure Regulator,1-1/2 NPT, Hydraulic Pilot,1:1 Ratio, 3000 psig
Input
Part Number: 309536-99 Revision: D05

4 702640-22-81 2 Ea
5 702640-23-11 1 Ea
6 702645-23-01 4 Ea
7 C01 111589-01 2 Ea Plate Inlet Seal,1-1/2 Model Dp Reg
9 702640-12-31 2 Ea
Retaining Ring, Truarc- Int for 2.750 Id Sst Basic Se-
12 203794 1 Ea
ries
17 702640-22-41 2 Ea Ms-1004 Nitrile Pkg And Qual /Ciw 702640 Obs, Use
702645-22-41
18 702640-11-91 2 Ea
Plate, Exhaust Seal,1-1/2 For 1 1/2" Dual Pilot Regu-
20 A04 112386-02 2 Ea
lator
23 702645-21-61 3 Ea
29 A03 107160 1 Ea Spring,Exhaust Return Od.700"
31 B02 110369 1 Ea Spring, Inlet Seal, 1-1/2" Hyd. Pressure Regulator
32 A02 107097 1 Ea Spring,Relief Seal 1-1/2" Model Dp. Regulator
33 702645-11-61 2 Ea
Ring,Seal,Relief,1.50" Model Dp Reg Type17-4 Ph
34 B01 107091-01 2 Ea
Sst
Washer, .250 Flat Type A Sst 18-8 .281 X .625 X .065
35 702528-06-03 1 Ea
Ansi B18.22.1
36 A02 107945 1 Ea Spring, 0.410 Od X 2-1/2 Lg X 0.072 Wire, 302 Sst
Regulator, 1-1/2" Sst Assembly- Hydraulic Pilot Op-
0 C01 309536 1 Ea
erated, 0-3000 Psi W.P.
TC8081 3-46
TC8081 3-47
TC8081 3-48
VI. 1½" HYDRAULIC REGULATOR
P/N 309536-01

sembly drawing.
The item number of each part referred to in the procedure, refers to
the item number on the parts list or the repair kit parts list; the part
B. Special Tools or Materials Required.
1. Cameron Repair Kit, P/N 309536-90 and/or 309536-99.
1. Turn off the hydraulic supply to the regulator.
2. Bleed off the hydraulic pressure from the regulator assembly.
3. Disconnect the hydraulic piping from the regulator. It is not necessary

to remove the pipe fittings from the regulator assembly.
4. Take the regulator assembly to a work bench or suitable area where

there is room to work.
TC8081 3-49
5. Remove the cap screws (items 25) from the inlet seal flanges (items
11).
6. Remove the inlet seal flanges from the regulator assembly. Pry the
flanges loose by inserting the sharp edge of a knife blade under the
edge of each flange.
7. Remove the inlet seal plates (items 7) from the inlet seal flanges by re-
moving the cap screws (items 10).
8. Remove the seal rings (items 19) and the spring (item 31) from the
regulator assembly.
9. Remove the cap screws (items 8) from the pilot end cap (item 2).
10. Remove the pilot end cap from the regulator assembly.
11. Remove the pilot bushing (item 3) from the regulator assembly.
12. Remove the supply piston (item 1) from the regulator assembly.
13. Remove the cap screws (items 15) from the relief seal flanges (items
22).
14. Remove the relief seal flanges from the regulator assembly. Pry the
flanges loose by inserting the sharp edge of a knife blade under the
edge of each flange.
15. Remove the relief seal plates (items 20) from the relief seal flanges by
removing the cap screws (items 10).
16. Remove the seal rings (items 34) and the spring (item 32) from the
regulator assembly.
17. Remove the cap screws (items 27) from the relief end cap (item 30).
18. Remove the end cap from the regulator assembly.
19. Remove the springs (items 29 and 36) from the regulator assembly.
20. Remove the relief pilot bushing (item 26) from the regulator assembly.
21. Remove the relief piston (item 21) from the regulator assembly.
1. Remove the "O" rings (items 6 and 9) from the inlet seal flanges
(items 11).
TC8081 3-50
2. Clean the inlet seal flanges.
3. Install the new "O" rings (items 6 and 9) onto the inlet seal flanges.
4. Clean and inspect the inlet seal plates (items 7). Replace a seal plate if
the polished surface has scratches or shows excessive wear.
5. Remove the "O" ring (items 23) from the inlet seal rings (items 19).
6. Clean and inspect the inlet seal rings. Replace a seal ring if the pol-
7. Install the new "O" rings (items 23) onto the inlet seal rings.
8. Replace the spring (item 31).
9. Remove the "O" rings (items 4, 5, and 6) from the pilot bushing (item
3).
10. Clean the pilot bushing.
11. Install the new "O" rings (items 4, 5, and 6) onto the pilot bushing.
12. Clean and inspect the piston (item 1). Replace the piston if the head of
guide pin has scratches or shows excessive wear.
13. Remove the "O" rings (items 17 and 18) from the relief seal flanges
(item 22).
14. Clean the relief seal flanges.
15. Install the new "O" rings (items 17 and 18) onto the relief seal flanges.
16. Clean and inspect the relief seal plates (item 20). Replace a seal plate
if the polished surface has scratches or shows excessive wear.
17. Remove the "O" ring (item 33) from the relief seal rings (item 34).
18. clean and inspect the relief seal rings. Replace a seal ring if the pol-
19. Install the new "O" ring (item 33) onto the relief seal rings.
20. Replace the spring (item 32).
21. Remove the "O" rings (items 4, 6, and 23) from the relief pilot bushing
(item 26).
22. Clean and inspect the relief pilot bushing. Replace the pilot bushing if
the bore has scratches or shows excessive wear.
TC8081 3-51
23. Install the new "O" rings (items 4, 6, and 23) onto the relief pilot
bushing.
24. Replace the exhaust return springs (items 29 and 36) and the washer
(item 35).
25. Clean and inspect the relief piston. Replace the piston if the head,
guide pin, or bore has scratches or shows excessive wear.
26. Clean and inspect the body (item 14) of the regulator assembly. Re-
place the body if the surface of the bore where the "O" rings seal
against has scratches, flaking, or pits.
1. lubricate all parts thoroughly with Lubriplate or light waterproof

