Manual of HSC16

COPYRIGHT NOTICE
Thismanualiscopyrightedasanunpublishedwork.
This manual contains the confidential and proprietary information of Yantai Jereh
Petroleum Equipment and Technologies Co., Ltd.
Neither this document nor any information contained herein may be reproduced or
redistributed in any form whatsoever without the express, written consent of an
authorizedagentofYantai Jereh Petroleum Equipment and Technologies Co., Ltd.
AnyattemptbyanypersonotherthananauthorizedagentofYantai Jereh Petroleum
Equipment and Technologies Co., Ltd. toalterthecontentsofthismanualinanyway
shallbeconstruedascopyrightinfringement,punishablebyallapplicablelaws.
All vendor literature contained in this manual is the copyrighted property of the
respective vendors, protected by the same laws governing this operation and
maintenancemanual.
©Copyright2015byYantai Jereh Petroleum Equipment and Technologies Co., Ltd.
Allrightsreserved.
©CopyrightYantaiJerehPetroleumEquipmentandTechnologiesCo.,Ltd.2015
FOREWORD
Thank you for choosing JEREH products. We will provide you with professional
productsandtimelyafter-salesservice.
ThisequipmentisindependentlydevelopedbyJEREH. Itisspeciallydesignedforthe
oil/gasfieldstimulationoperationsanditisanidealproductwithhighintelligenceand
automation.
This operation and maintenance manual consists of introductions regarding to
equipmentstructure,operation,safetyandmaintenance.
Readthismanualcarefullybeforeoperation.Itwillhelpyouto
a) Understandthestructureandperformancebetter.
b) Avoidanyimproperoperationthatwillcauseequipmentfailure.
c) Enhancethereliabilityoftheequipment.
d) Extendthelifeoftheequipment.
e) Reducemaintenancecost.
Please be informed that the figures in the manual are all illustrations which may
differentfromtheactualunitindetailsandthoughcontentsofthismanualarecorrect,
ourproductissubjecttoconstantchangeandsuchchangewillnotbenotified.
Yantai Jereh Petroleum Equipment and Technologies Co., Ltd.
HSC16 Foreword 1
WARNING, CAUTION, NOTE
There are kinds of potential hazards in oilfield operation. It’s necessary for the
operators of the equipment to be familiar with all relevant safety regulations and
preventive measures. Nonobservance of the safety regulations in this chapter or the
warning/cautioninotherchaptersmaycausedamageorfailuretotheequipment,or
injuryorinsomecaseslostoflife.Operatorsshallreadthefollowingsafetyregulations
beforeoperation.
COMMON PRECAUTION
Safety is every operator’s duty and safety should be given prior attention. To be
familiarwiththeguidelinesinthismanualwillhelptoguaranteepersonnelsafetyand
equipmentsafety.
ONLY approved qualified personnel are allowed to operate and maintain the
equipment.Alloperatorsshallbeequippedwithproperpersonalprotectiveequipment
during operation or maintenance and comply with all the safety regulations during
preparation, operation, shutdown and maintenance of the equipment. It’s the end
user and operator’s first responsibility to ensure the implementation of safety
regulations and training schedules. Any irrelevant people shall keep away from the
equipmentduringoperation,maintenanceorrepairing.Makesurethepressureofthe
pipelinesconnectingwiththeequipmentisreleasedbeforeanydisassemblyoperation.
DO NOT disassemble or maintain any parts unilaterally. Contact company
representativesforanyquestion.Anyliftingandconveyingdevicemusthaveadequate
ratedloadcapacity.
2 Foreword HSC16
SAFETY SYMBOLS
Look for these symbols that point out items of importance to the safety of the
individualandgroup.
Thesafetywarningsandcautionscontainedinthismanualaretypical,andarenotthe
onlytypesofgeneralprecautionsthatshouldalwaysbeobservedduringallphasesof
operation and maintenance. Actions during any unusual circumstances should be
directedbycommonsense.
Warningsandcautionswithinthismanualshouldbelearntbyheart.Butitshouldalso
bepointedoutthatthesewarningsandcautionsdonotcovereverything,whichshould
benoticedtoensurepersonalsafetyandlongequipmentlifetime.
WARNING
WARNING:Acommentpertainingtoanoperationormaintenanceaction,procedure,
practice condition, or statement that, if not strictly observed, will result in injury or
deathtopersonneland/ordamagetoequipment.
CAUTION
CAUTION:Acommentpertainingtoanoperationormaintenanceprocedure,practice,
or condition that, if not strictly observed, can result in injury or death to personnel
and/ordamagetoequipment.
NOTE
NOTE: An essential comment pertaining to the highlighting of a specification,
procedure, practice, or condition that aids in the maintenance or operation of the
HSC16 Foreword 3
equipmentfunctioninvolvedordescribed.
SAFETY ALERT
a) Applyproperequipmentprotectionbeforetransportationtoavoidanyimpactthat
willcauseanyaccident.
b) Inspect the equipment before the first operation or operations in winter. Inspect
and make sure all valves especially high pressure valves are at correct position.
Verifythatthesafetyvalvepressureissetcorrectly.
c) Addcoolantfluidtotheenginecoolanttank.Choosecoolantgradeaccordingto
differentseasons.
d) Selectproperdieselaccordingtooperationseasontoavoidthedieselfromwaxing.
e) Inspectlubricantlevelbeforeoperationeverytime.
f) Inspectthelevelofengineoil,coolantandtheairfilterindicator.
g) Beforeunitstartupandshutdown,thethrottleandgearcontrolvalvemustbein
initialposition.
h) Beforeturningenginespeedto1,800~2,100rpm,lettheenginewarmupatidle
speedforabout5minutesafterstartupinwintertime.Intheeventthattheengine
is shutdown by accident during operation, unload immediately and restart it to
avoiddamagetotheturbocharger.
i) DONOTopenwatertankcovertocheckfluidlevelduringorshortlyafterengine
operationtoavoidbeingscalded.
j) Adjustthrottleandshiftvalveslowlytoavoiddamagetotheequipment.
k) TheworkingpressureshallnotexceedtheMax.Ratedpressureoftheequipment.
l) ALWAYSwashthepipelinesaftereachoperation.
4 Foreword HSC16
m) After cleaning, carefully inspect the equipment according to pre-operation
inspectionitemlist.ALWAYSdrainthefluidendandpipelineafteroperationinall
seasons.
n) The transmission must be in lockup status when the unit has to run for a long
period!
o) In either summer or winter, please make sure that liquid in such systems as
pneumaticsystem(airbottle),high/lowpressuremanifoldandalldeliverypump
chambersaredrainedthoroughlyaftereachjob/operation.Thiswillhelptoavoid
corrosionorfrost.
HSC16 Foreword 5
WELDING NOTE
The correct welding procedure will protect the electric/electronic devices (including
engineECM,sensorandotheraccessories),bearingsandhydraulicpartsfromdamage.
Disassemble all the relevant parts if possible. In the event that they cannot be
disassembled,makesurethefollowingweldingproceduresareimplementedstrictly.
Correctactionsareasfollowing:
a) Stoptheengineandswitchoffthepower.
b) Disconnectthewirefromthebattery.
c) DisconnectthetwoplugsofECM.MovethemawayfromECMneedle.
d) Connecttheweldingmachine’sgroundwiretothelocationwhereitisclosetothe
welding position to minimize the damage to the electric parts, bearings and
hydraulicparts.
e) Weldingcurrentmaydamagetheelectricpartsiftheyareusedastheconnection
pointtothegroundwire,orinthemiddleofgroundwireandelectrode.
f) Protectthewiringsfromdamageduetotheweldingsinter.
g) Operationshallbedonebyexperiencedwelders.
6 Foreword HSC16
CAUTION
a) DONOTconnectthegroundwirewiththeelectricparts,bearingsandhydraulic
parts, such as the ECM, sensor, instrument and other hydraulic elements.
Impropergroundwiringwillcausedamagetotheseparts.
b) Theclampofthegroundwireshallbepositionedontheweldingpositiondirectly
andkeepascloseraspossibletotheweldingpoint(within60cm).Thiswillhelp
reducethepossibilityofdamage.
c) DONOTusetheengineortransmissionasweldingground.
d) DONOTweldthebodyofengineortransmission.Iftheengineaccessories(e.g.
exhaust pipe) need to be welded, they must be disassembled and then welded
separately.
e) Keep welding cable away from electric parts, instruments and wire harness, in
whichcasestheymaybedamagedbythecurrent.
HSC16 Foreword 7
UNIT CONVERSION
Unit Conversion Between Metric Units and Imperial Units
L
1bbl=42gal=158.76L;
bbl
1gal=3.785L
gal
g/cm3
kg/L 1g/cm3=1kg/L=8.35lb/gal
lb/gal
kg
1kg=2.205lb
lb
MPa
kPa
1MPa=1000kPa=10bar=145psi
bar
psi
ft
m 1ft=12in=0.3048m
In(″)
°C
℃=(℉-32)×5/9
℉
m3/min
m3/h
1m3/min=60m3/h=264.172gpm=2118.88SCFH
gpm
SCFH
8 Foreword HSC16
TABLE OF CONTENTS
CHAPTER1……………………………………………..………………..…………..…....ABOUTTHISMANUAL
CHAPTER2…………………………………………………………………………..………SAFETYANDHEALTH
CHAPTER 3…………………………………………………….……………………….BRIEF INTRODUCTIONS
CHAPTER 4……………………………………………………………………………………………………CHASSIS
CHAPTER 5…………………………………………………………………………………………POWER SYSTEM
CHAPTER 6…………………………………………………………….……………SAND BLENDING SYSTEM
CHAPTER 7……………………………………………..………………..…………..………HYDRAULIC SYSTEM
CHAPTER 8…………………………………………………………………………..………PNEUMATIC SYSTEM
CHAPTER 9…………………………………………………………………….….....…………ELECTRIC SYSTEM
CHAPTER10…………………………………………………………OPERATIONANDCONTROLSYSTEM
CHAPTER 11……………………………………………………………………………SOFTWARE OPERATION
CHAPTER12…………………………………………………………….…………OPERATIONREGULATIONS
CHAPTER 13…………………………………………………………INSPECTION AND MAINTENANCE
CHAPTER14…………………………………………………………….……………………TROUBLESHOOTING
CHAPTER 1 ABOUT THIS MANUAL
1.1 GENERAL USE
The manual provides sufficient descriptive material and illustrations to enable the
operator and maintenance personnel to understand the fundamentals of successful
operation. This manual is intended only as a guide and not as a substitute for
mechanics,electronics,orhydraulicstraining.Noliability,eitherexpressedorimplied,is
givenforanyinformationcontainedherein.
This manual does not intend to illustrate all possible situations. Study this manual
carefullybeforemakinganyattempttooperatethisequipment.Payspecialattentionto
CHAPTER 2—SAFETY AND HEALTHoutlinedherein.
Yantai Jereh Petroleum Equipment & Technologies Co., Ltd. assumes no
responsibilityforimproperuseofequipment,improperlytrainedpersonnel,improperly
maintainedequipment,orfailuretofollownormalsafetyprecautionsoutlinedhere,in
themanufacturerliterature,orbyproperlytrainedpersonnel.
For engine equipped with emergency shutoff valve, the operator should pay special
attention to the NOTE “BEFORE STARTING THE ENGINE, ALWAYS MAKE SURE ALL
EMERGENCYSHUTOFFVALVESOFTHEENGINEAREOPENED”inAIR INTAKE AND
EXHAUST SYSTEM of CHAPTER 5 POWER SYSTEM.Iftheoperatorsfailedtofollow
theNOTE,MANUFACTURERwillassumenoresponsibilityforenginedamagecaused.
HSC16 Chapter 1 About This Manual 1

Useofthismanualforanypurposeotherthanforthesafeandproperoperationand
maintenanceoftheequipmentandallitscomponentsconstitutesmisuse.Ifthereisany
discrepancy between information contained in this manual and the manufacturer
literature,themanufacturerliteratureisassumedcorrect.
PleaseusestandardpartsandmaterialsprovidedbyJEREH.Shouldanydamageoccur
duetoapplicationofpartsandmaterialsnotprovidedornotprovedbyJEREH,JEREH
will automatically terminate its quality warranty and all damages incurred shall be
bornebytheuser.
Allinformationinthismanualisbasedonthelatestproductinformationavailableat
thetimeofpublication.Ifyouhaveanyunsolvedproblemoranyquestionconcerning
thecontentsorformatofthismanual,pleasecontactourafter-salesserviceat:
Yantai Jereh Petroleum Equipment & Technologies Co., Ltd.
Add:No.27JerehRoad,LaishanDistrict,Yantai,Shandong,China.
P.C.:264003
Tel:+86-400-816-2161
Fax:+86-535-672-3171
2 Chapter 1 About This Manual HSC16

1.2 WARRANTIES OF QUALITY
A. YantaiJEREHwarrantsthatonthedateofacceptanceandforoneyearthereafter,
theGoodsshallbefreefromdefectsinJEREH’smaterialsandworkmanshipand
shall meet the additional express written statement of quality, if any, made by
JEREHinconnectionwiththeSaleofGoodsandsignedbyanofficerofJEREH.This
ExpressWarrantysetforthintheimmediateprecedingsentenceshallapplyONLY
infavoroftheUserandshallbesubjecttothefollowinglimitations:
a) TheExpressWarrantyofqualityshallapplyonlyif:
1) The goods have been exposed to normal use and service, have been
reasonablymaintained,andotherwiseusedinaccordancewithJEREH’s
instructions,
2) TheGoodsarereturnedtoJEREH’sfactoryinYantai,China(orsuchother
placeclosertothelocationoftheequipment,goodsorpartsasmaybe
designatedbyJEREH)withintendaysafterUserfirstdiscoversaclaimed
defectwithtransportationcostsprepaidbyUser;and
3) JEREH’sexaminationuponthereturnofsuchGoodssatisfiesJEREHthat
suchareinfactdefective.
b) TheExpressWarrantyofqualityshallnotapply:
a. To Goods that have been rebuilt (whether by JEREH or by any other
entity)， soasinJEREH’sjudgmenttoaffectthestability,reliability,or
performanceoftheGoods.
b. To Goods not manufactured entirely by JEREH (however, JEREH shall
assign to User, to the extent the same assignable, whatever warranty
JEREHhasreceivedfromthemanufacturerofsuchGoods).
c. To Goods that have passed the quality assurance period and have not

beeninqualityassurancetimerange.
d. ToGoodswhichhavebeenmisusedornotbeenusedwithinthedesigning
functions.
e. toGoodsthathavebeenunreasonablyusedbyUseroranyotherentity
afterUserorsuchentitykneworshouldhaveknownofthedefectinthe
Goods, Or which have been damaged due to unreasonable sue,
negligence,oraccidentofUseroranyotherentity,or
f. The operation and maintenance manual shall prevail for the Goods and
their uses, any advisory services and/or recommendations provided by
JEREH with respect to the Goods and their uses are notwarranted.Any
referencebyJEREHtoUser’sspecificationsandsimilarrequirementsare
madeonlytodescribetheGoodsingeneral,andnowarrantiesorother
terms therein shall any force or effect. The operation and maintenance
manualisforgeneralinformationpurposesonlyandshallnotbedeemed
toconstituteexpresswrittenstatementsofquality,anditemsmentioned
inthemanualhavenolegaleffect.
g. Maincomponentsoftheunit(suchaschassis,engine,transmissionand
pump) are operated improperly or are not maintained according to the
operationandmaintenancemanualoftheoriginalmanufacturer.
B. Otherthantheexpresswrittenstatementsofqualitymadeinparagraphoneabove,
all express warranties，engineering drawings, samples, models, or actions with
respecttothesaleofgoodswithoutJEREH’sapprovalhavenolegaleffects.
C. Whatiscalledimpliedwarrantiesexistingunderthelawwithrespecttothesaleof
Goods’ particularly the implied warranty of merchantability and the implied
warranty of fitness for a particular purpose ， we JEREH hereby negates and

disclaims.
D. Inaddition,allotherliabilitythatmayarisewithrespecttothesaleofGoods,either
in contract or tort, statutory or otherwise, including without limitation, strict
liabilityandliabilitybaseduponthenegligenceofJEREH,areexpresslydisclaimed
andnegated.
E. NorepresentativeofJEREH,otherthananofficerofJEREH,hasauthoritytoalteror
increasethisExpressWarrantyinmaymannerwhatsoever,andnoattempttorepair
or promise to repair, replace, or improve the Goods covered by this Express
WarrantyofrepresentativeofJEREHshallwaive,change,orextendthisWarrantyin
anymannerwhatsoever,unlesssuchaction,promiseorotherrepresentationisin
writingandsignedbyanofficerofJEREH.
F. User warrants through the purchase of the Goods that User is familiar with its
correctapplicationandtheproperusethereof.BeforeusingtheGoodshereunder,
User shall give the Goods reasonable and prudent examination and/or tests to
determinethesuitabilityofsaidGoodsforUser’sintendeduse.
G. AfteracceptanceofGoods,User’ssoleremedyandJEREH’ssoleliabilityforany
failure of the Goods to conform with the Express Warranty of Quality or for any
breachbyJEREHforanyobligationpertainingtothequalityoftheGoods(evenif
suchnonconformityresultsfromthenegligenceofJEREH,shallbelimitedtooneof
thefollowingatJEREH’soption:
1) Repairing or replacing (whichever JEREH shall elect) at JEREH’s factory in
Yantai,China(orsuchotherplaceclosertothelocationoftheGoodsasmaybe
designated by JEREH) the Goods whereby they comply with the Express
Warrantyofquality,or
2) PayingUseranamountequaltothecost(toUserattheoriginaltimeofsale)of

the part of the Goods which does not comply with the Express Warranty of
quality.InnoeventshallJEREHberequiredtorepair,replaceorreimburseUser
formorethanthepartoftheGoodsthatisfoundtobenotincompliancewith
the Warranty of quality. Any Goods or parts thereof that are repaired or
replacedbyJEREHpursuanttothisparagraphshallbearrangedasoftheirdate
ofdeliveryinaccordancewiththetermsandconditionsofthisAgreement.
H. The remedies provided herein shall be the sole and exclusive remedy of User for
JEREH’sbreachofwarrantiesorforanybreachofanycontractualorlegaldutyor
obligationarisingoutofthesaleofthegoodsbyJEREHtoUser.
I. JEREHshallnotunderanycircumstancesberesponsibleorliabletoUserortoany
user or to any third party for any economic loss or physical harm, incidental,
consequentialpunitive,orspecialdamages(includingwithoutlimitationdowntime,
lossofprofitsand/orlossofbusinessopportunities)arisingfromanydefectinthe
goods or services or any failure of the goods or services to conform with the
warranties made herein or any failure of JEREH to meet any obligation or duty
existingandapplicableunderthelawwithrespecttothesaleofthegoodswhether
suchdefectingoodsorfailureofthegoodstoconformwiththewarrantyorfailure
of JEREH to meet its obligations or duties result in damage or harm only to the
goodsortootherproperty.
J. ExcepttotheextentsuchobligationisinconsistentwithJEREH'sobligationtoUser
underthetermsoftheLimitedExpressWarrantystatedaboveinParagraphA,User
agreestodefend,indemnify,andholdJEREHharmlessfromandagainstanyandall
claims,liabilities,loss,costs(includingwithoutlimitation,thecostoflitigationand
attorney's fees), and expense made against or incurred by JEREH on account of
deathorbodilyinjurytopersonsorinjurytopropertyorloss,damageorexpense

(including without limitation, subsurface damage, subsurface trespassing, or
damagetothewellorreservoir),whichrelatestoorresultsfrom,orisinanyway
attributable to the sale, handling, use or operation of the Goods or any device,
material, or thing which the Goods are made a part or to which the Goods are
attached or within which the Goods are enclosed (while in User's possession or
subsequenttoanytransferofpossessiontoanyotherentity)orwhichrelatedtoor
resultsfrom,orinanywayattributableto,theGoodsorservicesprovidedbyJEREH
toUserhereunder.
K. User’sobligationstodefendandindemnifyandholdJEREHharmlessshallapply
and be fully enforceable, irrespective of whether such death of bodily injury to
personsorinjurytopropertyorloss,damageorexpensesiscausedbyorresults
from the sole or concurrent negligence or other fault of JEREH or any agent or
employee of JEREH or any independent contractor who is directly responsible to
JEREH.
L. Due to a policy of continuous product improvement, JEREH reserves the right to
change designs, materials, or specifications and to discontinue product without
notice.
M. No credit will be given on items returned without prior approval and written
instructionsaccompanyingtheitemsstatingthereasonsforreturnandthenameof
JEREH’srepresentativewhoauthorizedthereturn.OnlytheOfficersofJEREHmay
authorize return of items for credit. JEREH cannot be responsible for holding or
accounting for items returned without prior approval and proper written
instructionsbeingshippedwiththereturneditems.Iffreightisnotprepaidonthe
itemsreturnedforcredit,thecostoffreightwillbedeductedfromthecreditissued.
Non-standard items which are manufactured at the request of User cannot be

returnedforcredit.
N. Anactionforbreachofanyprovisionhereincontainedmustbecommencedwithin
oneyearafterthecauseofactionhasaccruedorsuchcauseisforeverbarred.
O. Alltermscontainedhereinareseparableandtheinvalidityofanyparthereofshall
notaffectthevalidityofanyotherpart.
P. The rights and remedies herein reserved to JEREH shall be cumulative and in
additiontootherrightsandremediesprovidedbylaw.ThefailureofJEREHtoinsist
uponstrictperformancehereofinanyoneinstanceshallnotconstituteareleaseof
itsrighttorequiresuchperformanceinthefuturewithrespecttosuchincidenceor
withrespecttoanylaterbreachoftheAgreementbyUser.
WARNING
Any one or User shall not disassemble or surveying and mapping the products
privately, and shall not behavior violating the patent rights. Otherwise, he shall be
responsiblefortheviolationandcompensateforalllossJEREHbears.
WARNING
Allrelatedcopyrights,patents,trademarks,businesssecretsandallotherownership
or rights belong to JEREH. This Manual shall only be used as a reference of unit
operation and maintenance, User shall not copy, reprint, modify or edit any
informationcontained,useitforanyothercommercialuseorprovideittoanythird
partywithoutthewrittenpermissionofJEREH.Otherwise,heshallberesponsiblefor
alllegalresponsibilityrelated.

AllrightsreservedbyJEREH.
WARNING
UndernocircumstanceshallJEREHberesponsibleforanyspecial,incidental,indirect
andsubsequentdamageandanylossofprofit,data,goodwillorexpectedeconomy.
WARNING
Iftheproduct(includingbutnotlimitedtothesoftwareandtechnicaldata)covered
bythisManualneedstobeexported,re-exportedorimported,Usershallfollowthe
applicablelawsandregulations.Usershallnotexport,re-exportorimporttheproduct
toanycountrythatsanctionedbyUSA,otherwise,theUsershallberesponsibleforall
responsibilityandloss.
WARNING
User’s rights and obligations under this Agreement may not be assigned or
transferredwithouttheexpresswrittenconsentofJEREH.


CHAPTER 2 SAFETY AND HEALTH
2.1 SAFETY AND HEALTH................................................................................................... 1
2.1.1 QUALIFIED PERSONNEL ........................................................................................ 1
2.1.2 PERSONAL PROTECTIVE EQUIPMENT ................................................................. 1
2.1.3 SAFETY PRACTICE .................................................................................................. 2
2.1.4 UNAUTHORIZED PERSONNEL .............................................................................. 2
2.1.5 HIGH PRESSURE ..................................................................................................... 2
2.1.6 UNAUTHORIZED MAINTENANCE ........................................................................ 2
2.1.7 LIFTING .................................................................................................................... 2
2.1.8 MOVING PARTS ..................................................................................................... 3
2.1.9 VISIBILITY ................................................................................................................ 3
2.1.10 PRE-START ............................................................................................................ 3
2.1.11 WORK AREA.......................................................................................................... 3
2.1.12 EQUIPMENT TRANSPORTATION ....................................................................... 3
2.2 SAFETY OPERATION GUIDELINE ................................................................................. 3
2.2.1 SAFE EQUIPMENT .................................................................................................. 4
2.2.2 SAFETY PROCEDURE .............................................................................................. 6

CHAPTER 2 SAFETY AND HEALTH
Theusersshallalwaysabidebyallrelatedproceduresandstandards,andwearpersonal
protectiveequipmentswhenworkingaroundtheunit.Whentheunitisrunning,please
payattentiontoallthemovingpartsandallunauthorizedpersonnelshallbeawayfrom
theunit.
2.1 SAFETY AND HEALTH
Thischapterintendstointroducetoyouthegeneralsafetyandhealth,aswellassafety
operationguidance.Personnelmustunderstandandapplytheseprecautionsduringall
phases of operation and maintenance of this equipment. For specific hazardous
operations, this manual introduces some detailed caution measures in forms of
WARNING.SomeWARNINGhasbeenmentionedinthismanualandtheyarestressed
hereinafter.
2.1.1 QUALIFIED PERSONNEL
Onlyqualifiedpersonnelshallbeauthorizedtooperateandmaintaintheequipment.
2.1.2 PERSONAL PROTECTIVE EQUIPMENT
Personnel operating and performing maintenance on the equipment must wear
appropriatePersonalProtectiveEquipment.
HSC16 Chapter 2 Safety and Health 1

2.1.3 SAFETY PRACTICE
Good overall safety practices must be adhered to at all times when setting up,
operating, shutting down and maintaining this equipment. It is the equipment
owner’s/operator’s responsibility to ensure that good safety practices, personnel
trainingprograms,andsafetypracticesaremaintained.
2.1.4 UNAUTHORIZED PERSONNEL
Keep unauthorized personnel away from the unit when operating, servicing or
performingmaintenance.
2.1.5 HIGH PRESSURE
Make sure the pressure of the pipeline connecting with the equipment is released
beforeanydisassemblyoperation.
2.1.6 UNAUTHORIZED MAINTENANCE
DO NOT attempt unauthorized disassembly or maintenance of components. Contact
yourJEREHrepresentativesforfurtherinformation.
2.1.7 LIFTING
Equipmentusedforliftingandmovingtheunitmustbeofsufficientratingtohandle
theweightinvolved.
2 Chapter 2 Safety and Health HSC16

2.1.8 MOVING PARTS
Keephands,hair,clothing,jewelry,ragsandtoolsawayfrommovingparts.
2.1.9 VISIBILITY
DONOTattempttooperateequipmentwithobstructedvisibility.Thisincludesbefore
sunriseandaftersunsetunlesssuitablelightingprovisionsareavailable.
2.1.10 PRE-START
Ensurealltheoperationcontrolsareincorrectpositionbeforestartup.
2.1.11 WORK AREA
Keep work areas clean and clear of obstructions, hand tools and other objects when
operatingtheunit.
2.1.12 EQUIPMENT TRANSPORTATION
Ensure that all components are secured before transporting the unit to another
location.
2.2 SAFETY OPERATION GUIDELINE
This guideline is to ensure the safe operation of this unit. The following are the
suggestedstandardswithrespecttotraining,equipmentsafetyandproceduresrelating

toequipmentoperation.
2.2.1 SAFE EQUIPMENT
a) Theunitisequippedwithtwofireextinguishersandallthepersonnelshouldknow
theirlocationandusingmethod.
b) Install a wind vane which can be seen from all directions on location for wind
direction visibility in the event of H2S exposure or any other potential breathing
hazard.
c) EquipeveryonewithappropriatePersonalProtectiveEquipment(PPE).
d) Setanemergencyareaatleast60m(200feet)awayfromtheupwindofwellsiteand
equipitwiththefollowing
1) ThreeH2Sdetectors(forH2Soranybreathinghazard);
2) Fireextinguishersuitableforflammableliquid;
3) First-aidkit;
4) Eyewashdevice;
5) Stretcher;
6) Transmitter-receiverorcellphoneforemergencycall.
e) Emergencywellpressurecontrolequipmentshallatleastincludethefollowing:
1) Wellkillingmanifolds;
2) Disabling valve of the remote controlling and hydraulic systems shall be
installedonthemanifoldsbetweenthetubekillingvalveandpump.
3) Pumpingequipment;
4) Wellkillingfluidtank;
5) Wellkillingfluid;

f) ForpossibleH2Sexposure,H2Sdetectorwithanaudiblealarmshallbeinstalledin
thefollowingpositions:
1) Thegroundneartothewell-head；
2) 30m(100feet)awayfromdownwindofthewellsite;
3) Roundwellhead.
g) Prepare emergency transportation vehicle that must be equipped with the
followingfacilitiesasaminimum.
1) First-aidkit;
2) Eyewashdevice;
3) Fireextinguishersuitableforflammableliquid;
4) Transmitterreceiverforemergencycall.
h) ForH2Scircumstanceorotherpotentialbreathinghazard,H2Sdetectorshouldbe
inplaces:
1) Emergencyresponseandfirst-aidarea;
2) Operationplatformoftheunit;
3) Liquidpumpingequipment.
i) Thefollowingmeasuresshallbetakenregardinguseofacidsoranyotherharmful
chemicals:
1) Clean (counteract) the area that has been polluted by harmful chemicals to
minimizephysicalorbreathingimpact;
2) Mobile communication devices on the same channel/frequency are required
equipment for the following personnel including site owner’s supervisor,
servicecompany’sfieldsupervisorandequipmentoperator.