grease.
2. Install the relief piston (item 21) into the regulator assembly.
3. Install the relief pilot bushing (item 26) into the regulator assembly.
4. Install the springs (items 29 and 36) into the regulator assembly.
5. Install the relief end cap (item 30) and the washer (item 35) onto the
regulator assembly with the cap screws (items 27).
6. Install the seal rings (items 34) and the spring (item 32) into the regu-
lator assembly.
7. Install the relief seal plates (items 20) onto the relief seal flanges
(items 22) with cap screws (items 15).
Important: Align the offset relief port in each seal plate with the port in each relief
flange.
8. Install the relief seal flanges and the attached seal plates onto the reg-
ulator assembly so that the relief ports are offset toward the pilot end
cap (item 2).
Important: Do not hammer the relief flanges into position. The flanges and at-
tached seal plates are brittle and may break. Push the flanges and seal
plates into position by hand.
9. Install the supply piston (item 1) into the regulator assembly.
TC8081 3-52
10. install the pilot bushing (item 3) into the regulator assembly.
11. Install the pilot end cap (item 2) onto the regulator assembly with the
cap screws (item 8).
12. Install the seal rings (item 19) and the spring (item 31) into the regula-
tor assembly.
13. Install the inlet seal plates (item 7) onto the inlet seal flanges (items
11) with the cap screws (item 10).
14. Install the inlet seal flanges and the attached seal plates onto the reg-
ulator assembly so that the inlet ports are offset toward the pilot end
cap (item 2).
Important: Do not hammer the inlet flanges into position. The flanges and at-
tached seal plates are brittle and may break. Push the flanges and seal
plates into position by hang.
15. Reinstall the regulator assembly.
16. Turn on the hydraulic supply to the regulator assembly.
17. Inspect the regulator assembly for leaks and proper operation.
TC8081 3-53
Description: Valve, Piloted Dual,1",3-Way,3000 Psi, Sst, Spring Return

10 702645-22-41 2 Ea
/Ms-1078 Nitrile Pkg
Valve,Piloted,1", 3-Way 2-Pos, 3000 Psi,Sst, Spring
40 A06 309932-01 2 Ea
Return, Manifold Inlet X 1" Npt Outlet
50 C01 111504-01 1 Ea Manifold For Dual Valve 1" Npt
Valve 1" 2-Pos 3-Way Pilot Operated Spring Return,
70 B02 309932 1 Ea
Stn. Stl. Assembly
OPTIONAL ITEM
80 A01 309932-01-88 1 Ea Seal Kit, Valve, 1" 3-Way, 2-Pos, 3 ksi Wp
90 B01 309932-01-99 1 Ea Repair Kit, Valve, 1" 3-Way 2-Pos 3 ksi Wp
Description : Valve,Piloted,1-1/2",3-Way,3000 Psi Sst, Spring Return

Note: For Surface Application See Optional Items On B.O.M. 309535-01
Part Number: 309535-02 Revision: C03