2.2.2 SAFETY PROCEDURE
a) Set up a detailed equipment layout in a conspicuous visible position on site that
clearlyindicatesdangerousareaandemergencyescaperoute.
b) Only authorized personnel shall operate the well-head valves and any related
equipment.
c) Controlentrancetothesitebykeepingasignaturerecord.
d) Setupalargewaterproofsafetylabelonsiteifanyhazardousmaterialisinuseand
itshouldatleastincludethefollowinginformation.
1) Chemicaltypeandcomposition;
2) Relatedpreventiveactionsofeachchemicalinplace;
3) Emergencycountermeasuresforchemicalspill;
4) First-aidcountermeasures;
5) Otherrelatedinformationsuchasemergencytelephonenumber.
e) It is recommended to conduct a safety meeting before operation which should
includeatleastthefollowing.
1) Operatingplanintroduction;
2) Riskanalysis;
3) Emergencyplanandprocedure;
4) Demonstratetofspecialsafetydevicesusage;
5) Distributionoftasksandresponsibilities;
6) Confirmationofprocedurecommunication.

CHAPTER 3 BRIEF INTRODUCTION
3.1 INTRODUCTION ............................................................................................................ 1
3.2 MODEL DEFINITION ..................................................................................................... 3
3.3 WORKING PRINCIPLE ................................................................................................... 4
3.4 APPLICATION ................................................................................................................ 5
3.5 MAIN TECHNICAL SPECIFICATIONS .......................................................................... 5
3.5.1 OVERALL DIMENSIONS ........................................................................................ 5
3.5.2 WEIGHT ................................................................................................................... 5
3.5.3 MAIN WORKING PARAMETERS .......................................................................... 6

CHAPTER 3 BRIEF INTRODUCTION
3.1 INTRODUCTION
ModelHSC16truckmountedsandblenderisdividedintotwoparts,thechassisandthe
on-deckpart.Thechassisismainlyusedtomovethewholeunitandsupplypowerfor
thedischargecentrifugalpump.Theon-deckpartisthekeypartofthesandblender
anditmainlyconsistsofthepowersystem,fuelsystem,coolingsystem,electricsystem,
pneumatic system, hydraulic system, mixing and manifold system, liquid additive
system, sand conveying system and instrument and control system. Through the
cooperationofallsystems,theunitcanachieveproportionalsandblendingandsupply
fracfluidthatcanmeetdifferentrequirementsforthefracturingunits.Itisapplicable
forlargeandmediumscaleacidizingfracturingoperations.
View from Driver Side:

1 2 3 4 5 6 7 8
14 13 12 11 10 9
HSC16 Chapter 3 Brief Introduction 1

View from Passenger Side:
15 16
19 18 17
Main Components of the Sand Blender
Item Name Description
1 ChassisAssembly Loadthedeckcomponentsoftheunit.
2 FuelTank Supplyfuelforthedeckengineandchassisengine.
3 HydraulicOiltank Supplyhydraulicoilforthehydraulicsystem.
4 Plate-finCooler Cooltheair,coolant,hydraulicoilandfuel.
Thecabinintegratesallinstrumentsandcontrol
5 ControlCabin switchestodisplaytheworkingconditionoftheunit
andcontroltheunit.
6 DryAdditiveSystem Adddryadditivetothesandblendingtub.
7 LiquidAdditiveTank Containtheliquidadditiveneededintheoperations.
Ittransfersthesandtothesandblendingtubthrough
8 Auger thescrewafterthesandissuppliedtothehopperfrom
thesandtanktruck.
9 ToolBox Auxiliaryequipmenttostoretools.
LiquidAdditive Itsuppliesliquidadditivetothesandblendingtub
10
System manifoldandliquidadditivetankduringoperation.
Itconnectsthesandblendingtubwiththedischarge
ManifoldBefore
11 pumpandabranchoftheliquidadditivemanifoldcan
DischargePump
beconnectedhere.
2 Chapter 3 Brief Introduction HSC16

Pumpthewellmixedfracfluidintheblendingsystem
12 DischargeManifold
tothefracturingunits.
Ladderonthedriversidetohelptheoperatortoreach
13 Ladder
theplatform.
Connecttheenginewiththehydraulicpumpsand
14 PumpDrive transferthepoweroftheenginetothehydraulic
pumps.
15 OperationPlatform Theworkingplatformoftheoperators.
DDCS60engine.Supplypowerforthesandblending
16 Engine
operations.
SuctionCentrifugal Transferthefracbasefluidsuckedinbythesuction
17
Pump manifoldfromoutsidetothesandblendingtub.
Transferthefracbasefluidsuckedinbythecentrifugal
18 SuctionManifold
pumptothesandblendingtub.
Ladderonthepassengersidetohelptheoperatorto
19 Ladder
reachtheplatform.
3.2 MODEL DEFINITION
Themodelofthesandblenderisdefinedbythemaximumclearwaterdisplacementof
thedischargecentrifugalpump.
ModelDefinition:

Vehicle Publication No. and Description: JR5312THSTruckMountedSandBlender
Description:
3.3 WORKING PRINCIPLE
The engineis thepower source ofthe unit. The chassis engine drives the driveshaft
through the full-power PTO to drive one set of closed-loop hydraulic system which
controlsthespeedofthedischargecentrifugalpump.Thedeckenginedrivessixsetsof
hydraulic systems through the pump drive installed on the engine flywheel. Three of
them are closed-loop hydraulic systems which drive the suction centrifugal pump
motor and two auger motors respectively; two of them are open-loop hydraulic
systemswhichdrivethedryadditivemotor,liquidadditivemotor,agitatormotor,air
conditioner,andtheliftingcylinderandseparatingcylinderoftheauger;theotherone
is one gear pump open-loop hydraulic system which drives the level control rotary
actuatorandhorizontalradiatormotor.Thesandblendertransfersthefracbasefluidto
thesandblendingtubthroughthesuctioncentrifugalpump.Thefracbasefluidmixes
withthedryadditiveandliquidadditivethatsuppliedbythedryadditivesystemand
liquidadditivesystemproportionallyandthenthemixtureisdischargedtothesuction
endofthefracturingunitsthroughthedischargepump.Therateddisplacementofthe

unit is 16 m³/min and it can meet the requirements of large and medium scale
fracturingoperations.Thefunctionsofthedischargeandsuctionofthemanifoldcan
beexchanged.Thecontroldevicesoftheengine,instrumentsandgaugeswhichdisplay
the working condition of the sand blender are gathered in the control console to
controlthestartup,shutdownandspeedoftheengine,andtheworkingconditionof
theengineandhydraulicpumps.
3.4 APPLICATION
Thisunitisapplicableforonshorefracturingandsandcontroloperations.Allsupplied
parts are suitable of humid, rainy and sand ambient environment that varies from
-20℃～+45℃.
3.5 MAIN TECHNICAL SPECIFICATIONS
3.5.1 OVERALL DIMENSIONS
Length 12,500mm
Width 2,600mm
Height 4,100mm
3.5.2 WEIGHT
UnitWeight 30,870kg
TotalWeight 31,000kg

3.5.3 MAIN WORKING PARAMETERS
Engine
Model DDCS60
Power 500hp
RotarySpeed 2,100rpm
Pump Drive
Model FUNK593W
GearRatio 0.89：1
Suction Centrifugal Pump
Model Gorman-Rupp12×12×14-7/8CentrifugalPump
RatedDisplacement 16m³/min(100bbl/min)
Max.DischargePressure 0.3MPa
Discharge Centrifugal Pump
Model Mission12×10×23CentrifugalPump
RatedDisplacement 16m³/min(100bbl/min)
Max.DischargePressure 0.69MPa
Liquid Additive Pump

Waukesha Waukesha Waukesha Waukesha
Model
015 018 040 060
RatedDisplacement
2.7～34 5.5～66 14.4～170 28.95～340
(L/min)
Fluid Supply Pump
Model Waukesha040 AS4197

RatedDisplacement
14.4～170 13.6～160
(L/min)


CHAPTER 4 CHASSIS
4.1 BRIEF INTRODUCTION ................................................................................................. 1
4.1.1 FIGURE..................................................................................................................... 1
4.1.2 MAIN PARAMETERS .............................................................................................. 2
4.2 OPERATION AND MAINTENANCE NOTICES ............................................................. 3
4.2.1 CAB OPERATION .................................................................................................... 3
4.2.2 BRAKE OPERATION ............................................................................................... 3
4.2.2.1 ENGINE BRAKE AND EXHAUST BRAKE ....................................................... 4
4.2.2.2 FREQUENT FOOT BRAKE ............................................................................... 5
4.2.3 DIFFERENTIAL LOCK OPERATION ....................................................................... 6
4.2.4 KEY SWITCH OPERATION ..................................................................................... 7
4.2.5 CLUTCH OPERATION ............................................................................................. 8

CHAPTER 4 CHASSIS
4.1 BRIEF INTRODUCTION
4.1.1 FIGURE
NOTE
Please refer to Operating Instructions of the chassis for details of operation and
maintenance.
HSC16 Chapter 4 Chassis 1

4.1.2 MAIN PARAMETERS
ProductNameandModel Mercedes-BenzACTROS41448×6
Max.TotalWeight About29,000kg
ChassisTotalWeight About13,000kg(withoutsubframe)
WheelBase 7,000mm
OM501LA.Ⅳ/1
Power:435hp(320kw)/1,800rpm
Engine
Torque:2,100Nm/1,080rpm
MeettheemissionstandardofGUOIV
G240-16/16.9-0.69,fullsynchronizing
16forwardgear,2reversegear
Transmission Intelligentgearshift
Transmissionlubeoilcooler
PumpDriveModel:VG2400-3W
Mainfueltankwithcapacityof780L
OilTank Fuelpre-heatingstartsystem.Thefueltankischangedto
oneof1,000LcapacitybyJereh.
Tiresthatboththefrontaxleandrearaxleuseare12.00
Tire R20tire.Model202G22
Asparetireisequippedaswell.
Safemediumcab,backsleeper,norearwindow,air
conditioner,airsuspensionandadjustabledriverseat,
radio,CDplayer,groundmirror,electricallycontrolled
adjustablerearviewmirror,powerwindow,toolkit,tireair
pressuregauge,halogenlampforfoggyweather,air
charginghose,jack,warningtriangle,twowheelchocks,a
boxofbulbs,innersunshield,emergencygear
Cab
engagementbolt,specialtoolsforreplacingfanbelt
Coolantpre-heater
Reservedvehicleremotemonitoringsysteminterface
Fuelconsumptionreal-timedisplaysystem
Theinstrumentpaneldisplaysparametersclearlyin
standardmetricunit.
Hydraulictiltabledevice.
2 Chapter 4 Chassis HSC16

4.2 OPERATION AND MAINTENANCE NOTICES
4.2.1 CAB OPERATION
Whenthecabisneededtobelifted,itmustbeliftedtotally;otherwise,itmaylower
automatically. Please check and verify that the cab has been locked up after the cab
returns back to the original position, otherwise, the cab tilting indicator on the
instrumentpanelwillilluminate.
NOTE
If the cab is not locked up, it willendanger the reliability and running safety of the
vehicle.
Iftherunningvehicleisbraked,thecabmaytiltforwardifitisunlockedandtraffic
accidentandpersonnelinjurymayoccur.Thevehiclecanbestartedonlywhenthecab
returnstoitsoriginalpositionanditislockedupandatthistimethecabtiltinglockup
indicatordoesnotilluminate.
4.2.2 BRAKE OPERATION
Releasetheparkingbrakebeforemovingthevehicle.Ifthevehicleismovedwiththe
parking brake locked, the brake system will accumulate heat which may lead to fire
hazard. The vehicle cannot run in riverway or road with water depth higher than the
heightofthebrakesystem,otherwisevehicledriftmayoccursincethebrakeshoeand
thebrakedrumarewetevenunderemergencytestrun.
Frequentuseofthebrakewillincreasetheinternaltemperatureofthebrakedrum.If
thereissmellofburningorwhitesmokebelchoutfromthebrakedrum,pleasestopthe

vehicleforinspectionimmediately.Ifnoabnormalityisfound,stopthewheels,release
the parking brake to cool the brake system down. Otherwise, the brake pad may be
damagedandthebrakedrummaybedeformed.
4.2.2.1 ENGINE BRAKE AND EXHAUST BRAKE
Enginebrakeisawaytodecreasethevehiclespeedbytheresistancegeneratedbythe
engineitself.Theenginebrakecanbeappliedorclosedbythemultifunctionaljoystick.
The engine brake effect is related to the engine rotary speed. The higher the rotary
speedis,thebettertheenginebrakeeffectwillbe.Theenginebrakewillachievebest
performancewhentherotaryspeediswithintheyellowrangeonenginetachometer.
Exhaust brake is a way to control the vehicle speed by closing the engine exhaust
channel. When the engine piston goes upwards, it will be resisted by the counter
pressureoftheairsoastocreatebrakeandcontrolthespeedofthevehicle.
Apply:pullthemultifunctionaljoystick.Ifthejoystickisatposition1,onlytheengine
brakeisappliedandthebrakeeffectistheminimum;ifthejoystickisatposition2,the
enginebrakeandexhaustbrakeareappliedatthesametimeAndbrakeeffectisthe
best.
Stop:pullthemultifunctionaljoysticktoposition0toclosetheenginebrake.


NOTE
Theenginebrakeisonlyanauxiliarybrakeanditcannottaketheplaceofpedalbrake.
Whenthevehicleisrunningdownalongslope,itsspeedcanbecontrolledbyengine
brake and shifting to low gear. Try to use engine brake when possible. Pedal brake
shallbeappliedunderemergency.
The engine will stop spraying fuel if engine brake and exhaust brake are applied.
Operatetheengineauxiliarybrakejoystickinturn,donotpushthejoysticktoposition
2directlytoavoidsafetyhazardcausedbytoofastspeeddecrease.
Engine brake or exhaust brake cannot be applied on wet, frozen or snow-covered
road,otherwise,accidentmayoccur.Whenthevehicleisrunningonnormalroadand
thelawpermits,pleaseuseenginebrakeasmuchaspossibletoextendtheservicelife
ofthebrakepad.
4.2.2.2 FREQUENT FOOT BRAKE
Frequentfootbrakeconsumeslesscompressedairthantheparkingbrake.Ifthedriving
conditionneedsfrequentbrake,pleasetrytousefrequentfootbrake.
Apply:
a) Press the upper part of the frequent foot brake switch, the indicator on the
instrumentpanelwillbeoffandthefrequentfootbrakeentersreadystatusbutnot
started.
b) Step downthe brake pedal until the vehicle is stationary. Then the frequent foot
brakewillbeengagedandworkswhenthevehiclestarts.
c) Applyparkingbrake.
Stop:Pressthelowerpartofthefrequentfootbrakeswitchandtheindicatoronthe

instrumentpanelwillbeoff.
NOTE
a) Step down the accelerator pedal and the frequent foot brake will be released
automaticallyafterthevehiclestarts.
b) Ifturnthekeyforwardandreverselywhenreleasingthebrakepedalandstarting
the frequent foot brake, the alarm buzzer will alarm. The frequent foot brake
indicatorontheinstrumentpanelwillflash.
c) Applyparkingbrakewhenthevehiclestops.Usechokestostopthewheelwhen
necessary,especiallywhenthevehicleisparkedonaslope.
4.2.3 DIFFERENTIAL LOCK OPERATION
Thedifferentialmechanismisusedtoachievethespeeddifferencebetweenwheelsat
the right side and left side and wheels of different axles. There is speed difference
amongthewheelswhenthevehicleisturningoritisrunningnormally.Thedifferential
lock is a device which locks differential mechanism override and keep the wheels
synchronous.
Thedifferentiallockhaspumpdriveaxledifferentiallock,wheeldifferentiallock(rear
axle)andwheeldifferentiallock(frontaxle).Thatlocksthewheelsonbothsidesofthe
frontaxleiswheeldifferentiallock(frontaxle),thatlocksthewheelsonbothsidesof
therearaxleiswheeldifferentiallock(rearaxle)andthatlockstheaxlesispumpdrive
axledifferentiallock.
Application:ice/snowcoveredpavements,muddyroadandgravelroad.

NOTE
a) Donotusethedifferentiallockwhenthewheelsareslippingtoavoiddamageto
thedifferentialmechanismoraccident.Thedifferentiallockcanbeusedonlywhen
allwheelsarestill.
b) Donotusedifferentiallockathighadhesionroad,otherwise,itmayleadtoserious
damagetothechassisandevenleadtoseriousinjuriesorevendeath.
c) Itisforbiddentousethedifferentiallockwhenthechassisisrunningdownaslope.
d) Itisforbiddentousethedifferentiallockwhenthechassisspeedishigherthan25
miles/hour(40km/h)toavoidrolloveraccident.
e) When the differential lock is engaged, the turning radius will increased by 3~5
times. Do not try narrow radius turns when the differential lock is engaged,
otherwise, the differential mechanism may be damaged seriously and rollover
accidentmayoccur.
f) Donotaddtoomuchoiltothedifferentialmechanism.Toomuchoilmayleadsto

toohighoiltemperature,whichwilldamagetheoilsealofthespindlehead.
4.2.4 KEY SWITCH OPERATION
Thevehicleisequippedwithspecialkeysystemandtheenginecanonlybestartedwith
thekeyscodedforthisunit.
Beforeturningoffthebatteryswitch,pleasemakesurethekeyisatOFFpositionorit
hasbeenunplugged.IfthekeyisatONposition,andthebatteryswitchisturnedoff
suddenly, the unit may alarm due to the sudden power cutoff of the chassis engine
computer. If alarm is caused due to sudden power cutoff, please turn off the battery
accordingtothecorrectsteps.ThenturnonthebatteryswitchandadjustthekeytoON
position5minuteslater,thenthealarmwillbereleased.

4.2.5 CLUTCH OPERATION
Ifthealarmbuzzeralarmswhenshiftthetransmissiontoalowergearduringvehicle
running,itindicatesthatthespeedexceedsthemaximumspeedoftheengine.Atthis
time select a higher gear rather than engaging the clutch (engine overspeed may
damagetheclutchandengine.).
Whenshiftingtoalowergear,stepdowntheclutchtotheendandstayforawhileto
ensurethebrakepadhaslockedthefirstshaftofthetransmissionsoastoachievemore
stablelowergearselecting.
Please refer to the Mercedes-Benz chassis operation and maintenance manual for
detailedinformation.

CHAPTER 5 POWER SYSTEM
5.1 SYSTEM INTRODUCTION ............................................................................................. 1
5.2 ENGINE BRIEF INTRODUCTION .................................................................................. 3
5.2.1 GENERAL DESCRIPTION........................................................................................ 3
5.2.2 ENGINE SPECIFICATIONS ..................................................................................... 5
5.3 COMPONENTS .............................................................................................................. 6
5.3.1 AIR INTAKE AND EXHAUST SYSTEM .................................................................. 6
5.3.2 COOLING SYSTEM ................................................................................................. 8
5.3.3 FUEL SYSTEM ........................................................................................................ 10
5.3.4 LUBRICATION SYSTEM ....................................................................................... 11
5.3.5 ELECTRIC CONTROL SYSTEM ............................................................................. 12
5.3.6 HEATING SYSTEM (CHOOSE ACCORDING TO THE ACTUAL UNIT) .............. 12
5.4 TROUBLE SHOOTING ................................................................................................. 16
5.4.1 OBJECTIONABLE EXHAUST SYMPTOMS AND PROBABLE CAUSES .............. 16
5.4.2 HARD STARTING SYMPTOMS AND PROBABLE CAUSES ............................... 17
5.4.3 ABNORMAL ENGINE OPERATION SYMPTOMS AND PROBABLE CAUSES 1 18
5.4.4 ABNORMAL COOLANT TEMPERATURE SYMPTOMS AND PROBABLE
CAUSES ........................................................................................................................... 19
5.4.5 ABNORMAL OPERATING CONDITION SYMPTOMS AND PROBABLE CAUSES
......................................................................................................................................... 20
5.5 PUMP DRIVE ................................................................................................................ 23
5.5.1 INTRODUCTION ................................................................................................... 23
5.5.2 MAINTENANCE .................................................................................................... 24

CHAPTER 5 POWER SYSTEM
5.1 SYSTEM INTRODUCTION
Theindependentpowermoduleismountedonthesub-frameofthechassisanditis
boltedtothesub-frameseat.Thepowersystemsuppliespowerforthewholeunitand
itmainlyconsistsoftheengine,pumpdrive,hydraulicpump,coolantheater,radiator
andhydraulicvalves.
HSC16 Chapter 5 Power System 1

Power System Structure Illustration:
1 2 3 4
8 7 6 5
Item Description Item Description
1 Cooler 2 WaterCoolingManifold
3 WaterChargingManifold 4 PurgingSystem
5 BalanceWheelShield 6 Engine
7 PumpDrive 8 AirFilter
2 Chapter 5 Power System HSC16

5.2 ENGINE BRIEF INTRODUCTION
5.2.1 GENERAL DESCRIPTION
The engine is installed in the middle of the power module for easy installation and
maintenance and it mainly consists of the air intake system, exhaust system, cooling
system, fuel system, lubrication system and electric control system. This manual only
introducesbasicinformationabouttheengineoperationandmaintenance.Pleaserefer
totheengineOperator’sManualfordetails.
Engine Front View:

1 2
6 5 4 3

1 GearboxCover 2 EngineAirIntakeManifold
3 StartingMotor 4 EngineOilDipstick
5 EngineECM 6 EngineFrontMountingSeat
7 FanBeltPulley 8 MotorDrivingBeltPulley
Engine Rear View:
9 10 11
15 14 13 12

9 EngineExhaustManifold 10 Turbocharger
11 Generator 12 WaterPump
13 EngineOilSump 14 EngineOilFilter
15 EngineFlywheelHousing
NOTE
PleaserefertoEngineOperator’sManualfordetails.
5.2.2 ENGINE SPECIFICATIONS
EngineModel DDCS60
CoolingMethod Fanandradiator
RatedPower 500hp
RatedRotarySpeed 2,100rpm
Dimensions 57.2×35.02×56.37in
NetWeight 1,300kg
ThrottleControl Electrical
ShutdownMethod Electrical
AirIntake AirFilter
AirExhaust Muffler+RainCap
Generator 24V/70A
StartingMethod Electrical
Turbocharger Equippedwiththeengine
TransmissionOilCooler Equippedwiththeengine
Mufflerhose,fuelfilter,90°elbowatsupercharger
Accessories
exhaustoutlet

5.3 COMPONENTS
Theenginemainlyconsistsofairintakesystem,exhaustsystem,coolingsystem,fuel
system,lubricationsystem,electriccontrolsystemandcoolantheatingsystem.
5.3.1 AIR INTAKE AND EXHAUST SYSTEM
Theairsuckedintotheenginegoesintotheturbochargerthroughtheairfilteranditis
compressedtherebeforeitiscooleddownintheair-to-aircooler(heatexchanger).The
air then flows into the air intake pipe and the cylinder where it mixes with the fuel
atomizedbytheinjector.
The exhaust goes to the turbocharger from the cylinder through the engine exhaust
manifold.Finally,theexhaustwillbedischarged.
Air Intake/Exhaust System Schematic:

CHARGE AIR COOLER
AIR
CLEANER
I E
I E
INTAKE
MANIFOLD I E
TURBOCHARGER
I E
I E
I E
EXHAUST
I = INTAKE VALVE OUTLET
E = EXHAUST VALVE
EXHAUST
MANIFOLD
NOTE
Beforestartingtheengine,makesuretheemergencyshutoffvalvesoftheengineare
opened.Ifthevalvesarenotopen,theenginecannotbestarted;andlargeamountof
dieseloilwillstackinsidethecylinder,whichmaydamagetheengine.Iftheoperators
failedtofollowtheNOTE,themanufacturerwillassumenoresponsibilityforengine
damagecaused.
Inordertopreventtheenginefromdamagescausedbydustorotherairpollution,the
elementofthedryairfiltershouldbereplacedwhenthemaximumamountofairhas
passthroughorithasbeenusedforoneyear,whichevercomesfirst.

5.3.2 COOLING SYSTEM
ThecoolingsystemsoftheS60enginesadoptcoolingfin/fan.Centrifugalwaterpump
is applied to recirculate coolant inside the engine. The coolant flow direction is
controlledbytwothermostatslocatedinsidethecasingwhichisconnectedtotheright
sideoftheenginecylinder.
Cooling System Schematic:
Thermostat Closed:
THERMOSTAT
ENGINE COOLING FAN

HOUSING
RADITATOR
CYLINDER HEAD
BYBASS
CYLINDER BLOCK & LINERS

FLYWHEEL
OIL COOLER
ENGINE
WATER
PUMP

Thermostat Open:
THERMOSTAT
ENGINE COOLING FAN

HOUSING
RADITATOR
CYLINDER HEAD
BYBASS
CYLINDER BLOCK & LINERS
FLYWHEEL
OIL COOLER
ENGINE
WATER
PUMP

5.3.3 FUEL SYSTEM
Thefuelsystemiscomposedoftheinjectionnozzleoftheelectronicpump,fuelfilter,
fueltransferpump,fuelsamplingvalveandnecessaryfuelconnectionpipelines.
Fuel System Schematic:

INJECTORS CYLINDER HEAD CHECK VALVE
FRONT
INTEGRAL
MAINIFOLD
(FUEL GALLERY)
RETURN
FUEL LINE
PUMP
FUEL FILTER
OIL INLET CHECK VALVE
OIL
DISTRIBUTOR
FUEL
COOLER
FUEL TANK


5.3.4 LUBRICATION SYSTEM
Thelubricationsystemismainlycomposedofengineoilpump,engineoilcooler,two
engineoilfilters,mainoilgallery,pistoncoolingjet,engineoilpumpandbypassvalve
of engine oil filter connection, and oil pressure adjusting valve incylinder vertical oil
way.
Lubrication System Schematic:
7 6 5 4 3 2 1
CAM BEARINGS ADJUSTABLE

IDLER
PISTON DOME PISTON PIN
BULL
GEAR
#7 ROD #6 ROD #5 ROD #4 ROD #3 ROD #2 ROD #1

MAIN MAIN MAIN MAIN MAIN MAIN MAIN
FILTER BYPASS LINE-TO-AIR

TURBOCHARGER VALVE COMPRESSOR
OIL OIL
PUMP COOLER REGULATOR
VALVE
RESTRICTION
TO OIL OIL PAN

PAN SUMP
RELIEF
VALVE


5.3.5 ELECTRIC CONTROL SYSTEM
This system includes starting motor, startup switch, AC alternator, battery and
necessaryelectricwire.
5.3.6 HEATING SYSTEM (CHOOSE ACCORDING TO THE

ACTUAL UNIT)
This unitisequipped with heatingsystem. This system heats the engine coolant and
thenexchangeheatwiththehydraulicoilanddieseloilsoastopre-heattheengine
body.
Schematic:
a) Checkbeforeoperation:
1) Beforeoperation,pleaseverifythatthecircuitofthesystemmainmachineis
connected correctly; fuel in the fuel bottle is sufficient; battery voltage is
normal;therecirculatingsystemisfilledwithfluid;andtheconnectorsatthe
recirculatingpipesandoilwayaresealedwell.
2) Puttheheaterhorizontallyandfirmly.Makesuretheairintakeoftheheatis

sufficienttoavoidtheburntgasfromenteringtheairline.Donotputthings
between the heater and the tool box and on the exhaust pipe to avoid
unnecessarydamage.
3) Please choose coolant with proper grade according to the lowest ambient
temperaturethatapplied.
4) Gasolineisforbidden.Usersshallchoosefuelwithpropergradebasedonthe
ambienttemperature.Otherwise,thefuelmaygetwaxedintheoilpipe,and
theheatercannotwork.Itshallbenoticedthattheoilpumpwilltakelonger
timetosuckinoilwhentheheaterworksforthefirsttime.Theoilpumpcango
to normal working condition after about one minute. Then the burning
procedure may start. Do not put things around the exhaust pipe to avoid
unnecessarylosssincethisheaterisequippedwithexhaustheatingpipe.
5) Beforeoperation,openthetwoballvalvesonthepipetomakesurethatthe
recirculatingpipeisfilledwithcoolant.Otherwise,thewaterpumpmaysuffer
hightemperatureduetodrygrinding,whichwilldamagethewatersealparts.
Themainmachineoftheheaterisequippedwithindependentspace.Please
keepthisspacecleananddonotputanycombustiblesaround.
6) Afterpre-heating,turnofftheheater,andthenclosethetwoballvalves(about
3minutesaftertheheateristurnedoff).Startdeckengine.
b) Maintenance
Pleaseclean,maintainandinspecttheheaterafteroperationinheatingseasonso
as to extend the service life and improve the working efficiency of the heater,
otherwise,itmayaffecttheworkingoftheheaterinnextheatingseason.
1) Eliminatethecarbondepositionatthecoolingfinandcombustionchamberif
thethermalefficiencyisdecreaseduetotoomuchcarbondepositionaftera

periodofworking.
2) Clean and eliminate the air intake pipe and exhaust pipe of the heat main
machineiftheyareblockedwithdirt.
3) Make sure the fuel bottle, oil pipeand filter are clean and the oil way is not
blockedbydirt.Checktheoilwayforleaks.
4) Check the heater water pump regularly according to the actual working
conditions.Ifthewatersealpartsleakwaterorthewaterpumphasdifficultyin
startingandrunning,pleaserepairintime.
5) Pleasemaintaintheautomaticcontrolboxandotherelectriccomponentson
theheatermainmachinewithmethodsofmaintainingcommonlowpressure
electric components. The performance parameters of the automatic control
box have been calibrated before delivery. Do not modify the parameters
casually.Checkthephotoelectricsensorandcleanwhennecessary.
6) The ignition electrode point of the heater will ignite. Replace or clean the
oxidizedelectrode.Theconnectorsoftheelectrodeshallbeinstalledreliably.
7) Checkthewireandconnectorsforcorrosion,loosenessandwear.
8) Checkwhetherthemechanicalpartsareloose.
9) There is no need to maintain the main machine of the heater under normal
working condition. They shall be maintained after long time of operation or
underabnormalworkingcondition.
10) Whentheheaterisnotusedinwarmseasons,pleaseturnontheheater2~3
timeseachmonthandmakeitworkforabout5minutestoensureitcanwork
normallyforthenextoperation.