17 702640-22-81 1 Ea
Valve,Piloted,1-1/2",3-Way,3000 psi, Sst, Spring Return
33 1 309535-01 1 Ea Note: for Surface Application Use Optional Items Per
B.O.M. (Preferred Valve Is 309915-05)
35 A01 111471-01 1 Ea Inlet Plate, Sst 4 X 4 X 1-1/2"Npt
36 702505-14-00-32 2 Ea Screw, Soc Hd Cap .625-11 X 3.25 sst 316
Cap Screw, 5/8-11x4" Lg., Socket Head 316 Sst W/ Full
37 C01 111417-01 2 Ea
Thread Length
Nut, Hvy Hex .625-11 Sst Ident & Pkg Per Dwg
38 2709000-07-39 2 Ea
2709000
Valve 1-1/2" Sst Assembly-Pilot Operated Spring Re-
0 B01 * 309535 1 Ea
turn 3-Way 3000 psi wp
Repair Kit, Valve, 1½“, 3-Way, Sst, 3000 Psi, Hyd Pilot,
0 J03 309535-01-99 1 Ea
Spring Return, Basic Assy
TC8081 3-54
Description: Valve,Piloted,1",3-Way 2-Pos,3000 Psi,Sst, Spring Return,
Manifold Inlet X 1" Npt Outlet
UNIT REV COMPONENT QTY UNIT DESCRIPTION

1 D02 111484-01 1 Ea Body, 1" Sst Valve
Valve, Relief-Manual 1/8m NPT SST 4000 PSI
2 705671 1 Ea Purge Type
3 B01 111270 1 Ea Pilot Piston, 2.5" Dia
4 A01 111479-01 1 Ea Pilot End Cap
5 A01 107039-01 1 Ea Valve Slide .88 Port
6 A01 112551-01 1 Ea Spring Retainer 1.375 Id X 2.62 Od
Spring, 2.62 O.D. X 3.88 Lg X 285 # Load X 0.312
7 A01 112550 1 Ea Wire Dia, 17-7 Ph Sst
8 A02 112552-01 1 Ea End Cap Inlet 1" Sst
9 A01 107034-01 2 Ea Ring,Seal,1.5 Id X 2.0 Od (17-4 Ph)
10 B01 107049 2 Ea Spring, 1.88 Od X 1.00 Lg X 10 Lb. Load
11 A02 111453-01 2 Ea Cap Seal Holder
12 702505-14-00-16 4 Ea /Ansi B18.3
13 702505-10-00-12 8 Ea /Ansi B18.3
14 203798 2 Ea B18.3
21 A02 2020055-07-88 1 Ea Tag, Component 1.937 X 1.000
22 202117 2 Ea B18.6.4
Part Ident: Low Stress Stamp, P/N, “Rev” Rev,
0 19 D-000100-09-04 1 Ea Purchase/Production Order No.
General Quality Plan For Control Systems Valves
0 A05 QP-000160-21 1 Ea And Components
TC8081 3-55
Description: Valve,Piloted,1",3-Way 2-Pos,3000 Psi,Sst, Spring Return,
Manifold Inlet X 1" Npt Outlet
UNIT REV COMPONENT QTY UNIT DESCRIPTION

Valve 1" 2-Pos 3-Way Pilot Operated Spring Re-
0 B02 309932 1 Ea turn, Stn. Stl. Assembly
0 A01 309932-01-88 1 Ea Seal Kit, Valve, 1" 3-Way, 2-Pos, 3ksi Wp
0 B01 309932-01-99 1 Ea Repair Kit, Valve, 1" 3-Way 2-Pos 3ksi Wp
TC8081 3-56

1 G01 111481-01 1 Ea Body, Valve Sst 1-1/2" Npt , 4" Sq X 8" Long
2 G01 107068 1 Ea Slide, 1-1/2 In. Valve
3 A01 111454-01 1 Ea Pilot End Cap/Stem, Sst
4 702645-12-81 2 Ea /Ms-1078 Nitrile Pkg and Qual /Ciw 702645
6 C01 107066 2 Ea Spring, 1.65 Od X 0.68 Lg
9 A01 111474-01 1 Ea Flange Outlet, Sst 4 X 4 X 1.5" Npt
11 B01 111472-01 1 Ea Flange Blind Seal, Sst 4"X4"X1.5"
12 D01 110004 1 Ea Spring, 1.87 Od X 5.5 Lg
13 D01 111480-01 1 Ea End Cap Inlet, Sst 4" Sq X 2.75 Lg. X 1.38 I.D.
20 702505-10-00-22 4 Ea /Ansi B18.3
21 702505-14-00-12 4 Ea /Ansi B18.3
22 702505-10-00-24 4 Ea /Ansi B18.3
23 203987 2 Ea B18.3
24 D01 107830 2 Ea Round Retainer Ring
TC8081 3-57