NOTE
a) The operator can turn off the heater manually according to actual working
conditions. When the temperature reaches 80℃, the heater will stop working
automatically.
b) Before operation, open the two ball valves on the pipe to make sure that the
recirculatingpipeisfilledwithcoolant.Otherwise,thewaterpumpmaysufferhigh
temperature due to dry grinding, which will damage the water seal parts. After
pre-heating, turn off the heater, and then close the two ball valves (about 3
minutesaftertheheateristurnedoff).Startdeckengine.

5.4 TROUBLE SHOOTING
5.4.1 OBJECTIONABLE EXHAUST SYMPTOMS AND PROBABLE

CAUSES
Blackor Gray Blue White

Probable Causes
Smoke Smoke Smoke
Damagedordirtyaircleaner √ × ×
Impropergradeoffuel √ × ×
Excessiveexhaustbackpressure √ × ×
Misfiringcylinders × × √
Engineoilnotburnedin
cylinder(beingburnedinexhaustmanifoldor × √ ×
turbocharger)
Faultyinjectortiming √ × ×
Faultyoilcontrolrings × √ ×
Excessiveinstallationangle × √ ×
Excessiveoilincrankcase × √ ×
Highambienttemperature √ × ×
Thinair(highaltitude) √ × ×
Cetaneratingoffueltoolow × × √
Airinthefuelsystem × × √
Remark:“√”meansrelatedand“×”meansnotrelated.


5.4.2 HARD STARTING SYMPTOMS AND PROBABLE CAUSES
Engine Will Low Cranking Engine Cranks But

Probable Causes
Not Rotate Speed Will Not Start
LowBatteryVoltage √ √ ×
Loosecrankingmotor
√ × ×
connections
Faultycrankingmotor √ √ ×
Faultycrankingmotor
√ √ √
switch
Internalseizure √ × ×
Improperlubeoil × √ ×
Fuseblownormissing × × √
Insufficient Fuel Supply
Airinfuel × × √
Outoffuel × × √
Loosefuelconnections × × √
Crackedfuellines × × √
Obstructedfuelfilters/lines × × √
Faultyfuelpump × × √
Faultyinjectoroperation × × √
Restrictedfuelfitting
× × √
missing
Improperinstallation/
operationoffuelcheck × × √
valveorshutoffvalve
Low Compression
Wornintakeandexhaust
× × √
valves
Wornpistonrings/liners × × √
Leakingcylinderhead
× × √
gasket
Improperintakeorexhaust
× × √
valveadjustments

5.4.3 ABNORMAL ENGINE OPERATION SYMPTOMS AND
PROBABLE CAUSES 1
RoughRunning or Low

Probable Causes Detonation
FrequentStalling Power
Misfiringcylinder √ √ ×
Insufficientfuel √ √ ×
Highreturnfueltemperature √ √ ×
Lowcompression √ √ ×
Highairinletrestriction/exhaust
× √ ×
backpressure
Wrongengineapplication × √ ×
Highairinlettemperature × √ ×
Highaltitudeoperation × √ ×
Incorrectenginegeartraintiming × √ ×
Lowcoolanttemperature × × √
Oilpickedupbyinletairstream × × √
Faultyinjectoroperation × × √
Incorrectinjectorheightsetting × √ √

5.4.4 ABNORMAL COOLANT TEMPERATURE SYMPTOMS AND
PROBABLE CAUSES
Probable Causes AboveNormal BelowNormal
Restrictedcoolingsystempassages √ ×
Restrictedradiatorcorepassages √ ×
Slippingfandrivebelts √ ×
Faultytemperature-controlledfan √ ×
Obstructioninfrontofradiatororintercooler √ ×
Lowcoolantlevel √ ×
Damagedhoses √ ×
Faultythermostats √ ×
Faultywaterpump √ ×
Faultyradiatorpressurecap √ ×
Airincoolant √ ×
Thermostatsnotfullyclosed × √
Leakagearoundthermostatseals × √
Faultytemperature-controlledfan × √


5.4.5 ABNORMAL OPERATING CONDITION SYMPTOMS AND
PROBABLE CAUSES
High Engine Oil

Probable Causes Low Oil Pressure
Consumption
Looseconnections √ ×
Crackedlines √ ×
Damagedgasketsorsealrings √ ×
Engineoillossatbreathertube √ ×
Leakingoilcooler √ ×
Leakingvalvestemseals √ ×
Worn/brokenoilcontrolrings √ ×
Scoredlinerand/orpiston √ ×
Excessiveengineinstallationangle √ ×
Crankcaseoverfilled √ ×
Oilinairtanks(aircompressormalfunction) √ ×
Pluggedcrankcasebreather √ ×
Oillevellow √ ×
Improperengineoilviscosity(fuelintheoil) × √
Faultyoilpressureregulatorvalve × √
Worncrankshaft,camshaftorconnecting
× √
rodbearings
Missingcupplugsinrockerarmshafts × √
Faultyoilpressurereliefvalve × √
Airleaksinoilpump(suctionside) × √
Wornordamagedoilpump × √
Faultyoilpressuregage × √
Pluggedoillineororifice × √

NOTE
a) Thecoolantmustbeanticorrosiveaccordingtotheoperationmanualofthediesel
engine;otherwisethecoolingsystemofthedieselengineandothercomponents
willbeheavilydamaged.
b) Usestartingmotorandfuelsystempre-chargingpumpovertimewilldamagethe
startingmotor,fuelpumpandinjector.
c) The turbocharger will be heavily damaged if the engine is started while the air
intake is closed. Make sure that the air intake emergency shutoff valve is at
openedpositionbeforestartup.
d) Iftheenginecannotstartwithin15seconds,loosetheswitchofthestarterand
coolingitforatleast30secondsbeforerestarting.Iftheenginefailstostartfor4
times,stopandfindoutthecauses.
e) Avoididlingifpossible.Itisactuallywrongtothinkthatidlingdoesnodamage
theengine.Idlingwillproducesulfuricacid,whichwillresolvetheengineoiland
corrodethebearing,pistonring,valverodandthesurfaceofengine.Thecoolant
ofdieselenginewillbedecreasedtolowerdegreethannormalworkingrangeif
theengineisidlingforalongtimewhenthetransmissionisinneutralshift.Incold
engine,theincompletelyexhaustedfuelwillcausethedilutionofcrankshaftlube
oilandadhesivefilmorgumdepositwillformonairvalve,piston,andpistonring.
Thesethingswillbedepositedandbecomesludgeintheenginerapidly.Whenit
isrequiredtoprolongtheidlingtime,therotaryspeedshouldbeatleast850rpm
inthespring/summerand1,200rpminautumn/winter.
f) Undernormalcondition,stoptheengineaccordingtothefollowingsteps:slow
downtheenginetoidlespeedandshiftthetransmissiontoneutralgear.Itwill
damage the turbocharger to stop the high-speed engine equipped with

turbochargerwithoutsufficientcoolingsincetheenginewillrunwhenthebearing
getsnolubeoil.
g) Ensurethehydraulicvalvesareinneutralorunloadpositiontodecreasethestart
loadbeforestartingtheengine.
WARNING
a) Inordertoavoiddamagefromtheenginewhenworkingaroundoroperatingit,it
is necessary to tighten the loosing clothes and decorations. Fasten or cover the
longhairtopreventdamagesfromsomemovingcomponents.
b) Wearprotectiveclothesandglasseswhenoperatingorworkingaroundtheengine
toavoiddamageandwearear-protectiondevice.
c) Wearprotectiveglovesandworkingclothestokeepskinawayfrompollutantsin
usedengineoil.
d) Thesplitliquidshouldbecleanedimmediatelytoavoidslideorfallingover.
e) Becarefulwhenworkingbesidethedrivingbeltofengineandrotatingparts.
f) DONOTsmokeormakeanyfirebesidetherunningenginetoavoidfiredisaster.
g) Theemissionofengineandotherunknowncompositionscancausecancer,birth
defectandotherphysiologicaldamages.
h) Startoroperatetheengineinareaswithgoodventilation.
i) Discharge the emission to the external environment if the engine is operated in
enclosedspace.
j) The exhaust system or discharge control system is prohibited to be modified or
weakened.

5.5 PUMP DRIVE
5.5.1 INTRODUCTION
NOTE
PleaserefertothePumpDriveOperationManualfordetails.

Pump Drive Specification:
Model 593W14P1LC
Direction Theoutputdirectionisreversetotheinputdirection.
Max.InputPower 522kW
SpeedRatio 0.89:1
Type Fouroutputports
It is equipped with oil dipstick, breather valve and high
Others
elasticitycoupling.
5.5.2 MAINTENANCE
NOTE
Besuretochecktheoillevelofthepumpdrivethroughthedipstickortheupperlimit
hole.Theoillevelshouldnotexceedtheupperlimit.


CHAPTER 6 SAND BLENDING SYSTEM
6.1 INTRODUCTION ............................................................................................................ 1
6.2 WORKING PRINCIPLE ................................................................................................... 1
6.2.1 MANIFOLD WORKING PRINCIPLE....................................................................... 2
6.2.2 LIQUID ADDTIVE MANIFOLD WORKING PRINCIPLE ........................................ 3
6.2.3 WORKING PRINCIPLE OF THE DRY ADDITIVE MANIFOLD .............................. 5
6.3 CENTRIFUGAL PUMP .................................................................................................... 6
6.3.1 INTRODUCTION ..................................................................................................... 6
6.3.2 PREPARATIONS BEFORE OPERATION ................................................................ 9
6.3.3 CENTRIFUGAL PUMP OPERATION .................................................................... 10
6.3.3.1 BOOSTING ..................................................................................................... 10
6.3.3.2 WORKING PERFORMANCE LIMIT .............................................................. 10
6.3.3.3 LUBRICATION................................................................................................ 11
6.3.4 CENTRIFUGAL PUMP DISASSEMBLY ................................................................ 11
6.3.4.1 EXPLODED VIEW ........................................................................................... 11
6.3.4.2 DISASSEMBLE AND ASSEMBLE .................................................................. 12
6.3.5 MAINTENANCE .................................................................................................... 12
6.3.6 TROUBLE SHOOTING .......................................................................................... 13
6.3.7 DISCHARGE PUMP PARAMETERS ..................................................................... 14
6.4 LIQUID ADDITIVE PUMP ............................................................................................ 15
6.5 SAND BLENDING TUB ................................................................................................ 17
6.5 SAND BLENDING TUB ................................................................................................ 18
6.6 SAND TRANSMISSION SYSTEM................................................................................ 19

CHAPTER 6 SAND BLENDING SYSTEM
6.1 INTRODUCTION
The sand blending system mainly consists of one GORMAN-RUPP 12×12×14-7/8
centrifugal pump, one Mission 12×10×23 centrifugal pump, suction manifold,
discharge manifold, bypass manifold, sand blending tub, liquid additive system, dry
additivesystemandrecirculatingsystem.
The parts mentioned above cooperate effectively through the reasonably arranged
pipelines,whichensuresanefficientsandblendingsystem.
6.2 WORKING PRINCIPLE
Low-pressure Manifold Principle Schematics:
HSC16 Chapter 6 Sand Blending System 1

Thereisaninterfaceheaderwhichconsistsofsix4”206Ffemaleunionsonthesuction
centrifugalpumpsideoftheunit,whilethereisaninterfaceheaderwhichconsistsofsix
4” 206M male unions on the discharge centrifugal pump side. Functions of the
suction manifold and discharge manifold are ex-changeable. A butterfly valve is
equippedwiththeunittoexchangefunctionsofthesuctionanddischargemanifolds.
Eitherofthemanifoldcanbeusedtosuckordischarge.Besides,throughcontrolling
thebutterflyvalve,fluidinsidethesuctioncentrifugalpumpcanbedischargedfromthe
discharge manifold through the bypass manifold directly rather than going into the
blendingtank.Thisprocedurecanmeettherequirementoftransmittingacidizingfluid
in a short time for acidizing operation. The suction and discharge manifolds are
equipped with one 8”electromagnetic flowmeter. Whichever side the sand blender
sucksfluidfrom,themixedgelcanbedischargedaftergoingthroughthedischarge
flowmeter.Detailedworkingprincipleisasfollows.(Note:butterflyvalvesthatarenot
mentionedintheprocedurebelowareallinclosedstatus)
6.2.1 MANIFOLD WORKING PRINCIPLE
a) For normal operation:
Water 12 ports on the suction pump side V3 butterfly valve Suction
pump 8”electromagnetic flowmeter flow control valve Sand blending tub
blending Discharge pump V7 butterfly valve 8”electromagnetic
flowmeter V2butterflyvalve 12portsonthedischargepumpside
b) Operation of exchanging functions of suction and discharge manifold:
Water 12 ports on discharge pump side V5 pneumatic butterfly valve V4
pneumatic butterfly valve Suction pump 8” electromagnetic
flowmeter Flow control valve Sand blending tub blending Discharge
2 Chapter 6 Sand Blending System HSC16

pump V7 butterfly valve 8”electromagnetic flow meter V1 butterfly valve
12portsonthesuctionpumpside
c) Acidizing operation:
Well-mixed acid fluid 12 ports on suction pump side V3 butterfly
valve Suctionpump 8”electromagneticflowmeter V6butterflyvalve 8”
electromagneticflowmeter V2butterflyvalve 12portsondischargepumpside
6.2.2 LIQUID ADDTIVE MANIFOLD WORKING PRINCIPLE
The fluid additive system consists of waukesha 015（1#）, waukesha 018（2#）,
waukesha 040(3#), waukesha 060(4#) and two waukesha 040, AS4197 fluid
supplypumps.
Suction method: 1# and 2# liquid additive pumps can suck in fluid from 1# and 2#
liquidnitrogentankorgroundliquidadditivetank;and3#,4#fluidsupplypumpscan
suckinfromthegroundadditivetank.
Dischargemethod:1#,2#,3#and4#liquidadditivepumpcandischargefluidtothe
sand blending tub and the manifold between the discharge pump and the sand
blendingtubrespectivelythroughtheacid-proofhose.Twoliquidsupplypumpscan
supplyfluidtothecorrespondingfluidadditivetanksrespectively.
Theliquidadditivesystemisdesignedwithtwoliquidadditivetanks(effectivevolume
is 300 L). The liquid additive tank can supply the unit with liquid additives in high
flowrateinarelativelylongtime,whichcanpreventtheadditiveaddingoperationfrom
cutoff.Theliquidadditivetankisdesignedwithalevelindicationdevicesotheoperator
canlearnabouttheadditivevolumeintime.FourliquidadditivesystemsalsohaveEMD
sensor motors whichare used to record the instantaneous and accumulated delivery
valueoftheliquidadditives.

NOTE
a) Ifthescrewpumpandgearpumpareusedastheliquidadditivepump,DONOT
runthescrewpump,gearpumpandplungerpumpdry,otherwise,therubberof
screwpumpstator,copperbushofthegearpumpandsealofthetriplexplunger
pump canbe damaged. The screw pump, gear pump and plungerpump canbe
started only when they are full of fluid. Clean the screw pump, gear pump and
plungerpumpwithdieseloilaftereachoperation!
b) Prime the liquid additive pump with coolant, lube oil or hydraulic oil after
operation.
c) The four liquid additive systems are all connected with the discharge manifold
throughtheacid-proofhosesandbreak-makeofthemanifoldiscontrolledbythe
ballvalve.Duringoperation,ifthereisnoneedtoaddtheliquidadditivetothe
manifoldbeforethedischargepump,makesuretheballvalveshowninfigure1is
closed.Theballvalvethatconnectedwithcheckvalveinfigure2shouldalwaysbe
open. Only when the ball valve in figure 1 fails can the ball valve in figure 2 be
appliedtocontrolthebreak-makeofthemanifold.

Fig. 1 Fig. 2

6.2.3 WORKING PRINCIPLE OF THE DRY ADDITIVE MANIFOLD
This sand blender is equipped with two dry powder delivery devices. Under normal
workingcondition,openthe2″ butterflyvalveofthedryadditivemanifoldtoadddry
powderadditivetothesandblendingtank.Theexternallysuppliedfracturingfluidgoes
intothedrypowdersprayerandthenchargesthedrypowderintothesandblending
tank after being pressurized through the crack, which guarantees the continuity and
uniformityofadditivesupplying.Thedrypowderfeederisequippedwithcountergear
andcountersensortoguaranteethecontrollabilityofadditivevolume.Thestructureof
thefeederisshownbelow:
Dry Additive Manifold Structure:


6.3 CENTRIFUGAL PUMP
6.3.1 INTRODUCTION
Thesandblenderisequippedwith2centrifugalpumps,thesuctioncentrifugalpump
anddischargecentrifugalpump.Thespecificationsandfunctionsareasfollows:
Suction Centrifugal Pump: GORMAN-RUPP 12×12×14-7/8

SuctionCentrifugalPumpPerformanceParameters:
No. Item Suction Pump

1 Model GORMAN-RUPP12×12×14-7/8
2 SuctionPortDiameter 305mm
3 DischargePortDiameter 305mm
4 Max.WaterDisplacement 16m3/min
5 Max.DischargePressure 0.3MPa
6 Max.WorkingSpeed 1,250rpm
7 SealType MechanicalSeal

Discharge Centrifugal Pump: Mission 12×10×23
DischargeCentrifugalPumpPerformanceParameters:
No. Item Discharge Pump
1 Model Mission12×10×23
2 SuctionPortDiameter 305mm
3 DischargePortDiameter 254mm
4 Max.WaterDisplacement 16m3/min
5 Max.DischargePressure 0.69MPa
6 Max.WorkingSpeed 1,150rpm
7 SealType MechanicalSeal


CAUTION
Specificationandworkingconditionofdifferentcentrifugalpumpsaredifferentandit
isnotpossibletocovereveryaspectoftheinstallation.Thusdescriptionrighthereonly
serves as a guideline. There are some points that need to be observed during
installation and operation, which should extend the pump service lift if they are well
followed.
a) Thecentrifugalpumpcanonlybeusedwithinitscapacity.
b) DO NOT ignore any warning during operation. Approved methods, material and
tools MUST be used. No potential safety hazard is allowed to exist. Accidents
usuallyresultfrompotentialsafetyhazards.Safetyiseverybody’sbusiness.
c) Make sure to open the ball valve and drain the centrifugal pump after each
operation to prevent the residualfluid freezing in winter. Ifthe centrifugal pump
cannotsuckinordischargefluidnormallyafterstartup,stoptheunitimmediately
tocheckthecentrifugalpumptoavoiddamagingthepump.

WARNING
Beforeanymaintenance,pleasemakesurethecentrifugalpumpisdisconnectedfrom
power or locked up to prevent any kind of power (mainly include electric power,
mechanicalpowerandpneumaticpowergeneratedbyaircompressor)transferringto
thecentrifugalpump.
Priortopumpmaintenance,makesure:
a) Drivinginputisclosedordisconnected.
b) Devicesconnectedtocentrifugalpumpareclosed.
c) Pressureinsideiscompletelybleedoffpriortoremoveanypipeline.

6.3.2 PREPARATIONS BEFORE OPERATION
Mechanical seal of centrifugal pumps has been set and tested before delivery. To
ensurenormaloperation,coolingsystemandflushingdevicesareacceptabletouse.
NOTE
DONOToperatethecentrifugalpumpwhenthereisnofluidtoavoiddamagetothe
mechanicalseal.
NOTE
Itisimportanttocheckthemotorrotarydirectionbeforeconnectingthecoupler.Even
a short time of operation at wrong direction can cause damage to impeller, shaft or
bearingshell.Thepumpshaftrotarydirectionisclockwisefromthemotorend.

Checkthefollowingitemsbeforeoperation:
a) Thepumpcanbeeasilyturnedmanually.
b) Thecouplerhasbeenwelladjusted.
c) Greasenippleisfullandatcorrectlevel.
d) Centrifugalpumpandsuctionpipelineshavebeenfilledwithfluid.
e) Thereiswaterinthestuffingbox.
f) Thedischargepipelinevalvesareslightlyopen.


6.3.3 CENTRIFUGAL PUMP OPERATION
6.3.3.1 BOOSTING
Boostingmeanstodriveawayairinsidethecentrifugalpumpandsuctionmanifoldand
thenfillthemwithfluid.Valvesonthedischargemanifoldshouldbeslightlyopenwhen
startingthepump.Itwillbeadjustedtorequestedpositionwhendischargepressure
hasbuiltupandbecomesteady.Closethedischargemanifoldvalveifthereisnofluid
andreopenitwhenthedischargingpressureisbuiltupafterafewseconds.
a) Improperpumpsizeorimproperinstallationwouldresultinpoorfluidflowrate.
Improperboostingoperationforlongtimewilldamagethesealingsurfaceofthe
mechanical seal since there are continuous vibration and dry friction between
movingpartsandfixedparts.
b) If the temperature goes from normal room temperature up to 121 ℃ within 30
seconds,theheatwouldbursttheceramicbracket.
c) DONOTstartthepumpwhilevalvesonthesuctionanddischargemanifoldsare
closed.
6.3.3.2 WORKING PERFORMANCE LIMIT
The data is gained on the condition of no insulation of the room temperature. The
socket ring should be cooled by water if the pumped fluid temperature is between
150 °F and 250 °F. It’s necessary to immerse the exposed shaft into the water to
preventtheshaftandsealringsfromoverheat.

6.3.3.3 LUBRICATION
Lubricatewithcommonlubeoil.Addlubeoiltothemiddlepositionoftheobserving
port.
6.3.4 CENTRIFUGAL PUMP DISASSEMBLY
6.3.4.1 EXPLODED VIEW
1 2 3 4 5 6 7
10
1 PumpBody 6 Bracket
2 Impeller 7 HoodShield
3 SealRing 8 TensionBolt
4 PumpCover 9 ClampNut
5 MechanicalSeal 10 Baseboard

6.3.4.2 DISASSEMBLE AND ASSEMBLE
a) Beforerepairingorreplacingparts,cutoffthepowersupply,closethevalvesatthe
inletandoutletofpumpblocksanddisconnectthepowersourcewiththepump
head(namelythecouplerofthepowersourceandthatofthepump);
b) Disassemble hood shield 7, loose the connecting bolts between bracket 6 and
pumpbody1andthosebetweenthebackupplateunderbracket6andbaseboard
10todisassembleimpeller2,pumpcover4,bracket6andmechanicalseal5from
pumpbody1.
c) Loosetheclampnut9onthepumpshaftend,raptheclampnut9anddraw-inbolt
8 with a cooper plate to disassemble the tail cone of impeller 2 from the taper
sleeveofpumpshaft,thenimpeller2,pumpcover4andmechanicalseal5canbe
disassembledfrombracket6along.
d) LoosetheAllenboltonthedynamicringofthemechanicalsealtodisassemblethe
dynamicringofmechanicalseal5fromimpeller2shaft.Thenremovethepump
cover 4, loose the Allen bolt on the mechanical seal gland (static ring gland) to
disassemblethestaticringofthemechanicalseal.
e) Ifpumpbody1needstobereplaced,disconnecttheinletandoutletpipesandthe
connectingboltsbetweenpumpbody1andbaseboard10.
f) Remove the circular flow on the tail cone before replacing impeller 2; (some
productsmayhavenocircularflow)
a) Assemblethepumpafterallpartsarereplacedaccordingtoreversedprocedures.
6.3.5 MAINTENANCE
a) Checkthepumpregularlyandreplacethevulnerableparts.
b) Cleantheflowchannelofthepumpwhentheunitwon’tbeusedforalongtime.

c) DONOTrunthepumpblockwhenthereisnofluidinsideit.
6.3.6 TROUBLE SHOOTING
Trouble Causes Solutions
1.Cleanthepipe.
2.Lowertheinstallation
1.Airexistsinsidethesuction heightofthepump.
pipeandtheinletisblocked. 3.Replacethepumpwith
2.Suctionportistoohigh. oneofahigherdelivery
Fluidcannotbe 3.Requireddeliveryheadis head.
pumpedout. higherthanthatofthepump. 4.Replacethedischarge
4.Thedischargepipeistoothin pipewithonewhoseorifice
andthepipelossistoobig. issamewiththatofthe
5.Pumprotatesreversely. pump.
5.Changetherotation
direction.
1.Replacetheimpeller
1.Impellerdamaged
2.Replacethesealingparts
2.Sealingpartsdamaged
3.Increaserevolution
3.Insufficientrevolutions
number
Insufficientflowrate 4.Intakepipetoothin
4.Re-assemblethepipe
5.Toomanyelbowonthe
accordingtospecifications
outletpipeleadstotoomuch
5.Reasonablyre-arrange
resistance
thepipe
1.Decreasemedium
1.Transmittedmediumhas
viscosityorincrease
Insufficientdelivery smell.
chargingpressure
head 2.Impellerandbladedamaged
2.Replacetheimpeller.
3.Insufficientrotaryspeed
3.Increaserotaryspeed
1.Sealingmaterialsare 1.Replacethestaticring
improperandcorroded. withappropriateone.
Serioussealleakage
2.Sealingmaterialsare 2.Replacetheworn-out
worn-outheavily. partsandadjustspring

3.Staticringanddynamicring pressuretoreduce
donotcoincide worn-out
4.Staticringbroken 3.Repositiontheloose
5.Dynamicsealofthe snapringsandboltsofthe
mechanicalsealdrawsback sealingassembly
4.Disassemblethewhole
pump,verticalityerror
betweenthe
newly-replacedstaticring
andshaftshallbelower
than0.10.Installthe
sealingassemblyaccording
torequirements.
1.Pumpshaftandpower
sourceshaftarenotconcentric. 1.Calibratethepumpshaft.
2.Theflowrateexceedsthe 2.Chooseproperpump
applicationrangeand androtatethepumpwithin
Noiseorvibrationin
cavitationcorrosionis itsapplicationrange
pump
produced. 3.Re-install
3.Draw-inboltisloose. 4.Cleanorreplacethe
4.Electricmotorshaft bearingandshaft
worn-out,bearingdamaged
6.3.7 DISCHARGE PUMP PARAMETERS
Pump
Displacement 100 95 90 85 80 75 70 60 40 25
(bbl/min)
Pump
Displacement 15.9 15.1 14.3 13.5 12.7 11.9 11.1 9.5 6.3 3.9
(m³/min)
Pressure(psi) 54.3 59.6 64.9 70.6 75.1 78.3 82.7 93.8 99.2 100
Pressure
0.373 0.411 0.448 0.487 0.518 0.54 0.57 0.647 0.684 0.688
(MPa)

6.4 LIQUID ADDITIVE PUMP
Waukesha Rotor Pump:

Waukesha 015 Rotor Pump Performance Parameters:
No. Item Rotor Pump
1 Model Waukesha015
2 Max.Displacement 0142gal/rev
3 Max.RotarySpeed 700rpm
4 SuctionPortType NPT1.5
5 DischargePortType NPT1.5
6 RatedWorkingPressure 200PSI
7 WorkingTemperature -40～93℃

No. Item Rotor Pump
1 Model Waukesha018
2 Max.Displacement 0.029gal/rev
No. Item Rotor Pump
1 Model Waukesha040
4 SuctionPortType NPT2
5 DischargePortType NPT2
No. Item Rotor Pump
1 Model Waukesha640

VIKING AS4197 Gear Pump Performance Parameters：
No. Item Gear Pump
1 Model VIKING AS4197

2 Max.Displacement 160 L/min
3 Max.RotarySpeed 1400 rpm
4 SuctionPortType 2”
5 DischargePortType 2”
6.5 SAND BLENDING TUB
ROPER 9722 Performance Parameters:
No. Item Gear Pump
1 Model ROPER9722
3 SuctionPortType 3＂
4 DischargePortType 3＂

6.5 SAND BLENDING TUB

Theblendingtubisdesignedtohaveduallayerstoensurecompleteandcontinuous
blendingperformance.Thisdesignalsohasthesandfluidstayinthetubasshortas
possible to enhance accuracy of measurement, additive system and control system.
Suction centrifugal pump sends fluid into tub from one side and the fluid flow in
tangentialdirectioninsidetheouterlayer.Afterrecirculatinginsidetheouterlayer,the
fluidgoestotheinnerlayerthroughholesontheouterwalloftheinnerlayerandmixes
withproppantsentherebytheaugers. Theinnerlayerisbigenoughtocompletely
soaktheproppantandthuspreventairbubble.Agitatorisinstalledatthecenterofthe
blendingtub.Itiscapableofcontinuouslyblendingthesandandpreventsairbubble
between inner layer bottom and discharge pump as much as possible. Fluid well

blendedisdrainedbydischargepumpintodischargepipeline.Thereisa4”butterfly
valveatthebottomofthetubtodrainandcleanthetubafteroperation.
Agitatorimpelleroftheblendingtubisverticalandbladesarein45°and90°tothe
inner chamber plate. Agitator shaft is driven by hydraulic motor with rotary speed
ranged from 0 to 120 rpm. Volume of the blending tub is 1.5m3. Blade speed is
controlled by the control valve on the instrument desk and it is adjustable. System
pressureissetto20MPa.
Theblendingtubalsohasmanualandautofluidlevelcontrolsystemwhichisusedto
controlthefluidlevelbyadjustingfluidsupplyflowrate.
WARNING
DONOTliftandmovetheunitwhenthereisliquidinsidetheblendingtub.