Tag, “Caution, Spring Is Compressed
25 A01 107130-29-71-01 1 Ea Use Two Jacking Screws (Provided) to Remove
and Install Spring", 1.25 X 3.5
26 202117 6 Ea B18.6.4
27 A02 107130-46-99-01 1 Ea Tag, Obs Use 2020055-07-88
Valve, Relief-Manual 1/8m Npt Sst 4000 Psi
28 705671 1 Ea Purge Type
Screw, .38-16 X 1.25 Lg. Brass, Hex Hd. Full
31 A02 110060 2 Ea Length Thd. Make From 704043
32 704042 2 Ea Nut, Hex Jam .375-16 Brass Ansi B18.2.2
33 042000-02-36 2 Ea Nitrile Parbak 8-Series
Valve 1-1/2" Sst Assembly-Pilot Operated Spring
100 B01 309535 1 Ea Return 3-Way 3000 Psi Wp
Repair Kit, Valve, 1-1/2", 3-Way, Sst, 3000 Psi,
95 J03 309535-01-99 1 Ea Hyd Pilot, Spring Return, Basic Ass’y
Flange, Blind Sst For 1-1/2" Valve for Surface
96 A01 2020436 1 Ea Use
Flange, Return 1-1/2" Npt Sst For 1-1/2" Valve
97 A01 2020437 1 Ea for Surface Use
98 702645-12-51 1 Ea /Ms-1078 Nitrile Pkg and Qual /Cameron 702645
O-Ring, Size AS-568-131 1.674 ID X .103 W 90D
99 702645-13-11 1 Ea /MS-1078 Nitrile Pkg and Qual /CC 702645
TC8081 3-58
Description: Repair Kit, Valve, 1" 3-Way 2-Pos 3ksi Wp
Part Number: 309932-01-99 Revision: B01

5 A01 107039-01 1 Ea Valve Slide .88 Port
Spring, 2.62 O.D. X 3.88 Lg X 285 # Load X
7 A01 112550 1 Ea 0.312 Wire Dia, 17-7 Ph Sst
9 A01 107034-01 2 Ea Ring,Seal,1.5 Id X 2.0 Od (17-4 Ph)
10 B01 107049 2 Ea Spring, 1.88 Od X 1.00 Lg X 10 Lb. Load
O Ring, Size As-568-228 2.234 Id X .139 W
702645
702645
702645
702645
702645
702645
Valve 1" 2-Pos 3-Way Pilot Operated Spring
0 B02 309932 1 Ea Return, Stn. Stl. Assembly
TC8081 3-59
Description: Repair Kit, Valve, 1-1/2", 3-Way, Sst, 3000 Psi, Hyd Pilot, Spring Return,
Basic Ass’y
Part Number: 309535-01-99 Revision: J03

702640
702645
702640
702640
702640
702640
702645
33 042000-02-36 2 Ea Nitrile Parbak 8-Series
702640
702640
TC8081 3-60
TC8081 3-61
TC8081 3-62
TC8081 3-63
TC8081 3-64
VII.THREE-WAY VALVE
P/N 309932-03
1. Repair the valve assembly in place.
2. Repair only one valve at a time.
6. Refer to the assembly drawing while following the procedure.
The item numbers in the procedure refer to the item numbers on the
assembly drawing.
number is opposite the item numb er.
B. Special Tools or Materials Required
1. Cameron Repair Kit, P/N 309932-01-99 and/or 309535-01-99.
TC8081 3-65
3. Remove the cap screws (items 13) from the seal holders (items 11) of
the valve needing repair.
4. Remove the seal holders from the valve.
5. Remove the seal rings (item 9) and the springs (item 10) from the seal
holders.
6. Remove the cap screws (item 33) from the inlet manifold flange (item
35).
7. Remove the manifold flange from the manifold (item 31).
8. Remove the cap screws (item 32) from the manifold.
9. Remove the manifold from the valve assembly.
10. Remove the cap screws (item 14) from the end cap (item 8) on the in-
let end of the valve.
Caution: The end cap is under spring pressure. Hold the end cap firmly to prevent
it from flying off.
11. Remove the end cap from the valve.
12. Remove the spring (item 7) and the spring retainer (item 6) from the
valve.
13. Remove the cap screws (item 12) from the end cap (item 4) on the out-
let end of the valve.
14. Remove the end cap from the pilot housing (item 2) of the valve.
15. Remove the pilot housing (item 2) from the valve.
16. Remove the pilot piston (item 3) from the valve.
17. Remove the slide (item 5) from the valve.
1. Clean and inspect the polished sealing surface of the slide (item 5). Re-
place the slide if it has scratches.
2. Remove the "O" ring (item 16) from the valve body (item 1).
3. Clean the valve body.
4. Install the new "O" ring (item 16) onto the valve body.
TC8081 3-66
5. Remove the "O" ring (item 20) from the pilot piston (item 3).
6. Clean the pilot piston.
7. Install the new "O" ring (item 200 onto the pilot piston.
8. Remove the "O" rings (items 15) from the pilot housing (item 2).
9. Clean the pilot housing.
10. Install the new "O" rings (items 15) onto the pilot housing.
11. Remove the "O" ring (item 20) from the end cap (item 4).
12. Clean the end cap.
13. Install the new "O" ring (item 20) onto the end cap.
14. Remove the "O" rings (items 15, 18, and 19) from the inlet end cap
(item 8.)
15. Clean the end cap.
16. Install the new "O" rings (items 15, 18, and 19) onto the end cap.
17. Clean the manifold.
18. Remove the "O" ring (item 34) from the inlet manifold flange (item
35).
19. Clean the inlet manifold flange.
20. Install the new "O" ring (item 34) onto the inlet manifold flange.
21. Remove the "O" rings (items 18) from the seal rings (items 9).
22. Clean and inspect the seal rings. Replace the seal rings if the polished
surfaces have scratches or cuts.
23. install the new "O" rings (items 18) onto the seal rings.
24. Remove the "O" rings (items 17) from the seal holders (items 11).
25. Clean the seal holders.
26. Install the new "O" rings (items 17) onto the seal holders.
TC8081 3-67