6.6 SAND TRANSMISSION SYSTEM
Sand transmission system includes augers shell, transmission shaft, storage hopper,
augerbracket,lifting/separatingcylinderandcouplings.
Auger Illustration:

Auger Specifications:
No. Item Auger
1 Size 12″
3 Min.RotarySpeed 7rpm
4 Max.SandFlowrate 150m3/h
5 SandVolume/Revolution 9～10L/rev
The main shaft of the auger is driven by the hydraulic motor directly and they are
connectedbytherollerchaincoupling.Thesandflowrateis9~10L/rev.Mainshaftof
theaugerismadeofwear-proofsteelbladesandsteeltubing.Theaugercanrotatein
bothdirectionstoavoidbeingblocked.Duringnormaloperation,theswitchisshiftto
FORWARD position. When the auger is blocked, zero the knob, shift the switch to
REVERSEpositionandlettheaugerturnreverselyandthentheblockcanbesolved.The
pressureoftheaugerhydraulicsystemissetto20MPa.Mainshaftisequippedwith
gearformeasurement.Signalissenttotheinstrumentpanelthroughthesensorand
cable.Bothinstantaneousflowrateandaccumulatedflowratecanbereadoutdirectly
fromtheHMIontheinstrumentpanel.Twosensorsarepreparedformeasurementand
theybackeachotherup.

CAUTION
DONOTchangetherotarydirectionoftheaugerwhenitisworking,otherwiseitwould
bedamaged.

NOTE
a) If the auger screw blade contacts with the proppant for a long period,
measurement deviation may occur, so the transmission capacity should be
calibratedregularly.
b) Landingtheaugersfirstbeforethesplittingoperationandmakesurethereisno
sandinthesandhoppersduringtheliftingorsplitting
c) After operation, open the sand discharge port on the bottom of the auger to
discharge the sand inside completely so as to prevent the sand inside from
affectingthestartupoftheaugerinnextoperation.

CHAPTER 7 HYDRAULIC SYSTEM
7.1 INTRODUCTION ............................................................................................................ 1
7.1.1 SUCTION LOOP ...................................................................................................... 4
7.1.2 DISCHARGE LOOP.................................................................................................. 5
7.1.3 SAND TRANSMITTING LOOP ............................................................................... 5
7.1.4 LOAD SENSITIVE LOOP ......................................................................................... 6
7.1.5 HYDRAULIC OIL RADIATOR RORATY ACTUATOR LOOP ................................. 6
7.2 COMPONENTS .............................................................................................................. 7
7.2.1 CLOSED-LOOP AXIAL PISTON PUMP.................................................................. 7
7.2.2 CLOSED-LOOP AXIAL PISTON MOTOR............................................................... 9
7.2.3 OPEN-LOOP AXIAL PISTON PUMP ................................................................... 10
7.2.4 PVG MULTI-TANDEM VALVE ............................................................................. 12
7.2.5 MV SERIES NEEDLE VALVE ................................................................................. 14
7.2.6 BENT AXIS PISTON MOTOR ............................................................................... 15
7.2.7 ORBITAL MOTOR ................................................................................................. 16
7.2.8 ELECTROMAGNETIC DIRECTIONAL VALVE ...................................................... 17
7.2.9 ROTARY ACTUATOR ............................................................................................ 17
7.2.10 RADIATOR .......................................................................................................... 18
7.3 MAIN FUNCTION ........................................................................................................ 19
7.4 MAINTENANCE ........................................................................................................... 19
7.4.1 FILTER MAINTENANCE ....................................................................................... 19
7.4.2 HYDRAULIC OIL MAINTENANCE ....................................................................... 19
7.5 HYDRAULIC SYSTEM TROUBLESHOOTING ............................................................. 21
7.5.1 COMMON TROUBLE SHOOTING ....................................................................... 21

7.5.2 TROUBLE SHOOTING BY ANALYSIS OF HYDRAULIC SCHEMATICS ............. 22
7.5.3 OTHER TROUBLE ANALYSIS METHODS ........................................................... 22
7.6 HYDRAULIC SYSTEM COMMON TROUBLESHOOTING .......................................... 23
7.6.1 SYSTEM NOISE AND VIBRATION TROUBLE SHOOTING ................................ 23
7.6.2 ABNORMAL SYSTEM PRESSURE TROUBLE SHOOTING ................................. 23
7.6.3 ABNORMAL SYSTEM REACTION TROUBLE SHOOTING ................................. 24
7.6.4 HYDRAULIC PUMP TROUBLE SHOOTING ........................................................ 25
7.6.5 HIGH SYSTEM OIL TEMPERATURE TROUBLE SHOOTING .............................. 29
7.6.6 HYDRAULIC MOTOR TROUBLE SHOOTING ..................................................... 30
7.6.7 PROPORTIONAL VALVE TROUBLE SHOOTING ................................................ 32
7.6.8 RELIEF VALVE TROUBLE SHOOTING ................................................................. 33
7.6.9 FLOW VALVES TROUBLE SHOOTING ................................................................ 37

CHAPTER 7 HYDRAULIC SYSTEM
7.1 INTRODUCTION
Thisunitisequippedwithfoursetsofindependentclosed-loophydraulicsystems(with
one variable displacement piston pump and one fixed displacement piston motor in
each system). The four systems drive a suction centrifugal pump, a discharge
centrifugal pump and two augers. This system is also equipped with an open-loop
hydraulicsystem(withapriorityflowrategearpump,anaxialpistonhydraulicmotor,
rotaryactuatorandhydraulicactuator),thepriorityflowrategearpumpinthissystem
drivesthecoolerfanandcontrolstheflowratecontrolvalvesandthemanifoldbutterfly
valves.Besides,theunitisequippedwithtwosetsofloadsensitivesystems(withone
open-loop piston pump and multi-tandem valve in each system). The load sensitive
systems drive the agitator motor, air conditioner motor, liquid additive motor, fluid
supplymotor,dryadditivemotor,liftingcylinders,separatingcylindersandplugvalve.
The hydraulic control system is equipped with hydraulic oil radiator to control the
hydraulicoiltemperaturewithinanoptimalworkingtemperaturerange.
Hydraulicmotors,hydraulicpumpsandhydraulicvalvesareallreputablecomponents
withsafeandreliableperformance.
PleaserefertotheHydraulicSystemSchematicfortheprincipleofthehydraulicsystem.
Please refer to the Hydraulic System Component List for detailed information of the
hydraulicsystemspareparts.

1 Chapter 7 Hydraulic System HSC16

Hydraulic System Schematic:
HSC16 Chapter 7 Hydraulic System 2

Hydraulic System Components List:
Item P/N Description Qty.
1 B080014791 PressureGauge 4
2 B010011116 SuctionPump 1
3 B020000214 SuctionMotor 1
4 B010000102 SandTransmittingPump 2
5 B030000422 FlushingValve 1
6 B020000223 SandTransmittingMotor 2
7 B010011094 DischargePump 1
8 B020013373 DischargeMotor 1
9 B080005844 SuctionOilFilter 2
10 B030000608 Thermostat 1
11 HydraulicOilRadiator 1
12 B030010223 CheckValve 1
13 B080005546 ReturnOilFilter 2
14 B010000145 LoadSensitivePump 2
15 B010000187 PriorityDiverterPump 1
16 B030039101 ControlValve 1
17 B030000266 OverrideRefrigerationValve 1
18 B030012269 TemperatureControlValve 1
19 B020000169 OilRadiatorMotor 1
21 B030018157 ProportionalDirectionalValve 1
22 B030000535 ThrottleValve 1
23 B040000593 RotaryActuator 1
24 B020026702 OrbitalMotor 5

27 B040029705 SeparatingCylinder 2
28 B040000607 LiftingCylinder 2
29 B030009395 HydraulicLock 2
30 B020000594 AgitatorMotor 1
31 AirConditionerMotor 1
32 PVGMulti-tandemValve 1
33 PVGMulti-tandemValve
34 B070011240 QuickDisconnectModule 2
35 OilTank 1
36 B030029732 FlushingValves 2
7.1.1 SUCTION LOOP
This loop is a closed loop which aims to make the suction centrifugal pump supply
fracturingbasefluidtotheblendingtub.Thisloopconsistsofsuctionhydraulicpump
02andsuctionmotor03.Suctionhydraulicpump02isdriventhroughenginepump
drive and sucks in hydraulic oil through suction oil filter 09 and then drives suction
motor03soastodrivethesuctioncentrifugalpump.Awaterbutterflyvalveisinstalled
on the suction manifold that is close to the blending tub inlet. The butterfly valve is
accurately controlled through rotary actuator 23 which is controlled by proportional
valve21,sotheflowrateofthebasefluidgoingintotheblendingtubcanbeaccurately
controlled.
Operation Instructions: operate by adjusting the electrically controlled knob on the
instrumentpanelofthecontrolcabin.Iftheknobisadjustedclockwise,thecurrent,the
displacementofthehydraulicpumpandthespeedofthesuctionmotorwillallincrease.
Iftheknobisadjustedcounterclockwise,thecurrent,thedisplacementofthehydraulic

pumpandthespeedofthesuctionmotorwillalldecrease.
7.1.2 DISCHARGE LOOP
Thisloopisaclosed-loopwhichaimstomakethedischargecentrifugalpumptosupply
fracturingfluidforotherequipmentsfromthesandblendingtub.Thisloopconsistsof
discharge hydraulic pump 07, discharge motor 08 and flushing valve 05. Discharge
hydraulic pump 07 is driven through the full-power PTO provision of the chassis
transmission.Hydraulicoilissuckedinthroughsuctionoilfilter09todrivedischarge
motor08soastodrivedischargecentrifugalpump.Thereisanexternalflushingvalve
05toflushthedischargemotor.Itcandecreasethesystemtemperaturebyreplacing
part of the hydraulic oil inside the closed-loop system; and it can flush the motor
housingtotakeouttheimpuritiesinsidethesystemsoastoextendtheservicelifeof
thecomponents.
7.1.3 SAND TRANSMITTING LOOP
Thisloopisaclosedloop.Itdrivestheaugertorotatethroughtheaugermotorsoasto
transmit sand from the hopper to the blending tub. This loop consists of sand
transmittinghydraulicpump04andaugermotor06.Sandtransmittinghydraulicpump
04isdriventhroughtheenginepumpdriveanditsuckshydraulicoilthroughsuction
oilfilter09.Thenitdrivesaugermotor06todrivetheauger.Itshouldbenoticedthat
whenthereistoomuchsandinsidetheaugerorsandgoesintotheaugerclearance,
theaugerwillbestuck.Underthiscircumstance,pleaserotatetheaugerreverselyto
makethesandfalloff.
Operation Instructions: operate by adjusting the electrically controlled knob on the
instrumentpanelofthecontrolcabin.Iftheknobisadjustedclockwise,thecurrent,the

displacement of the sand transmitting hydraulic pump and the speed of the auger
motor will all increase. If the knob is adjusted counterclockwise, the current, the
displacement of the sand transmitting hydraulic pump and the speed of the suction
motor will all decrease. If reverse rotation is needed, please shift the switch from
ForwardpositiontoReverseposition.Adjusttheknobclockwise,thecurrentandthe
speed increases; adjust the knob counterclockwise, the current and the speed
decreases.
7.1.4 LOAD SENSITIVE LOOP
Thisloopadoptsanopensystemwhichconsistsofhydraulicpumpandmulti-tandem
valve.Thisunithastwogroupsofhydraulicloops.Oneconsistsofhydraulicpump14,
multi-tandem valve 32, air conditioner motor, agitator motor, liquid additive motor,
fluid supply motor, lifting cylinder and separating cylinder; while the other branch
consists of hydraulic pump 14, multi-tandem valve 33, liquid additive motor, fluid
supplymotorandplugvalve.Hydraulicpump14isdrivenbypumpdrive.Itsucksin
hydraulic oil through suction oil filter 09 and supplies hydraulic oil to multi-tandem
valve 32 and 33 which then drives agitator motor to drive the agitating shaft, dry
additivemotortodrivethedryadditiveaugertoadddryadditive,liquidadditivemotor
todriveliquidadditivepumptoaddliquidadditive,fluidsupplymotortodrivethefluid
supply pump to add liquid into the liquid additive tank and lifting cylinder and
separatingcylindertoliftandseparatetheaugers.
7.1.5 HYDRAULIC OIL RADIATOR RORATY ACTUATOR LOOP
This loop adopts an open system and it consists of hydraulic pump 15, proportional
directionalvalve21,rotaryactuator23,throttlevalve22,oilradiatormotor19,control

valve16,overriderefrigerationvalve17andthermostatcontrolvalve18.Priorityflow
gear pump 15 has two pressure output ports. Port P1 is priority flowrate port and it
supplieshydraulicoilforrotaryactuator23.ThepressureandflowrateofportP1canbe
slightlyadjusted.Itcontrolstherotatingangleandspeedofrotaryactuator23through
proportionaldirectionalvalve21.Whenthehydraulicsystemfails,releasethrottlevalve
22counterclockwisetolinkoilfromportAandportBoftheactuatorandthenusecrow
bar to pry the actuator to achieve emergency operations. Port P2 is the main oil
pressure port used to supply radiator motor 19 with hydraulic oil. When the engine
coolanttemperatureislowerthan85℃,thermostatcontrolvalve18isopen,thecontrol
portofcontrolvalve16releasespressureanditsportSandportTareconnected,and
theoilcoolermotordoesnotact.Whenthetemperatureishigherthan85℃oroverride
refrigerationvalve17isclosed,backpressurewillbebuiltatthecontrolportofcontrol
valve16,theportSandportTwillbedisconnected,thecoolermotorstartsworking
andthesystembeginstocoolthehydraulicoil.
7.2 COMPONENTS
7.2.1 CLOSED-LOOP AXIAL PISTON PUMP
Suctionhydraulicpumpandsandtransmittinghydraulicpumpareaxialpistonpumps.
Allmodelsutilizetheparallelaxialpiston/slipperconceptinconjunctionwithatiltable
swashplatetovarythepump’sdisplacement.Reversingtheangleoftheswashplate
reverestheflowoftheoilfromthepump.
TheelectricdisplacementcontrolusesanelectrohydraulicPressureControlPilot(PCP)
valve to control the pilot pressure. The PCP converts an electrical input signal to a
hydraulicinputsignaltooperatea4-wayservovalve,whichportshydraulicpressureto
eithersideofadoubleactingservopiston.Theservopistontiltsthecradleswashplate,

thusvaryingthepump’sdisplacementfromfulldisplacementinonedirectiontofull
displacement in the opposite direction. The control has a mechanical feedback
mechanismwhichmovestheservovalveinrelationtotheinputsignalandtheangular
position of the swashplate. The electrical displacement control is designed so the
angularrotationoftheswashplate(pumpdisplacement)isproportionaltotheelectrical
inputsignal.Duetonormaloperatingforcechanges,theswashplatetendstodriftfrom
thepositionpresetbythemachineoperator.Drift,sensedbyfeedbacklinkagesystem
connecting the swashplate to the control valve, will activate the valve and supply
pressuretotheservopiston,maintainingtheswashplateinitspresetposition.
1 2 3 4 5 6 7 8 9 10
11
12
13
20
14
19
18 17 16 15
1 CylinderBlock 11 CradleBearing
2 SwashplateSupport 12 RollerBearing
3 SliderBlock 13 ShaftSeal
4 ServoPiston 14 InputShaft

5 Bushing 15 CradleGuide
6 ServoArm 16 Swashplate
7 Piston 17 SwashplateResetLever
8 Slipper 18 ChargePump
9 DisplacementControl 19 RearBushing
10 FeedbackLinkage 20 ValvePlate
7.2.2 CLOSED-LOOP AXIAL PISTON MOTOR
Thesuctionhydraulicpumpisaxialpistonmotor.Thisseriesofhydraulicmotorsadopt
high efficiency and axial design and arrange the axial piston/slipper guide shoe in
parallelpattern.Theswashplateisfixedtypeandthemotorcanachievebi-directional
rotation. The integration loop flushing valve of the motor can achieve the cooling,
cleaning and filter of the hydraulic oil in the closed-loop circuit. The piston motor
featureshighreliability,compactstructureandlightweight.
Closed-loop Piston Motor Structure:

1 2 3 4 5
7 6
1 LoopFlushingValve 5 OutputShaft
2 ValvePlate 6 FixedSwashplate
3 Piston 7 CylinderBlock
4 RollerBearing
7.2.3 OPEN-LOOP AXIAL PISTON PUMP
The hydraulic pumps used to drive liquid (dry) additivemotor, agitator motor, lifting
cylinders and separating cylinders are axial piston pumps. This pump adopts load
sensitive control mode. The pressure of the pump will be very low under standby
condition, which reduces the power loss effectively. The pump is equipped with
optimizedvalveplatewhichhelpstoimproveworkingefficiencyandreducenoise.This
pump has compact design and occupies small space. Heavy-load tampered roller
bearingisusedforextendingtheservicelifeofthepump.

Internal Structure of the Open-loop Piston Pump:
1 2 3 4 5
6 7 8 9 10 11
12
13
19
18
17 16 15 14

1 PCSpool 11 TaperedRollerBearing
2 LSSpool 12 ShaftSeal
3 LSControl(AttachedtoEndcap) 13 InputShaft
4 LSAdjustingScrew 14 Swashplate
5 PCAdjustingScrew 15 SetPlate
6 LSControl 16 CylinderBlock
7 ServoPiston 17 TaperedRollerBearing
8 BiasSpring 18 CylinderBlockSpring

9 Piston 19 ValvePlate
10 Slipper
7.2.4 PVG MULTI-TANDEM VALVE
The multi-tandem valves are PVG 32 multi-tandem valve made by SAUER USA. The
valvecanbeusedtocontroltherotaryspeedofliquid(dry)additivemotor,fluidsupply
motor,airconditionermotorandagitatingmotorandtheactionoftheliftingcylinders
and separating cylinders. The multi-tandem valve has features of good regulation
characteristics,energysaving,compactstructureandlightweightanditalsohasseveral
types of connection threads and valve plates of different flowrate share the same
outlook.
PVG Multi-tandem Valve Structure:

PVP
PVB
PVB
1 PressureReliefValve 11 MainSpool
PressureReductionValveforPilot
2 12 LSPressureLimitingValve
OilSupply
3 PressureGaugeConnection 13 ShockandSuctionValve,PVLP
4 Plug,OpenCentre 14 PressureCompensator

5 Orifice,ClosedCentre 15 LSConnection,PortA
6 PressureAdjustmentSpool 16 LSConnection,PortB
7 Plug,ClosedCentre 17 SuctionValve,PVLA
8 LSConnection 18 LoadDropCheckValve
9 LSSignal 19 PilotOilSupplyforPVE

Max.OilFlowAdjustmentScrews
10 ShuttleValve 20
forPortsAandB
7.2.5 MV SERIES NEEDLE VALVE
Theneedlevalveismainlyusedforthrottletoregulatethehydraulicoilflowratesoas
to control the motor rotary speed. The following is the appearance and principle
drawingoftheneedlevalve.Whenrotatetheneedlevalveclockwise,thesystemgains
pressure and the agitator motor starts working; when rotate the needle valve
counterclockwise,thesystemreleaseloadandtheagitatormotorstops.


7.2.6 BENT AXIS PISTON MOTOR
Theradiatormotorisabentaxispistonmotor.Thismotoradoptsuniquevalveplateto
increasetherotaryspeedandreducenoise.Themotorcankeepahightorqueoutput.
What’smore,themotorhasfeaturesofcompactstructureandlightweight.
BentAxisPistonMotorStructure:
1 2 3 4 5 6 7 8 9
1 BarrelHousing 6 RollerBearing
2 ValvePlate 7 BearingHousing
3 CylinderBarrel 8 ShaftSeal
4 PistonwithLaminatedPistonRing 9 Output/InputShaft
5 TimingGear

7.2.7 ORBITAL MOTOR
Theliquid(dry)additivemotorisanorbitalmotor.Theorbitalmotorisamotorwithlow
speed but high torque and its working torque is constant within whole speed range.
Themotorhashighstartingtorque,highworkingefficiencyandhighreturnoilpressure.
Itsbearingshellcanstandhighaxialandradialforce.
OrbitalMotorStructure:
2
3

1 Roller 3 DrivingShaftandDrivingValve
2 ValvePlate 4 MotorOutputShaftandBearing

7.2.8 ELECTROMAGNETIC DIRECTIONAL VALVE
Theelectromagneticdirectionalvalveisusedtocontroltheactionoftherotaryactuator
precisely.
1 2 3 4 5
A B
1 ProportionalElectromagnet 4 ValveBody
2 Amplifier 5 Plug
3 ValveSleeve
7.2.9 ROTARY ACTUATOR
This rotary actuator controls the butterfly valve at the connection of the suction
manifoldandsandblendingtubsoastocontrolthesuctionflowrate.

7.2.10 RADIATOR
Thisradiatorismainlyusedtocoolthehydraulicsystem.Theheatcreatedbyfriction
during the operation of hydraulic system makes the oil temperature rise. Oil
temperatureaffectstheoilpropertyverymuch.Astheoiltemperaturerises,oilviscosity
changes which increase system leakage and thus pump volumetric efficiency goes
down and the whole hydraulic system efficiency goes down. Meanwhile, high
temperature makes the hydraulic oil very easily be oxidized. Therefore, radiator is
adopted to cool the hydraulic oil and keep its temperature within ideal range from
40~60°C.Hydraulicoilmaximumworkingtemperatureis80°C.Thesystemisequipped
withaseparatehydraulicoilradiator.Hydraulicmotordrivestheradiatorfantocoolthe
hydraulicsystemdrainedoil.Cooledhydraulicoilreturnstothehydraulicoiltankand
mixeswiththeun-cooledoilsoastocooldownthewholehydraulicsystem.Abypass
oilwayisequippedwiththeradiator.Whenthedifferentialpressureoftheradiatorinlet
andoutletishigherthan0.3MPa,thebypassoilwaywillopenandtheoilwillflowback
to the hydraulic oil tank directly through check valve pipeline so as to protect the
radiator.

7.3 MAIN FUNCTION
Theenginedrivesthreeclosed-looppistonpumps,onegearpumpandtwoopen-loop
piston pumps through the pump drive. Then they supply hydraulic power to one
suction centrifugal pump motor,two augermotors, one hydraulicoil radiatormotor,
onerotaryactuator,oneagitatormotor,fourliquidadditivemotors,twodryadditive
motors,oneairconditionermotor,twofluidsupplymotors,twoliftingcylinders,two
separatingcylindersandplugvalve.Thedischargecentrifugalpumpisdriventhrough
the full-power PTO provision of the chassis transmission by the drive shaft and then
suppliespowertothedischargemotor.
7.4 MAINTENANCE
7.4.1 FILTER MAINTENANCE
Whenthesuctionoilfilterandreturnoilfiltergetdirty,theflowratewilldecreaseorthe
flowratewillfluctuate.Cleanthefilterregularlyoraccordingtotheexperience.Theyare
cleanedevery2or3monthsusually.
7.4.2 HYDRAULIC OIL MAINTENANCE
Hydraulic oil should be maintained properly and effectively to ensure the hydraulic
components perform to their optimal working life. The maintenance of hydraulic oil
requires:inspectionoftheoilwheninstallinghydraulicsystemandinspectionoftheoil
every3to6months.Theinspectionitemsinclude:viscosity,oxidation,watercontent,
consumptionandpollutionoftheadditives.Inspectionresultsshouldberecordedin
ordertofindwhethertheworkingoilisbecomingcontaminated.Inordertoobtainthe
bestinspectionresults,thehydraulicoilshouldbesampledwhiletheunitisworking

under normal temperature conditions. Most of the hydraulic oil manufacturers can
assistusersinoilsampleanalysis.
WARNING
a) Verifythattheoillevelinthelubeoiltankisnormalbeforestartingthehydraulic
system.
b) Verifythatallhydrauliccomponentsarenon-loadedbeforestartingthehydraulic
system.
CAUTION
a) The hydraulic oil needs to be filtered with a fine filter before being input to the
hydraulicsystem.Anoilfiltercartisrecommended.
b) DONOTusemixedhydraulicoil.Differenttypesofhydraulicoilsandeventhesame
typeofoilmadebydifferentcompaniesmaynotbecompatible.
c) Before disassembly for maintenance, drain the hydraulic oil inside and store is
separately.DONOTputtheoilbacktothetankunlessitisfilteredbyafinefilter.
d) Usually Mobil DTE25 hydraulic oil is recommended. It is recommended to use
Mobil DTE26 hydraulic oil in the south and in Middle East areas for summer
operation.Forequipmentsworkinginlowtemperatureareas,MobilDTE10Excel32
hydraulic oil with low condensation point is recommended (Contact JEREH for
recommendation). Preheat the hydraulic oil when its temperature is lower than
10℃.Thehydraulicsystemoilshouldnotexceed80℃.
e) DO NOT open the hydraulic system return circuit in rainy day in case of water
coming into the hydraulic system to accelerate the oxidation of the hydraulic oil

andinhibititslubricationproperties.
f) Replacethehydraulicoilregularly.DONOTusepollutedorunqualifiedhydraulic
oil.
g) Thehydrauliccomponentsshouldbeassembledordisassembledinsstrictclean
environment. It is not recommended to assemble or disassemble hydraulic
componentsinfiled. Ifnecessary,besuretowashthecomponentsnolessthan
threetimeswiththesametypeofhydraulicoilandusenewoilforwashingevery
time. Theusedoilcannotbeallowedbeingrefilledintothesystemoiltank.
h) The relief values of the relief valves in the hydraulic system have been preset by
JEREH and should not be adjusted. If necessary, do adjust strictly according to
equipmentmanualorfromadvicebyJEREH.
i) Oilfilterelementshallbecleanedorreplacedregularly.Usually,itiswashedevery
twoorthreemonthsandreplacedoncethefilterelementisreplaced.
j) Air filter in the hydraulic oil tank shall be cleaned regularly. If the equipment is
operatedinaharshenvironment,thestraineroftheairfiltercanbeblockedeasily.
Itisrecommendedtowashitmonthly.
k) Hydraulicoilshouldbereplacedregularly.Itisrecommendedtoreplacehydraulic
oilonceortwiceeveryyear.Theoilcanalsobereplacedbyseasons.
7.5 HYDRAULIC SYSTEM TROUBLESHOOTING
7.5.1 COMMON TROUBLE SHOOTING
a) The operator should know the performance of the equipment including the
hydraulic system, hydraulic pumps, cleanliness of hydraulic oil, inspection times
andwhenthefilterswerecleanedorchanged. Checkwhetherthehydraulicvalves

wereadjustedornotbeforethetroublebeganandwhethersealshavereplacedor
not. Askabouttheabnormalsymptomthehydraulicsystemcurrentlyshowsthe
possiblecauseofthetroubleandifthesystemhadthistroublebeforeandhowit
wassolvedthen.
b) Checkforabnormalhydraulicsystempressure,flowrate,oillevel,oilleakageand
vibration.
c) Listen to the hydraulic system to see whether there is any abnormal sound of
impactorpumpnoisetohelpjudgewhetherthehydraulicsystemisperforming
properly.
d) Feelalljointsandconnectorsforanabnormaltemperatureandvibrationtojudge
whetherallofthemovingpartsareperformingcorrectly.
7.5.2 TROUBLE SHOOTING BY ANALYSIS OF HYDRAULIC

SCHEMATICS
Analyzethetroubleinthehydraulicdrivingsystemthroughthehydraulicschematics
and try to find out the causes and solution. To assist with your diagnostics, use the
followingfailureandcauseflowcharttoassistwithasolution.
7.5.3 OTHER TROUBLE ANALYSIS METHODS
Whenthehydraulicsystemfails,theoperatormayanalyzeitwithhydraulicprinciplesor
othermethodstoeliminatethecausesonebyonetofindoutwherethetroubleis,that
istosay,toanalyzethetroublewithlogicalmethods.Operatormayalsousethelogical
flowchartorotherkindofchartstoanalyzeandjudgethetroubles.

7.6 HYDRAULIC SYSTEM COMMON TROUBLESHOOTING
7.6.1 SYSTEM NOISE AND VIBRATION TROUBLE SHOOTING
Trouble and Reason Solution

Pumpnoiseand Usehosesatthehydraulicoilinletandoutlet.
vibrationcausehose
Insertshockproofmaterialbeneaththepumpbaseandfuel
andoiltank
tank.
resonance
Changethespringrigidity.
Systemresonance Changethereliefvalvetooutsidedischarge.
causedbyvalve Exhausttheairinthecircuitcompletely.
spring Changethelength,diameterandmaterialofthepipeline.
Installmorepipeclampstominimizethevibration.
Enlargethepipelinediametertocontroltheflowspeed.
Seriousoilflowing Usepipewithlesscurveinsteadofelbow.
soundinthepipeline Usehoses.
DonotuserectangularelboworTeeswherethereiseddyflow.
Vibrationcausedby Exhausttheair.
airenteringthe Coatthehydrauliccylinderandthesealgasketwith
hydrauliccylinder molybdenumbisuphidegrease.
7.6.2 ABNORMAL SYSTEM PRESSURE TROUBLE SHOOTING
Reliefvalvebypassvalveisdamaged. Repairorreplace.
Insufficient
Pumpormotorisdamaged,ortheinternal
pressure Repairorreplace.
leakageisserious.
Unstable Fixleakage,addoiland
Airmixesintooil.
pressure bleedoffair.