grease.
2. Install the pilot piston (item 3) into the outlet end of the valve.
3. Install the slide (item 5) into the valve.
Important: Be sure to install the slide correctly. Refer to the assembly drawing.
4. Install the pilot housing (item 2) in the outlet end of the valve.
5. Install the end cap (item 4) onto the outlet end of the valve with the
cap screws (items 12).
6. Install the spring retainer (item 6) and the spring (item 7) in the outlet
end of the valve.
7. Install the end cap (item 8) onto the inlet end of the valve with cap
screws (items 14).
8. Install the manifold (item 31) onto the inlet end of the valve assembly
with the cap screws (items 32).
Important: Be sure that the exhaust port of the valve faces outward. Refer to the
assembly drawing.
9. Install the inlet manifold flange (item 35) onto the manifold with the
10. Install the inlet manifold flange (item 35) onto the manifold with the
10. Install the seal ring (items 9) and the springs (items 10) in the seal
holders (items 11).
11. Install the seal holders into the valve with the cap screws (items 13).
13. Inspect the repaired valve for leaks and proper operation.
TC8081 3-68
Description: Valve, Piloted Dual,1",3-Way,3000 psi, sst, w/Weld Flange

18 702640-22-41 2 Ea /Ms-1004 Nitrile Pkg And Qual /Ciw 702640 Obs,
Use 702645-22-41
Valve,Piloted,1",3-Way 2-Pos,3000 Psi,Sst, Spring
30 A06 309932-01 2 Ea Return, Manifold Inlet X 1" Npt Outlet
Manifold, 1" Ports, 303 Stainless for Mounting Two
31 D01 111486-01 1 Ea 1"Valves, Rc Pod
32 702505-14-00-36 4 Ea /Ansi B18.3
Screw, Soc Hd Cap .625-11 X 4.5 Sst 316 /A193 /Ansi
33 702505-14-00-44 4 Ea B18.3
O Ring, Size 217 1.171 Id X .139 W 6227-22 70d
34 200482 1 Ea /Ps-4-205
Flange, Inlet Manifold (Socket Weld 3 X 3.5 X 1" Id
35 C01 107750 1 Ea X 1.265 Tube Od
36 202117 4 Ea B18.6.4
Valve 1" 2-Pos 3-Way Pilot Operated Spring Return,
0 B02 309932 1 Ea Stn. Stl. Assembly
Seal Kit,Valve,1",3-Way,3000 psi, Hyd Pilot, Spring
0 A04 309534-01-88 2 Ea Return, Basic Ass’y
Repair Kit, Valve, 1", 3-Way, Sst, 3000 Psi, Hyd Pilot,
0 C05 309534-01-99 2 Ea Spring Return, Basic Assembly
TC8081 3-69
Description: Accumulator,Hyd 30 Cu In 3000 Psi 3/4 Npt Port Piston Type Viton Seals
.001 Thk Exterior Electroless Ni Pl
Part Number : 704132
No BOM exists
TC8081 3-70
Description : Repair Kit, Valve, 1", 3-Way, Sst, 3000 Psi, Hyd Pilot, Spring Return,
Basic Assembly

Valve Slide .88 Port Ring,Seal,1.5 Id X 2.0
5 A01 107039-01 1 Ea Od (17-4 Ph)
9 A01 107034-01 2 Ea Ring Seal, 1.5 ID x 2.0 OD (17-4 PH)
702645
702645
702645
702645
702645
702645
702645
TC8081 3-71
TC8081 3-72
Description: Valve, Piloted, ¼“,4-Way 2-Pos,3000 psi, sst, (Unbalanced)

1 B01 110350 1 Ea Body, Valve 2 X 2 X 4" Long
3 C02 110464 1 Ea Cylinder Head, 2.000" Sq X 1.5 Dia X .750 Dia.
5 B01 111281-02 1 Ea Piston 1/4 Piloted Valve Unbal. w/Detent
6 702645-11-61 2 Ea /Ms-1078 Nitrile Pkg and Qual / Cameron 702645
Seal Ring, Valve, 1/4" 5 Ksi WP .857 I.D. X .936 O.D.
7 A01 2185585-03 2 Ea X .566 Long
10 C01 111282 1 Ea Cylinder Head, 2" Sq. X 1.5" Od X .5" Id Sst
11 702505-02-00-06 8 Ea /Ansi B18.3
13 F02 105423 1 Ea Plate-Inlet Seal,1.75 Dia X 0.47 Thk X .250 Dia Hole
15 D01 110465 1 Ea Flange Inlet 2" X 2" X ¼“ Npt Sst
Plate-Outlet Seal, ¼” Failsafe Panel Valve, With Air
16 F01 105424 1 Ea Oper.
18 B01 110468 1 Ea Flange Outlet, Dual Port 2x2x1/4npt
19 702505-02-00-12 4 Ea /Ansi B18.3
Screw, Soc Hd Cap .250-20 X 1.5 Sst 316 / A193 /Ansi
20 702505-02-00-14 4 Ea B18.3
Ball, .312 Dia Sst , Hardened Afbma Type B Grade
21 200252 1 Ea 100
22 B01 103032 1 Ea Spring, Multipurpose
23 B01 105075 1 Ea Gasket-Detent, ¼“ Panel Valve, Copper
24 C02 105074 1 Ea Detent Holder
26 A02 2020055-07-88 1 Ea Tag, Component 1.937 X 1.000
TC8081 3-73
Description: Valve, Piloted, ¼“,4-Way 2-Pos,3000 psi, sst, (Unbalanced)

Valve,Drg,1/4", 4way, 2 pos, 3ksi WP Unbalanced,
0 A01 SK-122803-01 1 Ea Panel Mtd, ¼ Npt Supply/ Output, Npt Pilot Conns.
Repair Kit,Valve,1/4",4-Way, 2-Pos, 3000 Psi, Hyd Pi-
0 A01 309478-02-99 1 Ea lot, Unbalanced Cyl’s
TC8081 3-74
Description: Repair Kit,Valve,1/4",4-Way,2-Pos, 3000 Psi, Hyd Pilot, Unbalanced Cyl’s
Part Number: 309478-02-99 Revision: A01

6 702645-11-61 2 Ea /Ms-1078 Nitrile Pkg And Qual / Cameron 702645
Seal Ring, Valve, 1/4" 5 Ksi W.P. .857 I.D. X .936
7 A01 2185585-03 2 Ea O.D. X .566 Long
13 F02 105423 1 Ea Hole
Plate-Outlet Seal, 1/4" Failsafe Panel Valve, With
16 F01 105424 1 Ea Air Oper.
Ball, .312 Dia Sst , Hardened Afbma Type B Grade
21 200252 1 Ea 100
22 B01 103032 1 Ea Spring, Multipurpose
23 B01 105075 1 Ea Gasket-Detent, 1/4" Panel Valve, Copper
Valve,Drg,1/4", 4way, 2pos, 3ksi Wp Unbalanced,
0 A01 SK-122803-01 1 Ea Panel Mtd, ¼ Npt Supply/ Output, 1/8 Npt Pilot
Conns.
TC8081 3-75
TC8081 3-76
Description : Valve,Piloted,1/4",4-Way 2-Pos,3000 PSI, Spring Return, SST, for
Subsea Service