Reliefvalveiswornoutandspringrigidity
Repairorreplace.
ispoor.
Oiliscontaminatedandvalvedamping
Cleanandchangeoil.
holeisblocked.
Pumpormotorisdamaged. Repairorreplace.
Over-high Reliefvalvevalueissetwrong. Reset.

pressure Reliefvalveisblockedordamaged. Cleanorreplace.
7.6.3 ABNORMAL SYSTEM REACTION TROUBLE SHOOTING

Systempressure Mechanicalfailure Eliminatethefailure.
isnormalbut
Valvedoesnotwork. Adjust,repairorreplace.
actingelements
donotact. Cylinderormotordamaged. Repairorreplace.
Pumpoutputflowrateisinsufficientor
Check,repairorreplace.
systemleakageisserious.
Oilviscosityistoohighortoolow. Check,repairorreplace.
Actingelements Valvecontrolpressureisinsufficientor
Cleanandadjust.
reacttooslowly. valvedampingholeisblocked.
Externalloadistoolarge. Checkandadjust.
Valvecoreisstuck. Clean,filterorchangeoil.
Cylinderormotoriswornout. Repairorreplace.
Readjustorrepairrelief
Abnormalpressure
valve
Airmixedinoil Refilloil,releaseair
Actionabnormal
Valvecorestuck Cleanandfilteroil
Amplerfailsorimproperadjustment Repairorreplace
Sensorfeedbacknotsensitive Repairorreplace

7.6.4 HYDRAULIC PUMP TROUBLE SHOOTING
Trouble Cause Solution
Oilsuctionfilterisblockedand
Cleanorchangethefilter.
hasalargeresistance.
Theoilsuctionhoseistoo Lengthentheoilsuction
closetotheoillevel. hoseoradjustitslocation.
Lowerthepump
Theoilsuctionpositionistoo
installationheightor
highortheoillevelistoolow.
increaseoillevel.
Pumpandoilsuctionhoseseal
Checkandfasten.
isnottight.
SeriousAir Checkoilqualityand
Suction Oilviscosityistoohigh. chooseoilofappropriate
viscosity.
Heavy Keeptherotaryspeed
Pumprotaryspeedistoohigh
Pump lowerthanthemaximum
(usedimproperly).
Noise rotaryspeed.
Replaceitwithafilterwith
Oilfilterflowrateistoosmall.
largerflowrate.
Theairfilteronthetankis Cleanorreplacetheair
blocked. filter.
Pumpshaftoilsealfails. Replace.
Letreturnoilflowthrough
Oilcontainssomeairorsome
clapboardandapply
bubbleformsduringworking.
defoamer.
Bubble
Suction Keepadistancebetween
Theseriousreturnoilvortex suctionpipesandreturn
flowproducesfoam. pipe.Insertreturnoilpipe
belowoillevel.

Airexistsinthepipeorpump Runitwithoutloadto
housing. bleedofftheair.
Suctionpipeisnotimmersed Extendthesuctionpipeand
deepenoughintotheoil. addoiltothetank.
Bearinginsideiswornout Disassembleandclean,
seriouslyordamaged. replace.
Abnormal
Insidepartsofthepumpis
Pump Replace.
wornoutordamaged.
Running
Gearprecisionislowand
Rebuildorreplace.
run-outislarge.
Bad PTOconnectingboltsare
Fasten.
Installation loose.
Slidingpartsinsidethepump Disassembleandclean,
arewornoutheavily. repairandreplace.
Thetorqueoftheboltonthe
Fastenboltswitheven
pumpcoverisunevenorthe
torque.
boltisloose.
Low
Insufficient
Volume Replaceoilorcheckfor
Oil Oilviscosityislow(wrongoilor
Efficiency causesofhighoil
oiltemperaturetoohigh.)
temperature.
Bigclearancebetweencertain Repairandmakethe
pistonandcylinderleadstooil clearancewithin
leakage. specifications.
Improperclearance(suchas
insufficientclearancein Disassemble,cleanand
vane/rotorslot,constantrotor repairtokeepproper
Abnormal Bad whichcauseslidingpartshot clearance.
Heating installation andburnt)
Disassemble,cleanand
Drivingpartsarenotwell
rebuildittomeetthe
aligned.
technicalrequirements.

Thebearingfailsforitspoor
qualityoritisdamagedduring Disassemble,checkand
installorisnotcleanedbefore replacethebearing.
install.
Oilreturnportboltisclosed
anditisnotconnectedto Installthereturnoilpipe.
hoses.
Oilwayisdirty. Cleantheoilway.
Returnoilpipehastoomany
Replacewithstraightpipe.
turnsortwisted.
Oilviscosity-temperature
Chosehydraulicoilas
propertyispoorandthe
specified.
viscositychangesgreatly.
PoorOil
Toomuchwaterinoilcause Replacewithqualifiedoil
badlubrication. andcleantheoiltank.
Oilispolluted. Replaceoil.
Pipeline Suctionpipeistoothinand Choosebiggerandstraight

failure suctionresistanceislarge. pipe.
There’stoomuchexternal Eliminatebadexternal
External
heatanditisdifficultto influencesandadoptheat
Influence
radiate. insulationdevices.
Reinstallandreplacethe
Seallipisinstalledinversed.
damagedone.
Axlefilletisnotproperandthe Re-machineor
seallipisopen. re-assemble.
ShaftSeal Bad
Springfallsoff. Re-assemble.
Leakage Installation
Seallipisstuckwithforeign
Cleanandre-assemble.
objects.
Seallipisdamagedwhen
Replaceandrebuild.
goingthroughthespline.

Checkgroovesizeand
Sealbadalignment
reinstall.
Checkgroovesizeand
Oilsealseriouslydeformed
chamfer.
Checkshaftchamfersize
Sealliprolled andsurfaceroughness.
Greaseandreinstall.
Shaftdiameterisnotproper
Checkthesizeandreplace
andseallipbecomeshotdue
shaft.
tofriction.
Badshaftchamfercausesseal
Re-machineshaftcorner.
BadShaft lipstrained.
andGroove Refurnishandeliminate
Shafthassignsofscratch.
Quality. scratch.
Roughshaftsurfaceaccelerate
Re-machine.
seallipworn-out.
Badgroovemachine,scratch Replacepumpcover,repair
orotherdeflectsexists. grooveasspecified.
Thesealisunqualified.Pooroil
OilSeal Replaceitwithgood
resistance,deteriorationor
Defect rubberoilseal.
failureleadstoleakage.
Discharging
Hardtodischargeoilsmoothly
PipeToo Enlargethediameteror
anddischargingpressure
ThinorToo shortenthelength.
increases
Long

7.6.5 HIGH SYSTEM OIL TEMPERATURE TROUBLE SHOOTING
Failure and Reason Solution
Thepressureissettoohigh. Adjustthepressureproperly.
Thereliefvalvedoesnotworkwell. Correcttheelementabnormality.
Thepumpshelltemperaturerisesbecause
Changeoil,repairorreplacethehydraulic
oftheworseleakageinsidethepump
pump.
causedbylowviscosityorpumpfailure.
Nosufficientoilinthetank. Addoilorenlargethetank.
Modifythestructuretomakethe
Thetankstructureisnotreasonable.
temperatureriseevenly.
Coolerfailed,waterinletvalvenotwork Enlargethecooler,repairthecoolerand
well,lackofwater,ortheoiltemperature valve,addmorewater,repairthe
self-adjustdevicefailed temperatureregulator.
Thereliefvalve’sremotecontrolport
controlstheflowtoomuchandpressureis Adjustitproperly.
stilltoohighafterunloading.
Thepiperesistanceistoobig. Usepipeofproperdiameter.


7.6.6 HYDRAULIC MOTOR TROUBLE SHOOTING

Oilfilterisblocked. Cleanorreplacethefiltercore.
Oiltanklevelloworsuction
AddoilandenlargepipeID.
pipeIDistoosmall.
Insufficient Sealislooseandairgoes Tightenrelatedconnectorto

oilsupply inside. preventleakageorairinvasion.
Oilviscosityistoohigh. Chooseoilwithlowviscosity.
Largeclearancecauseserious
Repairhydraulicpump.
leakage.
Checkforhydraulicpump
Hydraulicpumpefficiency.
failuresandeliminatethem.
Low Low Reliefvalvefailsorthe Checkthevalveandre-adjust
rpm outputoil pressureisinsufficient. thepressure.
and pressure
small Oilpiperesistanceistoo
of Replacewithshorterand
torque large(Pipeistoolongortoo
hydraulic biggerpipe
thin.)
pump
Oilviscosityislowand Checkforinternaldrainage,
internaldrainage. replaceoilorseal.
Tightenthejunctionsurfaceor
Hydraulic Looseconnectionorbadseal
replacetheseal
motor
Motorinnercomponentsare Checkforwornparts,repairor
leakage
wornandleakageisserious. replacethem.
Supportingspringofoil
Checkandreplacesupporting
Failure distributingplateisstrained
spring.
andloseseffectiveness.
Internal Oildistributingplateisworn Checkoildistributingplateand

Leakage
leakage out. repair.

Checkandadjusttheaxial
Axialclearanceislarge. clearancetoareasonable
range.
Oildistributingplateand
cylinderbodysurfaceare
Repair.
wornout.Axialclearanceis
overlarge.
Springisstrained. Replacespring.
Replacethesealringandcheck
Oilsealiswornout.
thecauses.
Thesealringinthecover
External Replacethesealring.
plateisdamaged.
leakage
Junctionsurfacehasforeign Check,cleanandtightenthe
objectsortheboltisloose. bolts.
Pipejointsealisloose. Tightenthefitting.
Thesealislooseandair Checktherelativesealand
invades. fastentheconnection.
Hydraulicoilispollutedand Replacewithcleanhydraulic
airbubblesmixin. oil.
Noise
Replacewithoiloflow
Viscosityistoohigh.
viscosity.
Motor’sradialdimensionis Repaircylinderholeand
wornoutseriously. replacepiston.


7.6.7 PROPORTIONAL VALVE TROUBLE SHOOTING
Trouble Solution
Checkwhetherthesystemoilpressureisnormalornottojudge
theworkingconditionofthehydraulicpumpandthereliefvalve.
Actuatordoesnot Checkwhethertheactuatorisstuckornot.
workafterthe
Checkwhetherthesignalinputandoutputoftheservoamplifieris
controlsignalsare
normalornottojudgeitsworkingcondition
inputintothe
system. Checkwhetherthehydraulicoutputisnormalornotwhenthereis
signalinputorchangeoftheproportionalvalvesoastojudgethe
workingconditionoftheproportionalvalve.
Checkwhetherthesensorisconnectedtothesystemornot.
Actuatormove
towardsone Checkwhethertheoutputsignalofthesensorisconnected
certaindirection wronglywiththeservoamplifier.
afterthecontrol
Checkthepossibleinternalfeedbackfailureoftheproportional
signalsareinput.
valve.
CheckwhethertheproportionvalveNULLsignaladjustmentis
normalornot.
NULLpositionof
CheckwhethertheNULLsettingoftheproportionalvalveis
theactuatorisnot
normalornot.
correct.
Checkwhethertheshimmysignaladjustmentoftheproportional
valveisnormalornot.
Checkwhetherthemagnificationtimesoftheservoamplifieristoo
Vibrationexistsin bigornot.
theactuator. Checkwhethertheoutputsignalofthesensorisnormalornot.
Checkwhethertheoilpressureistoohighornot.
Actuatorcannot Checkwhetherthemagnificationtimesoftheservoamplifieristoo
keepupwiththe smallornot.

Checkwhethertheoilpressureistoolowornot.
Endplaybetweentheactuatorandthemovingpartsistoobig.
Stick-alip Thereisairintheoilway.
phenomenon
Toolargefrictionofthemovingelements
existinthe
actuator Notenoughpressureoftheoilsources
7.6.8 RELIEF VALVE TROUBLE SHOOTING
Mainvalvecoredampholeis
Cleanthedamphole,
jammed(valvecoreisnot
filtrateorreplacethe
cleanoroilispollutedwhen
oil.
install).
Disassemble,repair
Mainvalve
Mainvalvecoreisblockedat andreinstall.Evenly
fails.
theopeningposition. tightenthecoverbolt.
Filterorreplaceoil
Springisbrokenorbentso
Pressure
thatthemainvalvecannotbe Replacespring.
cannotbe
reposition.
adjusted
higher Pressureadjustingspringis
Replacespring.
broken.
Pressureadjustingspringis
PilotValve Installthespring.
notinstalled.
Fails.
Conevalveorsteelballisnot
Install.
installed.
Conevalveisdamaged. Replace.
Wronginstallforsuctionand
Wronginstall Correcttheinstall.
outletoilport.
Pressure Mainvalve Conicalsurfaceofthemain
cannotbe failsifthe valvecoreiswornornot Replace.
adjusted mainvalveis round.

Valveseatconicalsurfaceis
Replace.
wornornotround.
Impuritystickstotheconical
Clean.
surface.
Mainvalvecoreconicalsurface
andvalveseatconicalsurface Repair.
isnotconcentric.
Mainvalvecoreisblocked.The
connectionbetweenthevalve Repair.
coreandvalveseatisnottight.
Replacesealgasket
andreinstall.Make
Leakageonthemainvalve
surethescrew
cover.
tighteningforceis
equal.
Replace.
bent,toosoftandtooshort.
Pilotvalvefails
Thesealbetweenconicalvalve Check,repair,cleanor
andvalveseatisbad. replace.
Repairandreplace
Mainvalve Mainvalveisnotsensitiveand
spareparts.Filteror
fails. blockedatcloseposition.
replaceoil.
Pressure
increased Pilotvalvecoreandvalveseat Cleanandrepairor
suddenly Pilotvalve connectionsurfaceisstuck. replaceoil.
fails. Pressureadjustingspringis
Replacethespring.
bentandblocked.
Pressure Mainvalve Mainvalvecoredampholeis Clean,filterorchange
decreased fails. jammedsuddenly. oil.

Mainvalvecoreisnotsensitive Repairandreplace
andsuddenlyblockedatclose spareparts.Filteror
position. replacetheoil.
Mainvalvecoversealgasketis
Replaceseal.
brokensuddenly.
Pilotvalvecoreisbroken
Replacevalvecore.
Pilotvalve suddenly.
fails. Pressureadjustingspringis
Replacespring.
brokensuddenly.
Pressureadjustingspringis Replacespring.
bent.
Conicalvalveandconicalvalve
Pilotvalve Repairorreplacespare
seatarenotconnectedwell
fails. parts.
withunevenfriction.
Boltlocknutforpressure Lockthelocknutafter
adjustingisloose. pressureadjusting.
Repairandreplace
Mainvalvecoreisnotsensitive spareparts.Cover
Pressure andsometimesisblocked. screwtighteningforce
fluctuates shouldbeequal.
Disassembletoclean.
Mainvalvecoredampholeis
Checkoilqualityand
Mainvalve sometimesjammed.
replacetheoil.
fails.
Mainvalvecoreconicalsurface
andvalveseatarenot Repairorreplacespare
connectedverywellwith parts.
unevenfriction.
Dampholediameteristoobig Reducethedamphole
causingitcannotworkwell. diameterproperly.

Valveandmainvalvecoreisof
Checktheaccuracy
badaccuracywithburrsonthe
Mainvalve andremoveburrs.
edge.
fails.
Impuritystucktothevalve. Repairandreplace
Clearanceistoobigoruneven. spareparts.
Airinthe Pumpsuckairorairexistsin
Bleedofftheair.
system thesystem.
Valveisnot Passagevolumeexceeds Usewithintherated

Usedproperly. permittedvalue. volumerange.
Resistanceinsidereturnpipe
Increasepipediameter
Oilreturnway lineistoohighorreturnoil
andreduceelbows.
isnotsmooth. filterisjammedorpipeistoo
Replacefilter.
closetotheoiltankbottom.
Conicalvalveandvalveseat
arenotconnectedwell.Circle
Vibration surfaceisnotroundenough. Controlsealsurface
andnoise Bigroughnessexists.Pressure circularitytolerance
adjustingspringisnotevenly within0.005to
stressedmakingtheconical 0.01mm.
valvevibratemoreseverely
andnoiserises.
Pressureadjustingspringaxial
Increaseconicalvalve
Pilotvalve leadandendsurfaceisnot
accuracyandcontrol
fails. vertical.Needlevalveinclines
roughnessatRa0.4um.
causingunevenconnection.
Pressurespeedgovernor
inclinestoonesideonthe Replacespring.
locatingrod.
Thevalveseatisdeflected
Improveinstallquality.
duringinstall.
Replacespring.
bent.

7.6.9 FLOW VALVES TROUBLE SHOOTING
Checktheaccuracy
Valvecoreandvalvesleeve
andmakesurethe
Pressure geometryaccuracyisbadand
clearancemeetthe
compensation clearanceistoosmall.
request.
valvedoesnot
workandis Springisbentordeformed
Replacespring.
blockedat causingvalvecoreblocked.
closeposition.
Thespringisnotstrong
Replacespring.
enough.
Theoilistoodirtyandthe Checktheoil
throttleportisjammed. qualityandfilterit.
Noflowrate
changeafter Checkandfindout
Handleandthrottlecoreinstall
adjusting thereasonand
positionisnotsuitable.
throttlevalve reinstall.
handle.
Bondisnotinstalledontothe Replaceorreinstall
Throttlevalve
throttlecoreorfelloff. bond.
fails.
Cleanandrepair
Throttlecoreisblocked
theclearanceor
becauseofsmallclearance.
replacespareparts.
Screwthreadoftheadjusting
Disassembleand
barisjammedbyimpurity
clean.
causingbadadjustment.
Nooilinthe Directionvalvecoredoesnot Checkthereason

system. changedirection. andeliminate.
Actuator Pressure Repairtomakeit

Thevalvecoreisblocked.
moving compensation movefreely.

speedisnot valvefails. Cleandamphole.If
stable. Thedampholeofthevalveis
oilistoodirty,
sometimesjammed.
replaceit.
Springisbentanddeformedor
springendsurfaceandspring Replacespring.
axialisnotvertical.
Compensationdampholeis Cleandamphole.If
jammed.Andthevalvecoreis theoilisdirty,
blockedatopenposition. replaceit.
Valvecoreandvalvesleeve Repairtomake
accuracyisbadandthe surethattheycan
clearanceistoosmall. movefreely.
Springdentanddeformed
Replace
causingvalvecoreblocked.
Disassembleto
Throttlevalve Impurityexistsinthethrottle clean.Iftheoil
fails. portcausingjamsometimes. qualityisbad,
replaceit.
Checkthereason
foroiltemperature
Highoiltemperaturecauses increase.
flowratepassingthroughthe Decreaseoil
throttlevalvechange. temperatureand
controlitwithinthe
Badoilquality.
requestedrange.
Cleanandcheck
Oilistoodirtyandjamsthe theoilquality.If
throttleportordamphole. theoilisnot
qualified,replaceit.
Pipelines Eliminateallair
Airexistsinthesystem.
vibrate. fromthesystem.

Pipelinesvibrationlchanges Adjustandlocked
thesetposition. up.
Internalorexternalleakage Removethe
Leakage leadstounsteadyflowrateand leakageorreplace
abnormalactuatoraction. theelement.

CHAPTER 8 PNEUMATIC SYSTEM
8.1 SYSTEM INTRODUCTION ............................................................................................. 1
8.2 MAIN FUNCTION .......................................................................................................... 3
8.3 MAIN COMPONENTS ................................................................................................... 4
8.3.1 AIR COMPRESSOR ................................................................................................. 4
8.3.2 UNLOADING VALVE .............................................................................................. 5
8.3.3 AIR RESERVOIR ...................................................................................................... 5
8.3.4 AIR DRYER .............................................................................................................. 6
8.3.5 FILTER AND PRESSURE REDUCING VALVE......................................................... 7
8.3.6 PNEUMATIC VANE ACTUATOR ........................................................................... 8
8.4 TROUBLE SHOOTING AND MAINTENANCE ............................................................. 9

CHAPTER 8 PNEUMATIC SYSTEM
8.1 SYSTEM INTRODUCTION
Air compressor equipped with the engine is the air source of the whole pneumatic
system.Thecompressedairgoesintotheairbottleafterbeingdriedthroughtheair
dryeranditspressureis140psiusually.Thepneumaticsystemismainlyusedtocontrol
the butterfly valves, start the electric air horn and shutdown the deck engine under
emergency.
The tee plug valve installed on the platform handrail is the main switch of the
pneumaticsystem.Thefilterandpressurereducingvalveconnectedwiththeteeplug
valveisusedtoadjusttheworkingpressureofthewholesystem.Theworkingpressure
isusuallysetto120psi.
RefertoPneumatic System Schematic forworkingprinciple.
RefertoPneumatic System Components forcomponentdetails.

HSC16 Chapter 8 Pneumatic System 1

Pneumatic System Schematic:
2 Chapter 8 Pneumatic System HSC16

Pneumatic System Components:
1 B030030544 AirDryer 1
2 2305002631 FilterandPressureReducingValveAssembly 1
3 P060001084 ReliefValve 1
5 ---- AirCompressor 1
6 B080004797 Horn 1
7 P200005313 ValveTerminal 1
8 B030028373 Five-positionSolenoidValve 8
10 E030005502 BallValve 1
11 ---- AirReservoir 1
12 B030009768 SafetyValve 1
8.2 MAIN FUNCTION
a) Controlthebutterflyvalvepneumaticvaneactuator;
b) Controltheairhorn;
c) Controlthedeckengineemergencykill.

8.3 MAIN COMPONENTS
8.3.1 AIR COMPRESSOR
Air compressor is one of the important components of the equipment. It is the air
sourceforthepneumaticsystem.Theaircompressorisdrivenbytheengineanditcan
meet the working requirement of the unit. The connection hose between the air
compressor and air bottle is Teflon hose (working temperature varies from -54°C to
+204°C)whichissafetyandreliable.

8.3.2 UNLOADING VALVE
The main function of the unloading valve is to adjust the discharge pressure and
protect the air compressor. When air pressure exceeds the set pressure of the relief
valve, the unloading valve opens and bleeds off extra pressure so as to keep system
pressurewithinnormalworkingrange.Whenpneumaticsystempressureexceedsset
pressure, the unloading valve stops the air compressor so as to extend compressor
servicelife.
8.3.3 AIR RESERVOIR
Airreservoirisusedtostorethecompressedairproducedbytheaircompressorand
supplythewholepneumaticsystemwithcompressedgas.

8.3.4 AIR DRYER
Airdryerusesmolecularsievetodry.Itisintegratedwiththepressurereliefvalve.When
thepressurereliefvalvebleedoffair,thedryairinsidetheregenerationtankwillgo
through the dryer in the reverse direction and take away water on the drying agent
surface so as to regenerate the drying agent and prevent pneumatic elements from
beingerodedbywaterandthusextendtheirservicelife.
7 8 9 10
6 11
1 2 3 4 5
12
19 18 17 16 15 14 13

1 ControlValve 2 AirCompressor
3 EngineTurbine 4 ControlPort
5 Oil-waterSeparator 6 DryingLayer
7 DryingCylinder 8 CheckValve
9 ThroughHole 10 AirFlow

11 PurificationCavity 12 CheckValve
13 PassingPort 14 WaterDrainagePort
15 Thermoelement 16 VentHole
17 PurificationValve 18 TurbineCutPiston
19 AirReservoir
8.3.5 FILTER AND PRESSURE REDUCING VALVE
Thisvalveisusedtofilterairandadjusttheworkingpressureofthepneumaticsystem.
Itiscontrolledbytheknobonthetop.

1 Filter 3 PressureReducingValve
2 PressureGauge 4 AdjustKnob

8.3.6 PNEUMATIC VANE ACTUATOR
This actuator is made by foreign manufacturer. Control valve controls its rotation
directionsoastocontrolthebutterflyvalve.Itismadeoutofaluminum.Pleaseapply
propertorqueduringinstallation.
This actuator is reliable and endurable and it can stand harsh oilfield working
environment.

8.4 TROUBLE SHOOTING AND MAINTENANCE
Whenthepneumaticsystemrunsabnormally,theoperatormayinspectthesystemand
findsolutionsaccordingtothechartbelow.
Trouble Causes Solution
Hosestwistedorflattened Repairorreplace
Noair
Lowtemperatureofslurryor
pressurein Replacewaterseparator
environment,pipefrozen
pneumatic
Elementstuffedorfrozen Replacethefilterelement
system
Airleaksseverely. Replacethepipelineorconnector
Airleaksseverely. replacethefailedmanifoldoradapter
Insufficient Reliefvalveinsufficientoutput
Adjustbacktoworkingpressure
airsupply pressure
Aircompressorpistonwornout Replace
Airleaks. Replaceseal
Pressuredropstoomuch Replaceorcleanfilterelement
Condensedwaterdrainfrom Replace/Repairautomaticwaterdrain
Filter outlet. device
reducing Foreignobjectsexistatoutlet Replacefilterelement
valvefails Reliefportleaks Replacediaphragmandvalveseat
Pressurecannotsethigher Replacediaphragmorspring.
Replacevalveseat,valvecoresealor
Pressurecannotsetlower
resetspring.
Airleaksseverelyorpistonrod
Actuatornotreact
stuffed,replacethemandchecklines.
Actuator
Insufficientairsupply.Checkair
Abnormal Actuatorreactsslowly,not
supplypipelinepressureandorifice
sensitive.
flowrate.


CHAPTER 9 ELECTRIC SYSTEM
9.1 ELECTRIC SYSTEM FUNCTION ..................................................................................... 1
9.2 POWER ON AND OFF ................................................................................................... 1
9.3 LIGHTING SYSTEM ........................................................................................................ 2
9.4 INSTRUMENT SYSTEM ................................................................................................. 2
9.5 PARAMETER DISPLAY .................................................................................................. 2
9.6 CIRCUIT BREAKERS AND FUSES ................................................................................. 3
9.7 CAUTIONS ...................................................................................................................... 4
9.8 ELEMENT COMPONENTS ............................................................................................. 5
9.8.1 CONTROL BOX ....................................................................................................... 5
9.8.2 INDUSTRIAL PRESSURE TRANSMITTER ............................................................. 6
9.8.3 TURBINE FLOWMETER .......................................................................................... 7
9.8.4 ELECTROMAGNETIC FLOWMETER ...................................................................... 8
9.8.5 WATER BUTTERFLY VALVE AND VALVE POSITION SENSOR AND
PROPORTIONAL SERVO VALVE................................................................................... 10
9.8.6 SAND BLENDING TUB LEVEL METER ................................................................ 12
9.8.7 ENGINE ECM AND ELECTRIC STARTING MOTOR ........................................... 14
9.9 ELECTRIC WIRING SCHEMATICS............................................................................... 15
9.9.1 SENSOR WIRING SCHEMATICS ......................................................................... 15
9.9.2 CHEMICAL ADDITIVE AND AUGER WIRING SCHEMATICS ............................ 16
9.9.3 MULTI-WAY VALVE WIRING SCHEMATICS ..................................................... 17
9.9.4 PNEUMATIC CONTROL BUTTERFLY VALVE WIRING SCHEMATICS.............. 18
9.9.5 ENGINE WIRING SCHEMATICS .......................................................................... 19
9.9.6 LOAD WIRING SCHEMATICS .............................................................................. 20

CHAPTER 9 ELECTRIC SYSTEM
9.1 ELECTRIC SYSTEM FUNCTION
a) Controlenginestartup.
b) Controlsandblendingsystem.
c) Supplypowertoalldevicesandinstrumentstoensurealldevicesandinstruments
cansupplypowernormallyduringsandblendingoperation.
d) Supply all lights with electric power to ensure all the indicating lights can work
normallyduringoperationatnight.
e) Thedecksystemsharesthechassisbatterywiththechassisandthebatterycapacity
is220Ah.Aftertheengineisstarted,thegeneratorequippedwiththeenginewill
charge the battery. The parts on deck are of 12V DC and 24VDC. The voltage of
multi-tandemvalvebanks(liquidadditiveanddryadditiveequipments)is12VDC
andthatofotherequipmentsis24VDC.
9.2 POWER ON AND OFF
a) Beforesupplyingpower,pleasemakesurethepressureofthepneumaticcontrol
system is normal and the instrument power is off. Make sure all potentiometers,
controlknobsandcontrolswitchesareoff.
b) Turnonthemainpowerswitch.Batteryoutputatthistimeis24V.
c) InstrumentPanelPowerSwitch:
1) Turnthepowerswitch(selflockingstyle)oftheengineto“POWER”position.
Corresponding engine EDM starts and the deck engine gets power supply.
Power indicator on deck instrument panel will illuminate and the EDM will
displaythesystemvoltage.
HSC16 Chapter 9 Electric System 1

2) Turnthepowerswitch(selflockingstyle)oftheinstrumentto“ON”position,
thenthescreensandthecontrolsystemgetpower.
3) Turnonthelightsandhornsswitches(conventionaltype),coolantheaterswitch
whennecessary.
Thethreetypesofswitchesmentionedaboveworkindependently.
d) Whenpoweroff,turnoffthelightswitchesfirst,thenturnofftheinstrumentpower
switchandfinallyturnoffthemainpowerswitchonthebatterybox.
Enginepowerisonlycontrolledbythemainswitchratherthanthepowerswitches
oncontrolconsole.
9.3 LIGHTING SYSTEM
Switch No. Light Objects
Light1 Auger,controlconsoleandsandblendingtub
Light2 Suctionanddischargemanifold,engineandcontrolcabin
9.4 INSTRUMENT SYSTEM
InstrumentsontheinstrumentpanelincludestheengineEDM,touchscreenandsoon.
9.5 PARAMETER DISPLAY
Parameterdisplaysystemusestouchscreenanditdisplaysthesuctionflowrate,suction
pressure,dischargeflowrate,dischargepressure,suctionbutterflyvalveopennessand
flowrateofliquid/dryadditive.Theseparameterscanbecalibratedonthescreen.The
shiftbetweenautomaticcontrolandmanualcontrolcanbeachievedonthescreen.
2 Chapter 9 Electric System HSC16

9.6 CIRCUIT BREAKERS AND FUSES
There are 21 breakers in this system. All they have been tested before delivery. Each
breakeriscorrespondingtoonesetofelectricdevices.Ifpowerisnotavailable,please
checkthecircuitaccordingtothetablebelow.
Breaker and Fuse Specifications:

Code Model Specification Device
8Q1 15A VehicleBreaker PowersupplyofengineECM
8Q2 5A VehicleBreaker Enginecontrolpowersupply
8Q3 10A VehicleBreaker Powersupplyofdataacquisition
8Q4 10A VehicleBreaker Light1
8Q5 10A VehicleBreaker Light2
8Q6 30A VehicleBreaker Airconditionerpowersupply
8Q7 40A MiniatureBreaker Sparetiremotorpowersupply
8Q8 5A VehicleBreaker Heatercontrolpowersupply
8Q9 40A MiniatureBreaker Heaterpowersupply
8Q10 10A VehicleBreaker Airreservoirdryingpowersupply
8Q11 0.5A VehicleBreaker Switchboardpowersupply
8Q12 20A VehicleBreaker Instrumentmainpowersupply
8Q13 15A VehicleBreaker Dischargeflowmeterpowersupply
8Q14 5A VehicleBreaker Pneumaticcontrolvalvepowersupply
8Q15 5A VehicleBreaker HMIandPLCpowersupply
8Q16 5A VehicleBreaker Instrumentpowersupply
8Q17 5A VehicleBreaker Sensorpowersupply
8Q18 0.5A VehicleBreaker Pressure1and2powersupply
8Q19 5A VehicleBreaker Suctionanddischargepowersupply
8Q20 10A VehicleBreaker Multi-wayvalve1powersupply
8Q21 5A VehicleBreaker Multi-way2powersupply

9.7 CAUTIONS
a) Please turn off the main switches of the battery or other instruments after
operation;otherwisethebatterycannotbeusedanymoreduetolongtimeaton
position.
b) Tightentheelectricdeviceconnectingscrewsbeforerestartingtheunitafterlong
timenouseorthechassishasbeentransportingforalongtime.Beforestartthe
unitforthefirsttimeorrestartingtheunitafterlongtimenouse,measurebattery
voltageandcheckwhethervoltmeterworksinthenormalrangebetween20Vto
24V.Ifthevoltageislowerthan24V,pleasechargethebattery.
c) Iftheunitwon’tbeusedformorethanoneweek,thecableconnectingwiththe
batterycathodeoftheunitshouldbedisconnected.Applysomegreaseoncable
clampandbindingterminals.Iftheunitwon’tbeusedformorethanonemonth,
removethebatteryandkeepitinadryplacewithtemperaturebetween0℃ and
30℃. The battery must be recharged every three months. Check the electrolyte
levelevery6monthsorevery50,000kmoftransportationatmost.
d) If the battery is overused, it will lead to irreversible failure of the battery. The
battery discharged completely will freeze in low temperature, which will damage
thebattery.So,thefrozenbatterymustbeunfrozenfirstbeforeitischargedslowly.
e) Please check whether the sound, rotary speed and instrument displayed
parameters of the main components such as engine, liquid additive pumps and
centrifugalpumparenormalafterstart-up.
f) Pleasekeepthecontrolboxtidyandclean.Donotputunrelatedobjectsinsidethe
controlboxorontheinstrumentpanel,especiallyconductivematerials.Makesure
norain,snoworwaterleaksintotheelectriccontrolboxduringusageandstorage.