1 B01 110348 1 Ea Body, ¼“ 4-Way Slide Valve
2 B01 110482 1 Ea End Cap-Special ¼” 4-Way Valve
Spool- ¼“ Panel Valve 2-Pos., 4-Way, Air Actuated
3 D01 106854 1 Ea W/Spring Return
Plate-Outlet Seal, ¼” Failsafe Panel Valve, With
8 F01 105424 1 Ea Air Oper.
10 B01 110468 1 Ea Flange Outlet, Dual Port 2x2x¼ npt
11 702505-02-00-14 4 Ea /Ansi B18.3
12 F02 105423 1 Ea Hole
14 D01 110465 1 Ea Flange Inlet 2" X 2" X ¼“ Npt Sst
15 702505-02-00-12 8 Ea /Ansi B18.3
16 B01 103738 3 Ea Gasket, 2 X 2 X 1.5 I.D. X .03 Thk Material- Jm 961
18 A02 110483 1 Ea Rod Cover-Special-¼”-4-Way Valve
21 A01 110479 1 Ea Rod, Push
23 A01 110478 1 Ea Rod, Push
24 201017 1 Ea Plug, Pipe-Threaded Hex Hd Stl 3000 Psi
25 D01 110354 1 Ea Cap, Special End
26 702505-02-00-20 4 Ea Screw, Soc Hd Cap .250-20 X 2 Sst 316 A193
27 A01 110384 1 Ea Spring, Standard For ¼“ Valves
28 B02 110480 1 Ea End Cap-Lock For ¼”, 4-Way Valve
31 A02 107130-46-99-01 1 Ea Tag, Obs Use 2020055-07-88
TC8081 3-77
Description : Valve,Piloted,1/4",4-Way 2-Pos,3000 PSI, Spring Return, SST, for
Subsea Service

Valve, ¼“ Panel, 2-Pos. 4-Way With Spring Return,
0 C02 309069 1 Ea Sst
Repair Kit,Valve,4-Way,2-Pos,3000 Psi, Hyd Pilot,
0 G04 309069-05-99 1 Ea Spring Return
TC8081 3-78
Section 4
Troubleshooting
I. Special Instructions . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
II. Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . 4-3
TC8081 4-1
TC8081 4-2
TROUBLESHOOTING PROCEDURE
I. SPECIAL INSTRUCTIONS
A. Read the procedure carefully before beginning.
B. Follow the procedure step-by-step in numerical order.
C. Refer to the diagrams while following the procedure.
II. TROUBLESHOOTING PROCEDURE

When a stack function does not operate properly, follow the instructions be-
low.
A. Determine if the problem is electrical, pneumatic, or hydraulic.
1. Turn the operating mode switch on the Master Control Panel to the
LOCAL position.
2. Operate the stack function from the Master control Panel on the Hy-
draulic Power Unit.
a. If the stack function operates properly, the problem is pneumatic

or electrical. Continue to Step II-D.
b. If the stack function does not operate properly, the problem is hy-
draulic. continue to the next step for the surface hydraulic system
troubleshooting procedure.
B. Troubleshoot the surface hydraulic system.
Important: Refer to the hydraulic flow diagrams while following the procedure.
1. Starting at the hose reel, trace the flow of hydraulic fluid through the
1" I.D. supply line, Using the process of elimination, check every loca-
tion between the hose reel and the surface accumulators where possi-
ble for the presence of hydraulic pressure. The cause of the problem
TC8081 4-3
will be between the point where pressure is present and the point
where pressure is absent.
a. If a part is causing the problem, continue to Paragraph III to find

the part number and the maintenance procedure.
b. If the cause of the problem is not present along the 1" I.D. supply
line, continue to the next step.
2. Starting at the panel valve for the stack function on the master Con-
trol panel, trace the flow of the hydraulic fluid through the 3/16" I.D.
pilot line. using the process of elimination, check every location be-
tween the panel valve and the hose reel where possible for the pres-
ence of hydraulic pressure. the cause of the problem will be between
the point where pressure is present and the point where pressure is
absent.
a. If a part is causing the problem, continue to Paragraph III to find

b. If the surface hydraulic system has hydraulic flow and pressure

through the 1" I.D. supply line and the 3/16" I.D. pilot line all the
way to the hose reel, the problem is not in the surface hydraulic
system. Continue to the next step
C. Troubleshoot the subsea hydraulic system.
1. Retract the hydraulic connectors into the pod, and operate the func-
tion again.
a. If the function operates properly, the cause of the problem is on

the stack.
b. If the function does not operate properly, the cause of the prob-
lem is in the pod. Continue to the next step.
2. Retrieve the pod from the stack.
3. Check to see that hydraulic pressure from the 1" I.D. supply line is
reaching the pod valve that controls the stack function.
a. If hydraulic pressure from the 1" I.D. supply line is not reaching the
pod valve, trace back from the pod valve until you find the cause.
• If a part is causing the problem, continue to Paragraph III to find