9.8 ELEMENT COMPONENTS
9.8.1 CONTROL BOX
1 2 3 4
、
5 6
1 PLCControlSystemAssembly 2 Switchboard
3 UniversalTransmitter 4 CircuitBreaker
5 TerminalBlock 6 EngineStartingRelay

9.8.2 INDUSTRIAL PRESSURE TRANSMITTER
Theindustrialpressuretransmitterisapplicableforallindustrialapplicationfieldsandit
isespeciallysuitableformeasuringpressureofmediumwhichareviscous,pastyand
heavily polluted. The transmitter is mainly used to measuring the pressure of the
suctionmanifoldanddischargemanifold.
Industrial Pressure Transmitter:

Max.measuringrangetestedis1,000kPa.

9.8.3 TURBINE FLOWMETER
Pleaserefertotheactualunittodecidewhetherinstalltheturbineflowmeterornot.
FlowmeterisNUFLOturbineflowmeterwithhighaccuracy,high measurerangeand
withoutzerodeflection.
Measure Principle: when the measured fluid running through the turbo flow meter
sensor, the impeller rotates and its speed is in positive proportion to the average
pipeline flow rate. Meanwhile, magnetic force line which is produced by impeller
changes the coil magnetic flux. And according to the electromagnetic induction
principle,theelectricpulsesignalisinductedinthecoil.Frequencyofthissignalisin
positiveproportiontotheflowrateofthemeasuredfluid.Thepulsesarecalculatedby
computerforflowratemeasurement.
Flowmeter Illustration and Stitch Definition:

A + [ IN ]
B - [ COMMON ]
C [ OUT ]
PIN OUT
A +Voltage
B -Ground
C Signal Output Square Wave
Thebarinthemiddleistheflowfactor.It’saspecialdatauniquelycalibratedtothe
flowmeterbymanufacturer.
lowfactor:Theflowfactorof10”flowmeterisabout2whichmeansevery2output
pulsesrepresentsonegaloffluid.Theflowfactorsof8”flowmeterand4”flowmeter
are usually about 3 and 30 respectively. The flow factors of 2” flowmeter is usually
about55.
9.8.4 ELECTROMAGNETIC FLOWMETER
Electromagnetic Flowmeter Schematic:

Transmitter and Flowmeter Wiring:

Current Signal Wiring:
Fuse
+4–20 mA power –4–20 mA power

Frequency Signal Wiring:
+ –
– – 5–28 V dc
Electro-mecha
nical Counter Power
+ + Supply

Measurement Principle:
Inducedvoltagemaybegeneratedwhentheconductorismovinginthemagneticfield.
When measuring the flowrate under the electromagnetic inducation principle, the
flowing electric conduction medium can be treated as moving conductor in the
scientificlaw.Theinducedvoltageisindirectproportiontothemediumflowrate.Two
measuringelectrodesdetectthesingleoftheinducedvoltagesingalandtransmitthem
to the amplifier for amplification. The volumetric flowrate of the medium can be
calculatedaccordingtothecrosssectionalareaofthepipe.Alternatingcurrentproduce
aconstantmagneticfield.
9.8.5 WATER BUTTERFLY VALVE AND VALVE POSITION

SENSOR AND PROPORTIONAL SERVO VALVE
Water Butterfly Valve Position Sensor:
1/BN
L+ 1 Brown
4/BN
2 White
S1 2/WH
S1
Power
S0
5/GY 3 Blue
ON
S2
S2
4-20mA 4 Black
3/BU
L- 5 Gray
Water Butterfly Valve Position Sensor Installation Illustration:

Water butterfly valve module includes hydraulic rotary actuator system and valve
positionsensor.Thehydraulicoilflowdirectionandflowrateareadjustedthroughthe
hydraulicproportionalvalvewhichiscontrolledbyhydraulicrotaryactuatoraccording
tothecurrentoutputofthecontrolsystem.
Duringcalibration,makesurethebypassthrottlevalveisclosedforbettercontroland
operation.
The valve position sensor and hydraulic proportional valve are all imported products
whichcanguaranteetheaccurateworkoftheelectricsystem.
Proportional Servo Valve Illustration:
This kind of proportional valve supplies -20～+20 mA signals for AO output control
moduleforreal-timecontrol.Whenthesignalisattheneutralposition,namelyitis0
mA,theproportionalvalvedoesnotact.Ifitishigherorlowerthan0mA,thevalvewill
openorclose.Ifthecurrentsignalatneutralpositionleadstotheactionofthevalve,
theoperatorshouldadjustthecurrentvalueatneutralpositiononHMIfirstandthen
adjust the valve open/close current value to make the open and close speed of the
butterflybeingconsistent.

9.8.6 SAND BLENDING TUB LEVEL METER
The liquid level meter is a guided wave radar level indicator made by
ENDRESS+HAUSERanditisinstalledonthebracketofthesandblendingtub.Thelevel
meter provides two-wire signals and its wirings are quite simple. The level indicator
providesreliabledataforthemonitoringandcontroloftheliquidlevel.
Thesettingofmajorparametersisasfollows:
002standard
003>15
004fastchange
005950mm
006620mm
030tiedownisolated
Pleaserefertorelateddocumentsdeliveredwiththeunitfordetailedinformation.
Measuring Principle: The guided level radar is a “downward-looking” measuring
systemthatfunctionsaccordingtotheToFmethod(ToF=TimeofFlight).Thedistance
fromthereferencepoint(processconnectionofthemeasuringdevice)totheproduct
surfaceismeasured.High-frequencypulsesareinjectedtoaprobeandledalongthe
probe. The pulses are reflected by the product surface, received by the electronic
evaluation unit and converted into level information. This method is known as TDR
(TimeDomainReflectometry).
DisplayElements:LiquidCrystalDisplay(LCD)

measured value 000
43.2%

9.8.7 ENGINE ECM AND ELECTRIC STARTING MOTOR
1
2

1-ElectricStartMotor;2-EngineECMandRightSideControlPort


Operation and Maintenance Manual
9.9 ELECTRIC WIRING SCHEMATICS
9.9.1 SENSOR WIRING SCHEMATICS
Chapter 9 Electric System 15

9.9.2 CHEMICAL ADDITIVE AND AUGER WIRING SCHEMATICS
16 Chapter 9 Electric System

9.9.3 MULTI-WAY VALVE WIRING SCHEMATICS

9.9.4 PNEUMATIC CONTROL BUTTERFLY VALVE WIRING SCHEMATICS

9.9.5 ENGINE WIRING SCHEMATICS

9.9.6 LOAD WIRING SCHEMATICS


CHAPTER 10 OPERATION AND CONTROL SYSTEM
10.1 BRIEF INTRODUCTION ............................................................................................... 1
10.2 INSTRUMENT PANEL FUNCTIONS ........................................................................... 1
10.2.1 INSTRUMENT PANEL .......................................................................................... 2
10.2.1.1 MANIFOLD PRINCIPLE SCHEMATIC .......................................................... 3
10.2.1.2 HMI................................................................................................................. 3
10.2.1.3 ENGINE CONTROL AND OPERATION AUXILIARY CONTROL SECTION 4
10.2.1.4 OPERATION CONTROL SECTION ............................................................... 5
10.2.2 HYDRAULIC INSTRUMENT PANEL .................................................................... 8

CHAPTER 10 OPERATION AND CONTROL SYSTEM
10.1 BRIEF INTRODUCTION
The control cabin is the main part of the operation system and it includes operation
panel,fan,lightingdevicesandelectriccomponents.
Thewallofcontrolcabinadoptsdoublelayersdesignwithinsulatingmaterialsinthe
middle. The cabin is spacious, comfortable and it has an open view. It provides
operatorsanduserswithasafeoperatingenvironment.Theinstrumentsconsoleand
panelinsidethecabinismadeofstainlesssteel.
10.2 INSTRUMENT PANEL FUNCTIONS
Theinstrumentpanelintegratesmostofthevalvesandinstruments.
HSC16 Chapter 10 Operation and Control System 1

10.2.1 INSTRUMENT PANEL
Instrument Panel Illustration:

1 2 3
Item Description
1 ManifoldPrincipleSchematic
2 HMI
3 EngineControlandOperationAuxiliaryControlSection
4 OperationControlSection
Thewholeinstrumentpanelfeaturescompactlayoutandhasmanyfunctions.Thus,itis
dividedintofourpartsfordetailedintroduction.
2 Chapter 10 Operation and Control System HSC16

10.2.1.1 MANIFOLD PRINCIPLE SCHEMATIC

Switchesforpneumaticbutterfly Openorclosethebutterflyvalvesand
1
valvefromV1toV8 thedrainvalveofsandblendingtub.
10.2.1.2 HMI
TheHMIismainlyusedtodisplayrelatedparametersofthesandblendingsystem,set
keyparameterssuchassanddensityanddisplacement,andsimulatethesandlending
process.PleaserefertoCHAPTER11SOFTWAREOPERATIONfordetails.

10.2.1.3 ENGINE CONTROL AND OPERATION AUXILIARY
CONTROL SECTION
1 2 3 4 5
14
13
12
11 10 9 8 7 6
1 FanOverride Startthecoolermotormanually.
Displayrelatedparametersofthechassisengine,such
2 ChassisEDM as load, speed and oil pressure. Certain parameter
settingcanbedonehere.
Displayrelatedparametersofthedeckengine,suchas
3 DeckEDM load,speedandoilpressure.Certainparametersetting
canbedonehere.
Engine Control the power supply and shutdown of the deck
4
Power/Shutdown enginestartingmotor.
5 Start Startthedeckengine
6 EngineHeater Engineheaterswitch
7 E-kill Shutdownthedeckengineunderemergency.
8 Throttle Controlthethrottleofthedeckengine.
9 Throttle Controlthethrottleofthechassisengine.
10 AirDry heatingswitchofthedryer

11 Horn Controlthehorn.

Supplypowertothedeckinstrumentbeforetheunit
12 InstrumentPower
startup.
13 HMIDry SwitchtodryHMIscreen
DataCommunication
14 Theinterfacetogetthedatarelatedtotheoperations
Interface
10.2.1.4 OPERATION CONTROL SECTION
1 2 3 4 5 6 `7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26
45 44 43 42 41 40 39 38 37 35 34 33 32 31 30 29 28
36 27

LiquidAdditivePump1 Shiftbetweentheautoandmanualcontrolmodeof
1
Auto/ManualSwitch liquidadditivepump1.
LiquidAdditivePump2
2 Adjusttherotaryspeedofliquidadditivepump2.
SpeedAdjustingKnob
3
LiquidAdditivePump3
SpeedAdjustingKnob
5
LiquidAdditivePump4
SpeedAdjustingKnob
7 LiquidAdditivePump4 Shiftbetweentheautoandmanualcontrolmodeof

DryAdditiveSystem1
8 Adjusttherotaryspeedofdryadditivesystem2.
SpeedAdjustingKnob
DryAdditiveSystem1 Shiftbetweentheautoandmanualcontrolmodeof
9
Auto/ManualSwitch thedryadditivesystem1.
DryAdditiveSystem2
10 Adjusttherotaryspeedofdryadditivesystem2.
SpeedAdjustingKnob
DryAdditiveSystem2 Shiftbetweentheautoandmanualcontrolmodeof
11
Auto/ManualSwitch thedryadditivesystem2.
SuctionPumpSpeed
12 Controlthespeedofthesuctioncentrifugalpump.
AdjustKnob
SuctionPump Shiftbetweenthemanualandautocontrolmodeof
13
Manual/AutoSwitch suctionpump.
FlowControlValve
14 Controlthespeedoftheflowcontrolvalve.
SpeedAdjustKnob
FlowControlValve Shiftbetweenthemanualandautocontrolmodeof
15
Manual/AutoSwitch flowcontrolvalve.
DischargePumpSpeed Control the speed of the discharge centrifugal
16
AdjustKnob pump.
DischargePump Shiftbetweenthemanualandautocontrolmodeof
17
Manual/AutoSwitch dischargecentrifugalpump.
LeftAuger Controltheforwardandreverserotationoftheleft
18
Forward/ReverseSwitch auger.
LeftAugerAuto/Manual Shiftbetweentheautoandmanualcontrolofthe
19
Switch leftauger.
RightAuger Controltheforwardandreverserotationoftheright
20
Forward/ReverseSwitch auger.
RightAuger Shiftbetweentheautoandmanualcontrolofthe
21
Auto/ManualSwitch rightauger.
22 FrontLight Controlthefrontlightofthewholeunit.
23 RearLight Controltherearlightofthewholeunit.
24 A/CRefrigeration Controltheairconditioner.
25 PlugValve Remotelycontroltheplugvalveofthemanifoldunit

tounload.
LiquidSupply2Speed
26 Adjustthespeedoftheliquidsupplypump2.
AdjustKnob
LiquidSupply2 Controlthestartorstopoftheliquidsupplypump
27
Start/StopSwitch 2.
LiquidSupply1Speed
28 Adjustthespeedoftheliquidsupplypump1.
AdjustKnob
LiquidSupply1 Controlthestartorstopoftheliquidsupplypump
29
Start/StopSwitch 1.
AgitatorSpeedAdjust
30 AdjustthespeedoftheAgitator.
Knob
AgitatorStart/Stop
31 ControlthestartorstopoftheAgitator.
Switch
RightAugerSpeed
32 Controlthespeedoftherightauger.
AdjustingKnob
RightAugerStart/Stop
33 Startorstoptherightauger.
Switch
LeftAugerSpeed
34 Controlthespeedoftheleftauger.
AdjustingKnob
LeftAugerStart/Stop
35 Startorstoptheleftauger.
Switch
DischargePump Controlthestartorstopofthedischargecentrifugal
36
Start/StopSwitch pump.
FlowControlValve
37 Controlthestartorstopoftheflowcontrolvalve.
Start/StopSwitch
SuctionPumpStart/Stop Control the start or stop of the suction centrifugal
38
Switch pump.
DryAdditiveSystem2
39 Startorstopdryadditivesystem2.
Start/StopSwitch
DryAdditiveSystem1
40 Startorstopdryadditivesystem1.
Start/StopSwitch
LiquidAdditivePump4
41 Startorstopliquidadditivepump4.
Start/StopSwitch
42 LiquidAdditivePump3 Startorstopliquidadditivepump3.

Start/StopSwitch
LiquidAdditivePump2
SpeedAdjustingKnob
LiquidAdditivePump1
44 Startorstopliquidadditivepump1.
Start/StopSwitch
LiquidAdditivePump1
SpeedAdjustingKnob
10.2.2 HYDRAULIC INSTRUMENT PANEL

1 2 3 4
8 7 6 5

SuctionMainOil
1 Displaythemainoilpressureofthesuctionpump.
Pressure
DischargeMainOil Display the main oil pressure of the discharge
2
Pressure pump.
LeftAugerMainOil
3 Displaytheoilpressureoftheleftauger.
Pressure
RightAugerMainOil
4 Displaytheoilpressureoftherightauger.
Pressure

5 AirPressureGauge Displaysystemairpressure.
FanDriveHydraulicOil
6 Displayfanoilpressure.
Pressure
OpenHydraulicSystem2
7 Displaytheoilpressureofcomprehensivepump2.
PressureGauge
OpenHydraulicSystem1
8 Displaytheoilpressureofcomprehensivepump1.
PressureGauge

CHAPTER 11 SOFTWARE OPERATION
11.1 OPERATION PROCEDURE .......................................................................................... 1
11.2 INITIAL PARAMETER SETTING INTERFACE ............................................................. 3
11.3 DATA MONITORING INTERFACE.............................................................................. 8
11.4 STAGE SETTING INTERFACE .................................................................................... 11
11.5 PROCESS MONITORING INTERFACE ...................................................................... 13
11.6 CALIBRATION INTERFACE ....................................................................................... 14
11.7 STIMULATION FUNCTION ....................................................................................... 21
11.8 MAINTENANCE INTERFACE .................................................................................... 21
11.9 FAILURE INTERFACE ................................................................................................. 23
11.10 ALARM INTERFACE ................................................................................................ 24
11.11 PID PARAMETER INTERFACE ................................................................................ 24

CHAPTER 11 SOFTWARE OPERATION
11.1 OPERATION PROCEDURE
a) Startthetouchscreen.
b) Aftertheinstrumentgetspowersupply,pleaseturntheinstrumentpowersupply
switchontheinstrumentpaneltotheopenposition.Theautomaticcontrolsystem
startstheself-inspectionprocedureforabouttwominutes(thestartingtimemay
vary due to temperature differences in summer and winter.). Then the initial
operationandcontrolinterfacedisplaysasshownbelow.
c) Afterthecomputerstarts,itbootsintotheinitialpage–informationinterface.
d) Theinformationinterfacecanleadtoeveryworkinginterfacewithfunctionkeyson
the bottom of this interface. This software has the function of language shift
betweenEnglish,ChineseandSpanish,andunitshiftbetweenmetricandimperial.

HSC16 Chapter 11 Software Operation 1

1) Press 【LANGUAGE】toshiftbetweenEnglishandChinese.
2) Press 【IMPERIALUNIT】toshiftbetweenmetricunitandimperialunit.
3) Pressdifferentkeystoenterdifferentinterfaces.Eachinterfacehasitsown
functionwhichisdescribedindetailintheinstructions.
4) 【PID】isonlyforthecommissioningengineer.DONOTmodifyitcasually.
CAUTION
a) DONOTpressthetouchscreenwithsharpthingstoavoidscreendamage.
b) DONOTexposethetouchscreenundertheburningsun.Pleasewearsunglasses
tooperatethetouchscreeninstronglight.
c) LanguageshiftbetweenChineseandEnglishandunitshiftbetweenmetricand
imperialunitcanonlybeachievedunderthiswindow,andoncesetallwindows
are under the same setting. When calibrating the variable parameters, please
makesureunitsofinputparametervariablearesameasthesetting.
Function Section Introduction:
The sand blender automatic control system software operation mainly contains flow
chartfunctionsection,curvemonitorfunctionsection,datamonitorfunctionsection,
parameterssetfunctionsection,signalcalibrationfunctionsectionandPIDsetfunction
section.
Eachoperationscreenisdividedintofixedscreensectionanddynamicscreensection.
2 Chapter 11 Software Operation HSC16

Fixed Screen Section
Onthefixedscreendisplaysection,thefixedscreendisplaywindowalwaysshowsin
every interface. The working status of the sand blender can be monitored and
controlledunderfixedwindow.
Fixed Section Function:
Displayandsettheobservedormodifieddataduringoperation.Allwhitedataonthe
screen can be modified while all black ones are actual value during operation and
cannotbemodified.Press“START”beforeautomaticoperation.
Press “FORCE FLOWRATE” and input base fluid and mixing fluid value in
corresponding input box of the right side of the base fluid, which is convenient to
analogtheflowrateiftheelectromagneticflowmeterisdamaged.Andtheautomatic
operationoftheliquidadditiveanddryadditivewon’tbeinfluenced.
theforceflowrateselectioninterfaceof“FORCESUC”and”FORCEDIS”willshow
up.Inputtheforceflowratevalueontheleftsideafterchoosingcorrespondingfunction.
Force flowrate function will still work to control the additives and proppant
automaticallytokeepthecurrentoperationgoingononcetheflowmeterfails.
11.2 INITIAL PARAMETER SETTING INTERFACE
Press“PARAMETER”toentertheinitialparametersettinginterfaceasshownbelow:

Ontheinitialparametersettinginterface,time,dateandjobnumbercanbeset.
Levelvalue,highlevellimit,lowlevellimitandovertublevelvaluecanbesetinlevel
settingsection.
Pressure of suction manifold and discharge manifold can be set in pressure setting
section.
Proppant(sand)graindensity,volumedensity,basefluiddensityanddensitiesofdry
additive1and2canbesetinthedensitysettingsection.
The maximum setting pressure of the base fluid manifold and discharge manifold is
600KPa.Therecommendedsettingpressureofthebasefluidmanifoldis100~200KPaif
use the suction pressure automatic function. If the pressure is set too high, the
centrifugalpumpwillalwaysworkundermaximumrotaryspeedevenwhentheliquid
supplyisless,whichwillshortentheservicelifeofthecentrifugalpumpandcausethe
wholeunittoworkunstably.Ifthepressureissettoolow,itwillcauseinsufficientliquid
supplyandinfluencethestableliquidsupplyofthewholeunit.

The highest level of the sand blending tub is 100% of the whole tank. The
recommendedsettingvalueofthetublevelshallbewithin60~75%,notexceed75%
butitcannotbesettooloweither.Thehighestleveldistanceisrecommendedtobe
morethan15%ofthetankvolumetoavoidspilloveringorevacuation.
Whentheinputboxisclicked,thevaluewillchangecolorandchangeintoinputstatus,
and then input touch keyboard window will pop up. After value is input through the
touchkeyboard,itshouldbeconfirmedbyclickingENTERtoinputthevalueintothe
system.
a) When the suction pump is under automatic control status, set the manifold
pressure in 【Suction Pressure】 input box. The rotary speed of the suction
pump will be automatically adjusted according to pressure of the base fluid
manifold.Thus,thesuctionmanifoldsettingpressurewillbethesamewiththe
actualpressure.
b) Whenthedischargepumpisunderautomaticcontrolstatus,setthemanifold
pressurein【DischargePressure】inputbox.Therotaryspeedofthedischarge
pump will be automatically adjusted according to pressure of the discharge
manifold.Thus,thedischargemanifoldsettingpressurewillbethesamewith
theactualpressure.
c) Whentheliquidlevelisunderautomaticcontrolstatus,setthecorresponding
levelvaluein【SettingValue】,【HLM】and【LLM】.Theliquidlevelofthesand
blendingtubwillbeautomaticallyadjustedaccordingtothesetvaluetomeet
operationrequirements.
d) When1#,2#,3#,4#liquidadditivepumpsareunderautomaticcontrolstatus,
settheaddingvolumeofthefourliquidadditivesinliquidadditiveinputbox.

Theliquidadditivepumpswilladjusttherotaryspeedaccordingtothevalue
monitoredbytheflowmetertomeettheliquidadditivesetvalue.L/m³refers
tothevolumeofadditiveaddedinto1m³basefluid.Forexample,thesetvalue
ofliquidadditivepump1is10L/m³andtheactualbasefluidflowrateis2m³
/min, then the actual flowrate of liquid additive 1 is 10×2 = 20 L/min. (The
quantityoftheliquidadditivedevicesissubjecttotheactualequippeddevices
and this interface is just a standard one.) The adding amount of the liquid
supplysystemsiscontrolledthroughknobsontheoperationpanel.
e) When1#and2#dryadditivepumpsareunderautomaticcontrolstatus,setthe
addingvolumeofthedryadditiveindryadditiveinputbox.Thedryadditive
pumps will adjust the rotary speed according to the value monitored by the
flow meter to meet the dry additive set value. L/ m³ refers to the volume of
additiveaddedinto1m³basefluid.Forexample,thesetvalueofdryadditive
pump 1 is 15 L/ m³ and the actual base fluid flowrate is 2m³/min, then the
actualflowrateofdryadditive1is15×2=30L/min.
f) Whentheaugerisinautomaticcontrolstatus,setsandratioorconcentration
(sand ratio in metric unit and sand concentration in imperial unit) through
【SandRatioandSandConcentration】.Thesandaugerwilladjustitsrotary
speed according to the current displacement and sand concentration
automatically to meet the set value of sand ratio or concentration. During
operation,actualsandtransmittingefficiencywillchange.Whentheefficiency
decreases,adjustitthrough【AugerEfficiency】 toincreaseit.Whentheauger
efficiency increases, the auger rotary speed will decrease; when the auger

efficiencydecreases,augerrotaryspeedwillincrease.Nomatterhowtheauger
efficiency changes, the output sand ratio or concentration will be kept in a
stablestatus.Thedefaultvalueofaugerefficiencyis100%,themaximumvalue
is125%andtheminimumvalueis75%.
【MonitorDensitySelection】 isusedtochoosethemonitoringandfeedbackmethod
of discharge flowrate. The “DENSITOMETER” indicates that the displayed value of
sandratio,sandconcentrationanddensitycomesfromthedensitometer.“AUGER”
indicatesthatdisplayedvalueofsandratio,sandconcentrationanddensitycomesfrom
thecalibrationofsandflowrateanddisplacementflowmetersignals.“FLOWCALCU”
indicatesthatthedisplayedvalueofsandratio,sandconcentrationanddensitycomes
fromthecalibrationofsuctionflowrateanddischargeflowratesignals.Thesandratio
andsanddensitycalculatedbytheabovementionedthreewaysaredisplayedonthe
fixeddisplaysection.
【SandVolumeMonitor】 isusedtochoosethetwowaysofthesandratecalculation.
【Auger】 indicates the displayed value of the sand rate comes from the theoretical
calculationoftheauger,while 【Densitometer】 indicatesthedisplayedvalueofthe
sandratecomesfromthecalculationofthedensitysignal.
NOTE
a) Allvaluestobesetintheinitialparameterinterfaceshallbesetstrictlyaccordingto
workingconditionsandcannotbeomitted.
b) The set value can be stored automatically and it needs no reset if the working
conditionisthesame.