TC8081 4-4
• If hydraulic pressure from the 1" I.D. supply line is reaching the
pod valve, continue to the next step.
4. Check to see that the correct pilot pressure is reaching the pod valve.
a. If the correct pilot pressure is not reaching the pod valve, trace
back from the valve to find the cause.
• If a part is causing the problem, continue to Paragraph III to find

• If the correct pilot pressure is reaching the pod valve, continue to
the next step.
5. Check the pod valve for proper operation.
a. If the pod valve does not operte properly, continue to Paragraph III
to find the part number and the maintenance procedure.
b. If the pod valve operates properly, continue to the next step.
6. Inspect the retractable connectors and the seals for leakage.
a. If the retractable connectors or seals are leaking, turn to Paragraph

III to find the part number and the maintenance procedure.
b. If the retractable connectors or seals are not leaking, or the prob-

lem is intermittent, repeat Steps II-C-1 through II-C-6.
7. Switch to the other pod by operating the selector valve on the Master
control Panel.
8. Operate the function that is not operating properly again.
a. If the function operates properly, continue operations until you

can retrieve the stack.
b. If the function does not operate properly, retrieve the stack as

soon as possible. Continue to the next step.
9. Trace the flow of hydraulic pressure between the pod valve and the
stack function.
TC8081 4-5
TC8081 4-6

TC8081

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

TC8081

Uploaded by

Copyright:

Available Formats

Atlantic Star

Cameron · P.O. Box 1212, Houston, Tx 77251-1212 · 713-939-2211 · http://www.c-a-m.com

Copyright © 2006 all rights reserved

This book covers Cameron products, which are products of Cooper

Cooper Cameron Corporation

Control Pods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15

ITEM REV COMPONENT QTY UNIT DESCRIPTION

ITEM REV COMPONENT QTY UNIT DESCRIPTION

ITEM REV COMPONENT QTY UNIT DESCRIPTION

ITEM REV COMPONENT QTY UNIT DESCRIPTION

II. Run the Stack and riser . . . . . . . . . . . . . . . . . . . . . . . . 2-5

III. Retrieve the Stack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

IV. Retrieve the Pod . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

V. Lower the Pod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

I. INSTALL THE CONTROL PODS

A. Operate the following at the master hydraulic Control Panel.

1. Move the Operating Mode switch to LOCAL.

4. Move the Panel Pressure control switch to VENT.

B. Connect a Jumper hose to each reel.

D. Set the control pods in place on the female baseplate.

F. Operate the following at the Master Hydraulic Control Panel.

2. Set the Panel Pressure on 2000 psi.

3. Move the Panel Pressure Control switch to OPEN.

Note: Allow five minutes for the connectors to fully extend.

Note: Allow one minute for locks to operate.

6. Move the Pod Selector valve to BLUE.

8. Set the BOP regulator on 1500 psi.

9. Set the ball joint on 1000 psi.

11. Move the Selector valve to YELLOW.

G. Install the Riser Stab Assembly on the Blowout Preventer Stack.

1. Move the Stab Plate Locks to UNLOCK.

2. Move the Stab Plate Jacks to RAISE.

3. Install the Riser stab Assembly on the BOP Stack.

5. Move the Riser Connector to LATCH.

6. move the Stab Plate Jacks to LOWER.

7. Move the Stab Plate locks to LOCK.

H. Operate the following at the Master Hydraulic Control Panel.

3. Move the Selector valve to BLUE.

II. RUN THE STACK AND RISER

B. Operate the following at the Master Hydraulic Control Panel.

2. Move the Panel Pressure Control switch to VENT.

3. Set the Panel Pressure regulator on 1500 psi.

C. Disconnect the Jumper Hoses from the reels.

D. Operate the following at the Powered Hose Reel Panels.

1. Move the Stab Plate Jacks to LOWER.

2. Move the Stab Plate Locks to LOCK.

3. Move the Riser Connector to LATCH.

4. Move the Wellhead Connector to UNLATCH.

5. Move the Shear Ram to OPEN.

6. Move Ram #4 to OPEN.

7. Move the Retractable Connectors Stack to Extend.

8. Open the Pod Connectors and Pod Lock Actuator valve.

E. Select one pod for control.

F. Operate the following at the Master Hydraulic Control Panel.

G. Operate the following at the Reel Panel of the system selected.

1. Open the BOP Regulator valve.

2. Open the Panel Supply valve.

H. Lower the stack and riser according to rig procedures.

I. Operate the following at the Hose Reel Panel.

1. Move the Wellhead Connector to LATCH.

2. Test the wellhead connection accoring to rig procedures.

3. Close the BOP Regulator valve.

4. Close the Panel Supply valve.

5. Move all the valves to the center position.