11.3 DATA MONITORING INTERFACE
Press ”MONITOR”toenterthedatamonitoringinterface.
Thisinterfacedisplaysthedatathatneedtobemonitoredinthesandblendingsystem.
Blackwordsaretheactualoperationvalueofrelatedunitsandwhitewordsaretheset
valueofrelatedoperations.
Inthisinterface,parametersofdifferentdevicesareshownindifferentsectionsclearly.
Thebarinthemiddleindicatestheleveldirectly.Attheleftsideofthebar,itisthemain
dataandworkingstatusdisplaysectionofdischargepump,suctionpumpandaugers.
Attherightsideofthebar,itisthemaindataandworkingstatusdisplaysectionofthe
liquid/dry additive devices. The percentage of the suction pump, discharge pump,
augerandliquid/dryadditivewillbedeterminedaccordingtothepercentageofunit
maximumpower.Undermanualcontrolmode,thissectiondisplaysthecontrolvalue
input through knobs on the control console and under automatic control status, the

valuedisplayedistheloadvaluewhentheunitisrunning.
Manual Control:
Turn on the startup switch on the operation console to start the related devices and
shiftthemanual/autocontrolswitchtomanualposition.Atthistime,theindicationof
correspondingdeviceswillturnfromAUTOtoMANUAL.Thentheunitisundermanual
controlmode.Thenturnthepotentiometerknobtocontrolmanually.
CAUTION
a) There’snoneedtoshiftalldevicestomanualcontrolstatus.Operatorcanshifta
fewdevicesintomanualcontrolwhilethewholesystemisstillunderautomatic
controlstatus.
b) Themanualcontrolofallcontroldevicesareachievedthroughtheadjustmentof
the potentiometer analog. The sensitivity of the gate under manual control is
adjustedthroughadjustingvalvesinthehydrauliclooptochangetheflowrate.
Theopennessoftheadjustingvalvecannotbesetcasually.Keepingthegatecan
be controlled manually, then adjust the openness of the adjusting valves
accuratelytoreducetheprocesstime.
c) Ifacertainactuatorisnotgoingtobeusedforacertainperiodoftime,makesure
thatthestartupswitchisshutoffaftercorrespondingpotentiometeristurnedto
the lowest position soas to avoidthe unit start under load next time and thus
prolongunitservicelife.
d) DO NOT press the startup switch when the potentiometer is not in the zero
positiontoavoidstartingwithbigimpactandprematuredamagetotheunit.

Automatic Control Mode:
The automatic control mode is the main operation mode of the automatic sand
blending system. The operator shall be familiar with the unit and careful with the
operationbecausetheworkingparametersettingandoperationiscomplex.
Theautomaticcontrolissetpartbypartandcanbeshiftedautomaticallyandfreely,
easyforoperation.
100stagescanbesetinthiscontrolsystem.
AutomaticWorkingProcedureSet:
InitialParameterSet:
First of all, turn the switches of the liquid additive pump, suction pump, valves and
augerstoautomaticposition.Iftherearepumpsnotautomaticallycontrolled,thereis
noneedtoturncorrespondingswitchestoautomaticposition.
Then,switchtheHMIto“PARAMETERSETINTERFACE”,andsetthedate,time,job
number, base fluid density, sand grain density (particle density) and sand bulk
density(volume density), dry additive density, pressure of the suction and discharge
manifoldandthelevelofthesandblendingtub.
The parameters shallbe set reasonably and correctlyand allparameters shallbe set.
Duringoperation,theparametervaluecanbemodifiedaccordingtoworkingprocess.
Whethertocleartheworkingaccumulatedvalueisdecidedbytheoperator.Pleasezero
theflowmetersensorbeforeoperation.
Sand blending tub high level limit and low level limit set. Pay attention to the
relationshipbetweenthesetsandblendingtubwarningvalueandthesandblending
tubliquidlevelcontrolsetvalue.Thesetvalueshouldn’tbetooclosetothewarning
valuetoavoidfrequentcontrolfluctuation.

11.4 STAGE SETTING INTERFACE
Press”STAGESET”toenterstagesettinginterfaceasshownbelow:

Stageworkingsetinterfaceconsistsof20settinginterfaceswhichareusedtotheset
working parameters of 100 working stages. Press or to shift stage setting
interfacesandsettheworkingparametersforeachworkingstage.
Meaningofparametersetateachworkingstage:
StartConcentration:theinitialsandfluiddensityofthecurrentworkingstage.
EndConcentration:thefinalsandfluiddensityofthecurrentworkingstage.
Concentration Set Value refers to proppant weight (unit is kg) in unit volume of the
basefluid(unitism3).
The flowrate of the liquid and dry additive are set according to the additive volume
requiredineach1m3ofbasefluid.

NOTE
a) Operationstageshallbesetcontinuouslywithoutanybreak.
b) Pleasechecktheunusedstagestomakesurethattherenoothersetvaluesexcept
0.Ifthereissetvaluewhichisnot0,resetittozero.Besuretocheckandmake
certainthattheTTLSETis0.
c) Sandblendingtublevelshallbesetmanuallyclosetothelevelvaluesetatinitial
parameterinterface.
]Checkstageparameterstomakesurethattheyaresetcorrectlyandthenreturntothe
process interface or data interface. Then, press the ”START” on the fixed screen
display window and the operation starts. At this time, ”START” turns to green
backgroundanditindicatesthatallautomaticallycontrolledequipmentsareallstarted
and the equipments enter automatic working mode. Note: click ”START” before
operation.
Whentheunitturnstostageoperationfromcontinuousoperation,press“CONTIN"
andthekeywillshiftto“STAGE”.Thestagenumberswillturntowhitewordswith
black background. Press input box to input parameters for stages from 1~100. After
parametersofstage1havebeeninput,theywillbeuploadedtothefixedscreendisplay
sectionandthesystemwillrunwiththesetparameters.Whenactualaccumulatedvalue
ofthemixingfluidreachesthesetvalueofthestagevolume,theprocessorwillturnto
stage2fromstage1automaticallyandthentheunitwillrunwiththesetparametersof
stage 2. If the unit should go onworking of a certain stage, input the stage number
directly.Forexample,thecurrentrunningstageis1,ifoperatorsinput4intothestage
number,theunitwillrunwiththesetparameterofstage4.Iftheunithastorunata
certainstagecontinuously,press ”HOLD”directly.Ifthestagemixingfluidvolumeis

setto0atacertainstage,theprocessorwillturntothenextstageautomatically.During
operation, when it is needed to modify the operation set value, “ENTER” must be
clicked after the modification value are input, otherwise, the unit won’t work
accordingtothemodificationvalue.
Click“STOP”afteroperationandadialogbox”STOPJOB?”willpopup.Ifitissure
thattheoperationhasbeenfinished,pleaseclick“YES”andtheunitwillstopworking.
Iftheoperationhastogoonoritispressedbymistake,pleaseclick“NO”andthe
unit will go on working. During stage operation, the unit will stop working after it
carriesoutallsetdatastages.
11.5 PROCESS MONITORING INTERFACE
Press ”PROCESS”toentertheprocessmonitoringinterface.
This interface can be used as the main monitoring interface for manual operation or
operatorswhoarenotfamiliarwiththeunitanditcanmonitorthedataofallcontrolled
devices.Relatedprocessvalueisshowningroup.Thestartupandshutdownoftheunit
canbeindicatedthroughrelatedcolorsonthisinterface,whichwillmaketheoperation
easytooperate.
Thefollowingfigureshowstheunitbeforestartup:

This interface adopts static symbols and dynamic symbols to show the working
condition of all components during sand blending process. Through comparison, we
canseethataftertheunitisstartednamelystartswitchofthepumpandpneumatic
valvesswitchesareturnedontheinstrumentpanel,iconsfortherelevantdevicesarein
greenwhichmeanstheyareactivatedalready.
Thefollowingfigureshowstheunitafterstartup:
11.6 CALIBRATION INTERFACE
Thecalibrationinterfaceofthesandblendingsystemconsistsof3functioninterfaces,
namelyflowratecalibration,pressurecalibrationandknobcalibration.
Logonpasswordinputboxandasoftkeyboardjustasshownbelowwillpopupafter
pressanyofthefunctionalkeysonscreen.
Inputthepassword“111”throughthesoftkeyboardandpressENTERandthenpress
“OK”. Then the “Log on” password input box will disappear. Press any of the

calibrationfunctionkeystoenterthecalibrationinterface.After5minutes,thelog-on
password will be cancelled automatically and if you want to enter the calibration
interfaceagain,youshouldinputthepasswordagain.
“ALLRESET”liesinthelowerpartofeveryinterface.Whentheparameterscalibration
are not correct and need to be reset, please press “ALL RESET”. At the same time,
“INITIALIZE DEFAULT SET?”will pop up. Press “YES” to reset the calibrated
parameterstothedefaultvalue;press“NO”tocancelthedefaultvalueresetandquit
thiswindow.
Afterenteringintothe“CALIBRATION”interface, press or to
shiftstagesettinginterfaces.

DISPLAYshowscalibrationflowrate.SPEEDshowstheactualrunningspeedoftheunit.
FACTORshowsdisplacementperrevolutionoftheunit.Thisfactorisusedtocalculate
displacementatdifferentrotaryspeeds.
COEFFisusedtocorrecttheactualflowratebyadjustingthefactorwhenthisflowrate
doesnotdeviatefromsetvaluetoomuch(within ±5%)soastomeetpracticalworking
condition.
Methodstocalibratethecalibrationfactoroftheflowratesignal:
a) CalibrateSandDisplacementFactor
1) Ifthesandblenderadoptstwoaugers,itisbettertocalibratethemseparately
andcalibratethefirstonefirst.
2) Connect the sand blender signals and set K1=1, K2=0 according to standard
operation.
3) Make the measured sand go through the auger and make the instrument

calculatethetotalsandvolume.
4) Afterthesandistransmittedcompletely,refertotheinstrumentreading.Ifthe
sandmeasuredweigh4tonsor4m3,buttheinstrumentshows5tonsor5m3,
then calibrate the factor K1 =4/5=0.8. Input the set value K1=0.8 for further
calibration.Ifthemeasuredvalueissamewiththecalculatedvalue,thenwecan
confirmthatthecalibrationfactorisK1=0.8.
Thecalibrationmethodofdryadditive,fiberandliquidadditivefactorissamewiththat
oftheaugerfactor.
b) Calibratethesuctiondisplacementfactor
1) Let the measured base fluid go through the flowmeter and let the HMI
accumulatethesuctiontotalvolume.
2) Afterthebasefluidistotaledsuckedin,checktheaccumulativevaluedisplayed
ontheHMI.Ifthebasefluidismeasured4tor4m3beforehand,butthevalue
displayed on the HMI is 5t or 5m3, then modify K1=4/5=0.8; Then test after
setting K1=0.8. If the value displayed on the HMI is same with the measured
valuethecalibrationfactorisclear.
Thecalibrationmethodofdischargefactorandliquidadditivefactorissamewiththat
ofthesuctiondisplacementfactor.
Theaccumulatedvalueofrelatedequipmentswhenreal-timecalibrationiscarriedout
canbedisplayedontheaccumulationdisplaysection.Thesevaluesaretheaccordance
of adjusting related “Basic Parameter” and “Calibration Factor” and they can be
resetbythe“RESET”key.This“RESET”keywillnotaffecttheaccumulatedvalueon
the“INITIALPARAMETER”interface.
A. Input calibration factor
Thecalibrationfactorofflowratesensorandrotaryspeedsensorareprovidedbythe

manufacturers. Please make sure the unit is same with that on the sensor signal
calibrationinterfacewheninputtingdata.ItisL/Revonthescreenandthatindicates
thatthedischargedvolumeperrevolutionoftheequipment.
B. Default calibration factor upon delivery

Allthebasicparametershavebeencalibratedbeforedelivery.Ifanyflowrateisfound
different from the actual value, please calibrate the factor slightly according to the
actual value. If the factor is modified by misoperation, please press DEFAULT, then
select“YES” and the calibration factor of the current interface will go back to the
defaultvalue.Press“NO”,andthedefaultvaluewon’tbeinitializedandthiswindow
willbeclosed.
NOTE
Allcalibrationfactorsupondeliveryaredefaultedtobe1.
Pressure calibration function has two modes, namely static calibration and dynamic
calibration. Static calibration is applied when the unit is shutdown and dynamic
calibration is applied when the unit is running. Choose different calibration modes
accordingtodifferentconditions.
a) PressureCalibrationInstructions:
1) DISPLAY:displaytheactualpressurevalue;
2) CORRECT: under dynamic calibration mode, it is used to input the actual
pressurevalueofthemanifold;
3) RANGES(KNOBCLIBR.):understaticcalibrationmode,itisusedtoinputthe
maximummeasuringrangeofthepressuretransmitter;
4) CURRENT:displaytheoutputvalueoftheelectriccomponents;

5) FACTOR: used to calibrate the factor of the pressure. It is set to 1.00 before
delivery
6) RANGES:checkthemaximumvalueaftercorrection.
b) PressureCalibrationProcedures:
Whenthereisnofluidandpressureinsidethepipelines,press “ZERO” toeliminate
staticzerodrift.Theninputthemaximummeasuringrangeintothecorrespondingbar
ofthemaximumvalueandpress“RANGES”tofinishpressurecalibration.
c) Input certain working pressure value into the correct bar according to value
displayedonthemechanicalpressuregaugeorvaluemeasuredbyotherwaysand
thenpress“CORRECT”.Atthistime,valuedisplayedatpressuredisplaybarwill
besamewiththatsetinthecorrectvaluebar.
d) LevelCalibrationInstructions:
1) DISPLAY:displaytheactualvalueofthelevel;
2) CURRENT:displaytheoutputvalueoftheelectriccomponents;
3) FACTOR:usedtocalibratethefactorofthelevel.Itissetto1.00beforedelivery.
Calibration method: press “ZERO” when the tub is empty, and press “RANGES”
whenthetubisfullofwater.
e) LocalDensitometerCalibrationInstructions:
1) DISPLAY:displaytheactualdensity;
2) CURRENT:theoutputvalueoftheelectricelement;
3) RANGES:thesetmax.rangevalueofthedensitometer;
4) CORRECT: input the value actually measured by the densitometer during
dynamiccalibration;
5) FACTOR:tocalibratethecalibrationfactorofthedensity.Itisdefaultedtobe
1.00upondelivery.

CalibrationMethod:Press“ZERO”whenthedensitometerinstrumentdisplays0g/cc;
inputfullrangevalueintoMAX.RGEandpress“RANGES”tofinishthecalibration.
Ifthedensityisnotconsistentwiththevaluemeasuredbythedensitometer,inputthe
actualdensityvalueinto“CORRECT”andthenthedisplayedthedensitywillbecome
theinputvalueat“CORRECT”.
a) KnobCalibrationInstructions:
Potentiometerknobisontheinstrumentpaneloftheoperationconsole.
b) KnobCalibrationProcedures:
1) Turn the knob counterclockwise to the minimum and press ZERO to carry out
zerocalibration.Thedisplayvaluewillbe0.
2) Turn the knob clockwise to the maximum and press RANGE to carry out full
rangecalibration.Thedisplayvaluewillbe100.

NOTE
a) Duringcalibration,alwayskeepthecalibratedvaluestable.Nowidefluctuationis
allowed.
b) DONOTupendthecalibrationorder.CalibratezerofirstandthentheSPAN.
c) If abnormal value is measured, please check the sensor first. DO NOT calibrate
casuallytoavoidthedisorderofthesamplingvalue.
d) Thecalibrationpersonnelshouldhavecertainknowledgeoftheinstrumentsand
measurementproducts,relatedskillsandexperience.

11.7 STIMULATION FUNCTION
Withstimulationfunction,thesystemcanbeoperatedwithoutstartingtheenginefor
userstoknowtheoperationperformanceoftheunit.
Press “STIMULATION” on the initial interface, the key will start flashing, which
indicates that the stimulation function is started. Users can start corresponding
components according to normal operation process and operation value will be
displayedontheinterface.Functionssuchasmanual/autocontrol,failurediagnosisand
alarmingfunctioncanbetested.
NOTE
a) Stimulationfunctionisonlyfordailytest.DONOTapplyitduringoperation.
b) Whenthestimulationofsuctionpumpanddischargepumparestarted,therewill
becontrolsignaloutputandcorrespondingcomponentswillactiftheengineis
started. So, the engine must be shut down when the stimulation of the suction
pumpanddischargepumpisused.
11.8 MAINTENANCE INTERFACE
PressMAINTAINontheinitialinterfacetoentermaintenanceinterfacewhichprovides
themaintenanceinformationofthemainpartsanditwillreminduserstomaintainthe
parts according to the set maintenance time. The main parts include engine, pump
drive, hydraulic system, pneumatic system, electric system, mixing system and
centrifugalpump.

ENGINE includes the maintenance information of each part of the engine. LAST
MAINTAIN DATE records the time of last maintenance. Press MAINTAIN to add the
current time into the last maintenance time. OPERATION HOUR refers to operation
hourstillnowfromwhenthepartismaintainedandthetimewillberecordedonlyafter
theunitgettingpower.OPERATIONDAYreferstothedaysfromlastmaintenancetill
the current time which will be recorded no matter start the unit or not. MAINTAIN
PERIOD refers to the numbers of hours and months after which the parts should be
maintained.Thesystemwillcalculatetheoperationhoursanddaysofeachpart.The
systemwillalarmwheneitherthemaintenancehoursormonthsisreachedtoremind
userstomaintaintheparts.

11.9 FAILURE INTERFACE
PressFAILUREoninitialinterfacetoenterfailureanalysisinterfacewhichwilldisplaythe
operationinformationofeachpartandindicatepossiblefailurestousersaccordingto
currentcontrolstatus.
a) NoPower:refersthatthepowersupplyswitchisatoffposition.
b) Knob:refersthatthepotentiometerofthecontrolpartsfails.
c) Output:refersthatcontrolpartsoutputnosignals.
d) Hyd.Press:refersthatthereissomethingwrongwiththehydraulicsystemofthe
part.Thisunithasnohydraulicsystemmonitoringfunction.
e) Mechanical Failure: refers that there is something wrong with the mechanical
elements.
f) Fluid Supply Failure: refers to there is something wrong with the fluid supply
manifoldanditisonlyforthefailureanalysisofthesuctionpumpanddischarge
pump.

11.10 ALARM INTERFACE
Press ALARM on the initial interface to enter alarm interface which will display the
alarming information of the unit. Press HELP and the system will provide possible
failures.
11.11 PID PARAMETER INTERFACE
Press”PIDSET”ontheinitialinterface,auserlog-inwindowwillpopup.Inputcorrect
passwordtoenterthePIDinterface.
NOTE
ThePIDparametershavebeencalibratedbeforedelivery,soitisnotrecommendedto
changetheimportantparametersandDONOTchangethePIDcontrolparameters.If
the PID parameters are modified by mistake, press “DEFAULT” and ”INITIAL
DEFAULTSET?” willpopup.Click“YES”,theoriginalparameterswillberegained;
click“NO”,nooperationwillbedone.Re-calibrateparametersoftheunitcontrol
systemifanyofthefollowingconditionsoccurs:
a) Deck mechanical and hydraulic components need heavy maintenance and

replacement.
b) Controlcomponentsofsignificantelectricalequipmentsneedmaintenanceand
replacement.
c) Operationconditionchangesleadtogreatchangeoftherawmaterialsthatthe
operationrequired.
d) Items that are not mentioned above but may influence the control system
directly.
If the above mentioned conditions occur, please contact the manufacturer to
recalibratetheparameters.
There are four liquid level control ways and they are “flow-butterfly valve” and
“pressure-pump”, “level-butterfly valve” and “pressure-pump”, “flow-pump”
and “level-pump”. Select different liquid level control way in 【 PID 】 interface,
“flow-pump” and “level-pump” are recommended to be selected. When
“level-pump” isselected,thelevelwillbecontrolledthroughcontrollingtherotary
speed of the suction pump. When “flow-pump” is selected, the level will be
controlledthroughcontrollingthesuctionflow.Forbothways,thebutterflyvalvesare
controlledmanuallyandthevalveopennesscanbeselectedaccordingtotherequired
fluid supply pressure. The butterfly valves and suction pump are automatically
controlled when “flow-butterfly valve” and “pressure-pump”, “level-butterfly
valve”and“pressure-pump”,areselectedtoensurestablepressureandflowbythe
cooperationofthebutterflyvalveandthepump.
Thecontrolofbutterflyvalvehasquickopen,quickclose,slowopenandslowclose.
Thecurrentatneutralpositionis0mA.Ifthevalvedoesn’tactsmoothly,adjustthe
fourcurrentvalues:quickopen,quickclose,slowopenandslowclose.

CHAPTER 12 OPERATION REGULATIONS
12.1 PRE-OPERATION CHECK ............................................................................................ 1
12.1.1 CHASSIS CHECK ................................................................................................... 1
12.1.2 DECK UNIT CHECK ............................................................................................... 2
12.1.2.1 CHECK THE ENGINE ..................................................................................... 2
12.1.2.2 CHECK OIL TANK LEVEL............................................................................... 3
12.1.2.3 CHECK THE DRIVE SHAFT ........................................................................... 4
12.1.2.4 CHECK THE CONTROL CABIN AND ELECTRIC CONTROL BOX............... 5
12.1.2.5 CHECK THE AUGERS .................................................................................... 5
12.1.2.6 CHECK SUCTION AND DISCHARGE MANIFOLD ...................................... 5
12.1.2.7 CHECK THE LIQUID ADDITIVE SYSTEM ..................................................... 6
12.1.2.8 CHECK THE COOLING SYSTEM ................................................................... 6
12.1.2.9 CHECK OTHER ACCESSORIES AND PIPES ................................................. 6
12.2 UNIT STARTUP ............................................................................................................ 6
12.2.1 CHASSIS PTO ENGAGEMENT AND DISENGAGEMENT ................................... 6
12.2.2 STARTUP PROCEDURES ...................................................................................... 7
12.2.3 CHECK AFTER STARTUP ..................................................................................... 9
12.2.3.1 CHECK DECK ENGINE ................................................................................... 9
12.2.3.2 CHECK THE CONTROL CONSOLE INSTRUMENT PANEL ......................... 9
12.2.3.3 CHECK THE COMPONENTS ON DECK ....................................................... 9
12.2.3.4 CHECK MANIFOLD FLOWMETER................................................................ 9
12.2.3.5 CHECK THE LIQUID ADDITIVE PUMP ...................................................... 10
12.2.3.6 CHECK THE DRY ADDITIVE CONVEYER ................................................... 10
12.2.3.7 CHECK THE ELECTRIC LINES, PNEUMATIC & HYDRAULIC PIPES OF THE
OVERALL UNIT .......................................................................................................... 10
12.2.4 OPERATION ........................................................................................................ 10
12.2.4.1 OPERATION PROCEDURES ........................................................................ 10
12.2.4.2 MECHANICAL OPERATIONS ..................................................................... 11
12.2.4.3 SOFTWARE OPERATION ............................................................................ 12
12.2.5 INSPECTION DURING OPERATION ................................................................. 12
12.2.5.1 CHECK THE DECK ENGINE ......................................................................... 12
12.2.5.2 CHECK THE OVERALL UNIT ....................................................................... 12
12.2.5.3 CHECK THE HYDRAULIC SYSTEM............................................................. 12
12.2.5.4 CHECK THE COOLING SYSTEM ................................................................. 12
12.3 UNIT SHUTDOWN .................................................................................................... 13

CHAPTER 12 OPERATION REGULATIONS
All hydraulic and pneumatic controls, engine control device and butterfly valve
pneumatic switches are located on or around the instrument panel for convenient
operation.
12.1 PRE-OPERATION CHECK
Pre-operationcheckwillensurethesteadyandlong-lifeworkofthecementingunit.
Checktheunitaccordingtotheprocedures.
PleasecheckoillevelandtypeateachlocationaccordingtoCHAPTER13INSPECTION
ANDMAINTENANCEandmakesureboththeoiltypeandlevelarecorrect.
12.1.1 CHASSIS CHECK
a) Level Check
1) Chassisenginelubeoillevel;
2) Enginefuellevel;
3) Gearoilleveloftransmission;
4) Lubeoillevelofeachaxledifferential;
5) Coolantlevel;
b) Fixed Parts Check
1) TireScrew;
2) Drivingcablocking;
3) Fastening of the coolant tank, battery, air intake pipeline, supercharger,
transmissionandengine;
4) Fastening of the driving shaft, center axle, real axle, lacing wire and brake
HSC16 Chapter 12 Operation Regulations 1

cylinder.
c) Damage and Leakage Check
1) Alloil,waterandairpipelines;
2) Fanbelt,alternatorbelt;
3) Brakemastercylinderandwheelcylinder.
d) Actuator Sensitivity and Effectiveness Check
1) Brakingagency
2) Drivingandsteeringagency
3) Door,windowandrainwiper.
4) Theanglesoftheinstrument,light,horn,viewmirrorandrearviewmirrorare
normal.
NOTE
Pleaserefertothetechnicalspecification,operationandmaintenanceregulationsofthe
chassisforothercheckitems.
12.1.2 DECK UNIT CHECK
12.1.2.1 CHECK THE ENGINE
a) Checktheengineoil
Check items and requirements: the oil level shall between ADD and FULL of the
dipstick,andclosertotheFULLposition.Addwhennecessary.
b) Checkthecoolant
Checkitemsandrequirements:thelevelshallbeatthemiddle/upperpartofthe
expansiontank.Addcoolantwiththesamegradewhennecessary.
2 Chapter 12 Operation Regulations HSC16

c) Checkthepneumatic/hydraulicpipes
Checkitemsandrequirements:allpneumaticandhydraulicpipesandconnectors
shallbeconnectedfirmlywithoutleaks.
d) Checktheinflationpumpandgeneratorbelt.
Checkitemsandrequirements:thebeltsareingoodconditionwithpropertension.
12.1.2.2 CHECK OIL TANK LEVEL
a) Fueltanklevel
Check items and requirements: the fuel shall be sufficient and the fuel pipelines
shallbefirmwithoutleaks.
1-FuelTankDipstick

b) Hydraulicoiltanklevel
1-HydraulicOilTankDipstick
Checkitemsandrequirements:thehydraulicoillevelshallbeabove2/3ofthedipstick
andthehydraulicpipesshallbefixedfirmlywithoutleaks.
12.1.2.3 CHECK THE DRIVE SHAFT
Checkitemsandrequirements:thedriveshaft,crossshaftandalllubricationpointsof
thedriveshaftareingoodcondition;theboltsonthedriveshaftarefixedfirmly.
NOTE
Thedriveshaftshouldbereplacedevery2,000hoursofoperationundertheworking
conditionofrotaryspeedbeing2,600rpmandthetorquebeing1,200Nm.

12.1.2.4 CHECK THE CONTROL CABIN AND ELECTRIC
CONTROL BOX
Checkitemsandrequirements:theelectriccomponentsinsidetheelectriccontrolbox
are fixed firmly, the wirings are connected tightly and there are no foreign objects
insideit.Afterpoweron,theindicatorsontheinstrumentpanelcanworknormallyand
theparametersonthescreenaredisplayednormally.Allknobsareatoffposition.
12.1.2.5 CHECK THE AUGERS
Check items and requirements: make sure the bearing and seal at both the top and
bottomoftheaugersarelubricatedwell.Theslidesarelubricatedwell.
1 2
1-TailBearingGreaseFitting;2-TailSealGreaseFitting;3-TopBearingGreaseFitting
12.1.2.6 CHECK SUCTION AND DISCHARGE MANIFOLD
Check items and requirements: all butterfly valves are in good condition and can be
openedandclosedflexiblywithoutleaks.

12.1.2.7 CHECK THE LIQUID ADDITIVE SYSTEM
a) Liquidadditivemanifold
Check items and requirements: all ball valves on the testing manifold are at closed
statusandthepipesareconnectedreliably.
12.1.2.8 CHECK THE COOLING SYSTEM
Checkitemsandrequirements:thesupportbracketisfixedfirmly,noboltsare
damaged,coolingfan,coolantmotor,hydraulicpipesandradiatorareingood
conditionwithoutleaks.
12.1.2.9 CHECK OTHER ACCESSORIES AND PIPES
Checkitemsandrequirements:allaccessoriesandpipesshallbefixedfirmly,theshields
ofallcomponentsareprotected,andthefasteningboltsaretightenedreliably.
12.2 UNIT STARTUP
12.2.1 CHASSIS PTO ENGAGEMENT AND DISENGAGEMENT
CAUTION
PleaseoperatethePTOaccordingtothestepsbelowtoavoiddamagetoit.
a) Checktomakesurethedriveshaftthatdrivingthedischargehydraulicpumphas
nolooseness.
b) Make sure the rotary speed of the engine is no higher than 1,700 rpm before
engagingthePTO.

c) Engage3#PTOduringoperation.
d) ItisforbiddentomovethechassiswiththePTOengaged!
NOTE
Makesurethedriveshaftthatdrivesthedischargehydraulicpumpisnotloosebefore
engagingthePTO!DONOTmovethechassiswiththePTOengaged.
12.2.2 STARTUP PROCEDURES
a) Parkthesandblenderatrightplaceandengagethehandbrake.
b) Turnonthepowersupplyswitchofthechassisanddeckbatterybox.
c) StartthechassisandturnonthechassisPTOswitch.
d) Opentheswitchofthefilterandpressurereducingvalveofdeckpartspneumatic
systemandsupplyairforthedeckparts.
e) Enter the control cabin. First, turn on the deck engine power supply switch to
supply power for the deck engine. Check to make sure the knobs of all
potentiometersontheinstrumentconsoleareatoffposition,shiftallmanual/auto
switch to Manual position. Start the engine after the Murphy gauge stops
self-inspection(pushthestartswitchupwardforabout3seconds).Releasethestart
switchandletitreturntotheoriginalpositionaftertheengineisstartedandkeep
thethrottleatidlespeed.
f) Pushthe“InstrumentPower”switchupwardtosupplypowerforthePLCscreen.
Thentheautomaticcontrolsystemstartsselfinspectionforabout2minutes(the
starttimemayvarywiththeambienttemperature)andentertheinitialinterface.
g) Releasetheaugers

1) Pulloutthelowerlimitpinoftheaugerandthenlowertheaugerthroughthe
multi-tandem valve on the operation console until the sand hopper reaches
theground.Putastowwoodifnecessary.
2) Turn on the auger power supply switch, shift the Auto/Manual switch to
Manual position, and turn the auger potentiometer knob to ensure all work
normally.
3) Transfer the sand to the sand hopper until both augers are full of sand, and
thenstoptheaugers.
NOTE
Undercoldweather,preheattheengineoil,coolant,hydraulicoilandfuelwithengine
heaterbeforestartingtheengine.
a) Thestartingtimeeachtimeshouldbelessthan10s.Iftheenginecannotbestarted
atthefirsttime,startitagainafteraboutoneminute.Iftheenginespeedgetsabout
100rpmforseveraltimesatthestartup,pleasecheckit.
b) If the pressure gauge displays no value 5 seconds after startup or the engine oil
pressureislowerthan0.15Mpa15secondsafterstartup,stoptheunitimmediately
forinspection.
c) Run the unit at idle speed for about 5~10 minutes until the coolant temperature
reaches 54 ℃ (130 ℉) and all parts work normally. Then, increase the throttle to
speeduptheengineto1,200～1,300rpm.Runtheunitwithloaduntilthecoolant
temperaturereaches70℃andoiltemperaturereaches75℃.DONOTruntheunit
withloadatlowtemperatureandDONOTincreasethrottleviolently.
d) Whentheenginetemperaturereaches70℃,DONOTruntheunitatidlespeedfor
longtime,otherwise,theenginemaybedamagedseriouslyandcarbondepositand

cylinderdamagemaybecaused.
e) When preheating the whole system, check whether the value displayed on the
instrumentscanmeettherequirementsspecifiedintheinstructionsandcheckfor
leaks.Ifproblemsarefound,stoptheengineandrepair.
12.2.3 CHECK AFTER STARTUP
12.2.3.1 CHECK DECK ENGINE
Checkitemsandrequirements:whentheengineisidling,theoilpressuredisplayedon
the Murphy gauge shall be within 0.27~0.4 Mpa. If the engine alarms 15s after it is
started,pleaseshutdownitintime,findoutthereasonsandeliminate.Thenre-start
theengine.
12.2.3.2 CHECK THE CONTROL CONSOLE INSTRUMENT PANEL
Check items and requirements: all parameters displayed on the screen should be
accurate.Ifthereiserrorsorproblems,stoptheunittocheckrelatedcomponentsand
removetheproblems.
12.2.3.3 CHECK THE COMPONENTS ON DECK
Check items and requirements: the engine, pump drive, suction and discharge
centrifugalpumpworknormallywithoutabnormalnoise.
12.2.3.4 CHECK MANIFOLD FLOWMETER
Checkitemsandrequirements:theflowmeterworksanddisplaysdatanormally.

12.2.3.5 CHECK THE LIQUID ADDITIVE PUMP
Checkitemsandrequirements:liquidadditivepumpworksnormallyandalllubrication
pointsarewelllubricated.
12.2.3.6 CHECK THE DRY ADDITIVE CONVEYER
Checkitemsandrequirements:thedryadditiveconveyerworksnormallywithoutstuck.
12.2.3.7 CHECK THE ELECTRIC LINES, PNEUMATIC &

HYDRAULIC PIPES OF THE OVERALL UNIT
Checkitemsandrequirements:theelectriclines,pneumaticpipesandhydraulicpipes
arenormalwithoutleaks.
12.2.4 OPERATION
12.2.4.1 OPERATION PROCEDURES
Runtheengineatidlespeedforabout5~10minutesfirst.Afterallpartsworknormally,
speeduptheengineto1,200～1,300rpmuntilthecoolanttemperaturereaches54℃
(130℉).Atthistime,thethrottlecanbeincreasedbutnotfullyopened.Onlywhenthe
temperaturereaches70℃canthethrottlebetotallyopen,namelytoenterthefullload
workingcondition.Thespeedundernormalworkshouldbewithin1,750～1,800rpm.
NOTE
DO NOT run the engine at idle speed for long time, otherwise, the engine may be
damaged seriously and carbon residue and cylinder damage may be caused. For the
engines with turbocharger, the engine speed shall not exceed 1,000 rpm if the oil
pressureislessthan0.35MPa.

12.2.4.2 MECHANICAL OPERATIONS
a) WhentheDDCS60isrunningforready,startthedischargeandsuctionpumpto
boost and drain the fracturing pump. Carry out the following procedures after
boosting.
1) Clearallvaluedisplayed.
2) ShiftallAuto/ManualswitchestoManualposition.
3) Speedupthedeckengineto1,800～2,000rpm,startthedischargepumpand
thedischargepressurecanreach0.25～0.4MPa.
4) OpenV1valve(thesuctioncontrolvalve)andstartthesuctionpumpuntilthe
levelofthesandblendertankhasreachedrequiredlevel.
5) Start the agitator of the sand blender tank to start sandblending operation
andsupplyfluidtothefracturingpump.
6) Adjusttheauger,liquidadditivedeviceanddryadditivedeviceaccordingto
theinstructionsofthefracturingoperationdirectortomakethesandamount
andchemicaladditiveamountreachtheoperationrequirements.
b) Checktomakesuretheallpartsworknormallyandwaitfortheinstructionsofthe
directors.
NOTE
The speed range of the engine under normal working condition is
1,800~2,000rpm.

12.2.4.3 SOFTWARE OPERATION
Control system is the core of the electric system. It includes six automatic control
sub-systems and they are the automatic control system of suction, discharge, level,
auger, liquid additive and dry additive. Please refer to CHAPTER 11 SOFTWARE
OPERATIONSfordetailedoperationofthesoftware.
12.2.5 INSPECTION DURING OPERATION
12.2.5.1 CHECK THE DECK ENGINE
Check items and requirements: the engine oil pressure is within 58~87 psi, coolant
temperatureisnohigherthan99℃.Theunitwillalarmwhenthetemperaturereaches
102℃andstopautomaticallyat107℃.Thesystemairpressureiswithin100～120psi.
12.2.5.2 CHECK THE OVERALL UNIT
Checkitemsandrequirements:theunitworksstablywithoutabnormalnoiseorleaks.
12.2.5.3 CHECK THE HYDRAULIC SYSTEM
Checkitemsandrequirements:thesystempressureiswithin700～3,500psi(pressureof
differentsystemsvariesduetodifferentspeedandload).
12.2.5.4 CHECK THE COOLING SYSTEM
Check items and requirements: the cooling fan shall work normally; and the cooling
motorandpipesareconnectedfirmlywithoutleaks.

12.3 UNIT SHUTDOWN
a) Afterfracturingoperations,closethebutterflyvalveafterthedischargepumpand
the one before the suction pump,decrease both the deck and chassis engines’
speedtoidlespeed,andturnthecontrolknobsofallhydrauliccomponentstooff
position. Run the engine without load for at least 2 minutes and decrease the
enginetoidlespeed.
b) Dischargetheleftsandinsidethehoppers.Lifttheaugerstotravellingpositionand
insert the limit pin. Lower the augers to make the pins support their weight. DO
NOTusetheliftingcylinderstosupporttheirweight.
c) ReturntheHMIbacktotheinformationscreen.
d) Shutdownthedeckengine,turnofftheinstrumentconsolemainpowerswitchand
turnoffthedeckpowersupplyswitch.
e) Turnofftheswitchoffilterandpressurereducingvalveindeckpneumaticsystem.
f) Retracttheladderandinsertthefixedpin.
g) Enter the chassis cab to start the chassis engine and discharge the residue fluid
insidethesuctionmanifoldanddischargemanifoldtotherequiredplaces.
NOTE
DOdrainthefluidresidueinsidethesuctionpumpanddischargepumpandthe
manifoldafteroperationsinwintertoavoidfreezing.
h) Draintheresidualliquidadditivethoroughlyandcleanwithcoolant.
i) Cleantheresidualdryadditivethoroughly.
j) Clean the whole unit and carry out routine inspection after operations after
operation.

k) The operator should record the daily working condition of the unit in details,
maintainthemaintenanceandinspectionrecords,andrecordthesolvedaswellas
theunsolvedproblemsduringoperation.

CHAPTER 13 INSPECTION AND MAINTENANCE
13.1 LUBRICATION GUIDE ................................................................................................. 1
13.2 USAGE OF OIL.............................................................................................................. 2
13.2.1 ENGINE.................................................................................................................. 2
13.2.1.1 DIESEL ............................................................................................................ 2
13.2.1.2 ENGINE OIL ................................................................................................... 3
13.2.1.3 COOLANT ...................................................................................................... 4
13.2.2 PUMP DRIVE LUBE OIL ....................................................................................... 5
13.2.3 HYDRAULIC OIL ................................................................................................... 6
13.2.4 GREASE.................................................................................................................. 7
13.2.5 OIL LIST ................................................................................................................. 8
13.3 LUBRICATION TABLE FOR SAND BLENDER (COMPONENTS ON DECK) ............. 9
13.4 MAINTENANCE REGULATIONS .............................................................................. 11
13.4.1 COMPONENTS UNDER DECK........................................................................... 11
13.4.2 COMPONENTS ON DECK .................................................................................. 11
13.4.2.1 DAILY MAINTENANCE ............................................................................... 11
13.4.2.2 CHECK AND MAINTENANCE ITEMS OF EVERY 10 HOURS OF
OPERATION ................................................................................................................ 12
13.4.2.3 CHECK AND MAINTENANCE ITEMS OF EVERY 50 TO 80 HOURS OF
OPERATION ................................................................................................................ 13
13.4.2.4 FIRST LEVEL SERVICE OF EVERY 120 TO 150 HOURS OF OPERATION 13
13.4.2.5 FIRST LEVEL SERVICE OF EVERY 250 TO 280 HOURS OF OPERATION 14
13.4.2.6 SECOND LEVEL SERVICE OF EVERY 750 TO 850 HOURS OF OPERATION
..................................................................................................................................... 14
13.4.2.7 CAUTIONS FOR AIR CONDITIONER OPERATION AND MAINTENANCE15
13.4.2.8 COATING MAINTENANCE ......................................................................... 16
13.4.2.8.1 COATING MAINTENANCE REQUIREMENTS .................................... 16
13.4.2.8.2 NON-COATING MAINTENANCE REQUIREMENTS .......................... 17
13.5 LIST OF UNIT MAINTENANCE ................................................................................. 20
13.6 MAIN VULNERABLE PARTS LIST ............................................................................ 22

CHAPTER 13 INSPECTION AND MAINTENANCE
13.1 LUBRICATION GUIDE
Thisguideisonlyusedforreferenceandmaynotcoverallthelubricationpointsofthe
unit.Operationandmaintenancepersonnelmustinspectthisunitandgetfamiliarwith
allthelubricationpointsbeforefeedlubricationtothemduringmaintenance.
a) Check all pivot areas. Where there is no grease fitting, grease may need to be
appliedgenerallyoverthesurfacearea.
b) Clean the grease fitting before servicing. This will help keep debris out of the
lubricationarea.
c) Refer to lubricant recommendations in this manual or your company
documentationofthecorrectgradeoflubricant.
d) PleaserefertotheMercedes-BenzChassisOperationManualfordetailsofchassis
maintenance.
e) PleaserefertotheDDCS60OperationManualfordetailsofenginemaintenance.
f) Please refer to the FUNK pump drive Operation Instructions for pump drive
maintenance.
Thesmoothusageofthemachineryinjobsiteiscloselyrelatedtotheoperationhabits.
Proper design principle, excellentmanufacturing technology and responsible starting
maintenanceandprocedureswillmaketheunitworknormallyandextenditsservice
life.Theremustberesponsibleandproperfieldmaintenancetoextendtheunitservice
life to the maximum. System pollution usually leads to hydraulic system failure.
Althoughthesystempollutionwillnotcauseoveralldisastrouspartsfailure,itcauses
thefollowingproblems:
a) Thegraduallossofstrengthandspeed.
HSC16 Chapter 13 Inspection and Maintenance 1

b) Operationfunctionsdisorder.
c) Rodsealleaks.
Lackofproperlubricationisalsoacommoncauseforcomponentsandsystemfailure.It
isveryimportanttocontroltheviscosityandchemicalcompositionofthehydraulicoil
bytemperatureandhumidity.Pleasecomplywithrelatedrequirementsandprocedures
whenrepairingorreplacingpartsinthejobsite.PleasecontactwithJEREHfordetailed
information.
13.2 USAGE OF OIL
Theoiltypeandvolumearespecifiedhereinafter.Theusershallchooseproperoil
accordingtothelocaltemperature.
13.2.1 ENGINE
13.2.1.1 DIESEL
Type: 0#lightdieseloil;use-10#,-35#ordieseloilwithlowercondensationinwinter
topreventtheoilfromwaxing.
Dosage: about990L.
NOTE
Thecondensationpointofthedieselshallbehigherthanthelowesttemperatureofthe
service environment. Use different light diesels according to different areas,
temperatures and seasons. Use light diesel with lower condensation point if the
ambienttemperatureislow;uselightdieselwithhighercondensationpointwhenthe
ambienttemperatureishigh.
2 Chapter 13 Inspection and Maintenance HSC16

13.2.1.2 ENGINE OIL
a) Type:15W/40CH-4engineoil
b) Dosage:32L
c) Functions:
1) Lubricate all parts inside the engine and produce reliable oil film between
frictionsurfaces.
2) Absorbheatfromenginepartsandreduceenginenoiseduringrecycling.
3) Preventthemovingpartsfromfrictionbyforminganisolatingoilfilmbetween
them.
4) Sealthepiston,pistonringandcylinderwall.
5) Clean the cylinder and other parts and take away carbon residue and
mechanicalimpuritywhichwouldbeinterceptedbythefilter.
NOTE
a) Replace the lube oil after the running-in period. The running-in process would
producemanymetallicparticleswhichcouldworsenthefriction.
b) Qualified lube oil is a transparent liquid and lube oil of higher viscosity is light
yellow.
c) DO NOT mix different brands of engine oils as they have different additives.
Mixed-usewillcauseoildeterioration.
d) Daily check the engine oil level and insure the engine works under normal
temperature.Stoptheengineandwaitfortheengineoiltoreturnbacktotheoil
sump.Thencheckandmakesuretheengineoillevelisatappropriatepositionof
thedipstick.

e) Whenfillingengineoil,keepoillevellowerthanthescaleofthelubeoildipstick.If
thereisnosufficientengineoil,theoilpumpwillsuckinair.Frictionwouldincrease
duetoinsufficientlubricationandrodbearingmaybeburnt.Iftoomuchengineoil
isfilled,althoughitreducesenginebearingburningpossibility,itwillcauseother
problems.Becausecrankshaftandconnectingrodmoveviolently,toomuchengine
oilwouldlowertheirefficiency;increasedengineoilsplashedontothecylinderwall
would get on fire and produce smoke; what’s more, friction inside engine oil
wouldincreasetheoiltemperatureandthenaccelerateoiloxidization.Sopleasedo
notfeedtheenginewithtoomuchengineoil.
13.2.1.3 COOLANT
a) Type & Dosage:Mobil-45#,about104L.
b) Functions:
1) Preventtheradiatorandenginecylinderbodyorcoverfromfrozendamagein
winter.Preventtheoilfromboilinginsummer.Itshighboilingpointandlow
freezing point ensure that the engine can work within normal temperature
range.
2) Protect the radiator of the cooling system and other parts from corrosion.
Majorcomponentsofthecoolantareglycol,waterandsomeadditiveswhich
canpreventglycolfromoxidation,corrosionandfoaming.
3) Avoid the generation of scales which can weaken the cooling effect of the
radiator.

NOTE
a) Engine coolant should be anti-freezing, anti-boiling, anti-scaling, and foamless
regardlessofseasonandregion.Itisrecommendedtousecoolantallyearround.
b) Themaximumtemperaturetousecoolantcannotbehigherthan99℃.
c) The frequency to change the coolant is normally two years. Daily inspection is
recommended.Changethepollutedoroxidizedcoolantintime.
13.2.2 PUMP DRIVE LUBE OIL
Type and Dosage:Mobil80W/90GL-5,about5.2L,accordingtothedipstick.
NOTE
a) Payattentiontolubeoiltemperature.Oiltemperaturewouldincreaseduetolong
timeofhighspeedrunning,whichwillaccelerateoiloxidation.Residueandcarbon
deposit produced will block slim holes and oil circuit, which will further increase
lubeoiltemperatureandfinallyleadtopumpdrivedamages.
b) Checktheoillevelregularly.Whentheengineisrunning,theoillevelshouldbeat
somewhere between the upper and lower scale marks at normal oil working
temperature. Feed more if needed. If the oil level falls too quickly, leakage is
suspicious.So,findoutthecausesandremoveitimmediately.
c) Payattentiontotheoilconditionwhencheckingoillevelorreplacingoil.Dipsome
oilwithyourfingerandfeelforparticlesandsmellthedipstickforabnormalodor.
Appearancecheckalsoreflectssomeproblems.

13.2.3 HYDRAULIC OIL
a) Type and Dosage:MobilDTE25;about336L.
b) Application:
1) Thisanti-wearhydraulicoilismainlyusedforsuchhydraulicsystemsasvane
pump with heavy load, medium and high pressure, plunger pump and gear
pump.
2) This oil is used to hydraulic systems of such medium and high pressure
engineering machine, equipment and vehicle as tunnel borer, pedrail crane
andcomputercontrolledmachine.
c) Advantages:
1) Ithascertainviscosityandgoodviscosity-temperaturepropertytoensurethe
hydraulic parts can be well lubricated, cooled and sealed even though the
workingpressureandtemperaturechange.
2) Itisofgoodfriction-proofpropertytoensurehydraulicpump,motor，control
valve and frictional pair in the cylinder can be well lubricated under high
pressureorhighspeedconditionsandreducefriction.
3) Ithasstrongresistivitytooxygen,water,hightemperatureandhighpressure.
4) Itisofgoodanti-foamingandairreleasingpropertytoensurefoamproduced
duringtheoperationcandisappearimmediatelyandtoensureairintheoilcan
release within short time. This can assure accurate, sensitive and stable
pressuretransmission.
5) Itisofgoodanti-emulsificationproperty.Ifwaterinvadesintoit,thehydraulic
oilcanseparatefromthewaterquicklytoavoidemulsificationfluidwhichwill
corrodeordegradethehydraulicparts.
6) Itisofgoodanti-rustpropertytoavoidmetalsurfacerust

NOTE
Polluted hydraulic oil is usually the main reason for system malfunction. Please pay
attentiontothepointsbelow:
a) Beforeorafterhydraulicsystemassembly,partsshouldbethoroughlycleaned.All
componentsshouldbecleanedtoavoidimpuritymixedintothehydraulicoilwhen
changingthehydraulicoil.
b) Whenstoreorusethehydraulicoil,makesurethestoragecontainerandoilfilling
toolsarecleantopreventoilfrombeingpolluted.
c) Cleantheoriginalhydraulicoiltankthoroughlywhenusingnewtypeofoil.Keep
the hydraulic system clean during daily maintenance. Repair the disassembled
componentsindust-freearea.
d) Choosehydraulicoilaccordingtodifferentworkingconditionsofcustomers.
e) Whenfillinghydraulicoil,ensuretheoillevelstaysbetween1/2and2/3oftheoil
level scale, no higher or lower than the observation level (when the system is
running).
f) DO NOT repair the hydraulic components or open the hydraulic oil tank during
rainingdaytoavoidrainrunningintothehydraulicoil.
g) The hydraulic oil temperature should not be too high. Normally its temperature
shallbewithin15~60 ℃ with80 ℃ tothemaximum.
13.2.4 GREASE
3#lithium-basedgreaseisusedallyearround.

13.2.5 OIL LIST
Change
Item Application Oil Type Specification Amount (L)
Frequency
Mobil15W/40 250hours/a
1 Engine EngineOil 32
CH-4 year
Dailycheck/2
2 Radiator Coolant Mobil-45# 104
years
Mobil80W/90 2,000hours/6
3 PumpDrive LubeOil 5.2
GL-5 months
Anti-wear
4 HydraulicOilTank MobilDTE25 336 6～12months
HydraulicOil
Check
5 FuelTank DieselOil 0# 1,000
regularly
Suction Mobil15W/40 Appropriate Check
6 EngineOil
CentrifugalPump CH-4 Amount regularly
EngineFan
Bearing,Upper
andLowerBearing
oftheAugers,
3#
Discharge Appropriate Check
7 Grease lithium-based
CentrifugalPump, Amount regularly
grease
Discharge
HydraulicPump
DriveShaftand
RotorPump
Diesel
Chassis
ChassisAdblue Check
8 Exhaust AUS32 40
Tank regularly
Reducing
Agent
Middle
Mobil80W/90 positionof Check
9 RotorPump LubeOil
GL-5 theoillevel regularly
window

13.3 LUBRICATION TABLE FOR SAND BLENDER
(COMPONENTS ON DECK)
Lubricatethedeckcomponentsaccordingtothelubricationpointillustration.
1 2 3 4 5 6
10 9 8 7
Lubrication
Lubrication Check Change
Item Points Lubricant Volume
Points Frequency Frequency
Location
Newly
DriveShaft
Lithium-based added Two
Universal 2
Grease grease months
Joint
flowsout
1
Newly
DriveShaft Lithium-based added
1 Twoweeks
SplineHub Grease grease
flowsout

Lubrication
Location
Newly Change
Lithium-based added according
2 ButterflyValve 24
Grease grease totheoil
flowsout condition
Change
DryAdditive Lithium-based Appropriate according
3 4
AddingDevice Grease amount totheoil
condition
Change
AugerUpper Lithium-based Appropriate according
4 2
Bearing Grease amount totheoil
condition
Change
Auger Lithium-based Appropriate according
5 2
Slideway Grease amount totheoil
condition
Change
AugerLower
Lithium-based Appropriate according
6 Bearingand 4
Grease amount totheoil
Seal
condition
Change
Horizontal Lithium-based Appropriate according
7 2
Radiator Grease amount totheoil
condition
Middle
Change
Suction positionof
according
8 Centrifugal 1 EngineOil theoil
totheoil
Pump dipstick,full
condition
oilcup
Discharge Change
Lithium-based Appropriate
9 Centrifugal 2 according
Grease amount
Pump totheoil

Lubrication
Location
condition
Middle Change
positionof according
6 EngineOil
theoil totheoil
dipstick condition
10 RotorPump
Change
Lithium-based Appropriate according
24
Grease amount totheoil
condition
13.4 MAINTENANCE REGULATIONS
13.4.1 COMPONENTS UNDER DECK
NOTE
Pleasefollowthetechnicalspecification,operationandmaintenanceregulationsofthe
chassis.
13.4.2 COMPONENTS ON DECK
13.4.2.1 DAILY MAINTENANCE
a) Checktheoillevelandqualityoftheengine,pumpdrive,suctioncentrifugalpump
andhydraulicoiltank.Addifnecessary.
b) Check whether all instruments of the engine or on the instrument panel works
normally. Check all sensors and the electric wiring connections and tighten or
replacewhennecessary.

c) Draintheresidualfluidorsandfluidinsidethecentrifugalpumpchamberandthe
lowpressuremanifoldthoroughlyaftersandaddingorfracturingoperations,and
flushthemthoroughlytoavoidcorrosion.
d) Checkandtightenthetighteningboltsofthekeycomponentsandtheconnectors
oftheelectricline,pneumaticpipesandhydraulicpipestoensurethereisnoleak.
Drain the condensation water inside the air bottle. Charge the tire when its air
pressureisinsufficient.
e) Theoperatorsshallrecordthedailyunitoperationconditionsandthemaintenance.
Makethefoundandsolvedandunsolvedproblemsclear.
13.4.2.2 CHECK AND MAINTENANCE ITEMS OF EVERY 10

HOURS OF OPERATION
a) Dodailymaintenance.
b) Check the tightness and wear of the generator belts. Replace or adjust when
necessary.
c) Checkthedisplayconditionofallinstrumentsandchecktomakesureallsensors,
electric lines and connectors are in good condition. Replace or repair when
necessary.
d) Check whether there are connectors getting loose or leaks on the oil pipes,
pneumaticpipesandwaterpipes.Makesureallpipesareingoodconditionand
tightenproperly.
e) Check the battery wiring harness connectors, cable connection and electrolyte
levels.Addwhennecessary.
f) Check the oil level and condition of the pump drive oil. Add or replace when
necessary.

g) Checkthetighteningpositionoftheconnectionstoensuretheyaresecure.
h) Start the engine and check the working condition of the components. Check
whether the value displayed on the instruments are within the technical
requirements.Maintainandrepairwhennecessary.
13.4.2.3 CHECK AND MAINTENANCE ITEMS OF EVERY 50 TO

80 HOURS OF OPERATION
a) Performthemaintenancementionedinevery10hoursofoperation.
b) Check the wear condition of the bearing seal ring at the auger bottom and the
bearing.Replacewhennecessary.
c) Checktomakesurethefireextinguisherisingoodcondition.
13.4.2.4 FIRST LEVEL SERVICE OF EVERY 120 TO 150 HOURS

OF OPERATION
a) Performthemaintenancementionedinevery50~80hoursofoperation.
b) Greasethelubricationpoints.
c) Makesurethebearingsealringofthedrypowderconveyerandtheliquidadditive
flowratesensorareingoodcondition.
d) Checktheknobsonthecontrolconsoleforstuckorfailure,andreplaceifnecessary.
Checkthecableplugandsocketsarecontactedwell,andtightenifnecessary.
e) Checkthehydraulicpipesandpneumaticsystemsareingoodcondition.Removeit
forcleaningifnecessary.

13.4.2.5 FIRST LEVEL SERVICE OF EVERY 250 TO 280 HOURS
OF OPERATION
a) Performthemaintenanceitemsmentionedinevery50~80hoursofoperationand
120～150hoursofoperation.
b) Checkthewearconditionoftheimpellerandvoluteofthesuctionanddischarge
pump.Ifthepressureislowerthan0.25Mpaduetotheseriouswearofthesuction
anddischargepump,replacethepumpimmediately.
c) Checktheoilsandreplaceifnecessary.
d) Checktomakesurethepumpdrive,transmissioninputshaftareingoodcondition.
Checkandtestwhethertheperformanceparameterindexofthepumpdrivelube
oilcanmeetthestandards.Replacewithoilofthesametypeifnecessary.
13.4.2.6 SECOND LEVEL SERVICE OF EVERY 750 TO 850 HOURS

OF OPERATION
a) Performthemaintenancementionedinfirstlevelservice.
b) Checkandadjustthevalveclearanceandignitiontiming(pleaserefertotheDetroit
S60engineoperationandmaintenancemanualfordetailedadjustingmethod).
c) Checkthecoolingsystemthermostat.Thethermostatwillopenwhenthecoolant
temperature is 86 ℃ (186 ℉) at one atmospheric pressure; and it will fully open
when the coolant temperature is 92 ℃ (197 ℉). If the thermostat cannot work
normally,pleasereplaceit.
NOTE
Check, clean and repair the cooling system if there is dirt or grease in the coolant.
Replacewhennecessary.

d) Checktheturbochargerimpeller,turboandboostercavitycover.Rotatetofeeland
observe the axial clearance, friction, stick and abnormal noise. Repair or replace
whennecessary,andcleanthedepositontheturbo.
e) Recordthemaintenanceofeveryitemunderallperiodclearly.
13.4.2.7 CAUTIONS FOR AIR CONDITIONER OPERATION AND

MAINTENANCE
Iftheunitisequippedwithairconditioner,pleasepayattentiontothefollowingitems
duringtheoperationandmaintenanceoftheairconditioner.
a) The on-off interval of the air conditioner shall be at least two minutes. The air
conditionercannotbeturnedonandoffcontinuously.
b) Pay attention to the running of the air conditioner. If there are abnormal noises
suchasmetalimpactsoundandshellchatter,stoptheairconditionerimmediately
andfindoutthecauses.
c) Regularly check the connector of the air conditioner pipes for leak. If oil dirt is
found it indicates there is leak, please deal with it immediately. Otherwise, it will
leadtoinsufficientrefrigerantwhichwillaffectthecoolingeffectandevendamage
thecompressor.
d) Thereshallbenoobstructionsattheairintakeandoutletwhentheairconditioner
isworking;
e) Clean the filter screen, vaporizer and condenser regularly during operation to
ensure the air conditioner can work normally. It is recommended to clean them
once or twice a year. The cleaning interval should be shortened in
high-temperatureanddustyconditions.
f) Iftheairconditionerisputasideforlongtime,runit(forabout10minutes)atleast

once every month to ensure the sealing parts, O-rings and bearings inside the
compressorarelubricated.
g) Iftheairconditionerheatsthroughwatercirculation,thecirculationwatershallbe
addedwithcoolanttopreventthecorefrombeingfrozentoburst.
13.4.2.8 COATING MAINTENANCE
13.4.2.8.1 COATING MAINTENANCE REQUIREMENTS
a) MaintenanceRequirementsforCommonCoating
MaintenancePosition:thedamagedcoatingorthecoatingatpositionswherethereis
rusting.
MaintenanceInterval:Checkthecoatingonceamonth.
Maintenance:Repairthecoatingfromwhichlayeritisdamaged.De-oilandgrindthe
damagedorrustedareascompletelyandgrindtheedgestobeveledtomakesurethe
loosecoatingandrustsareallremoved.Then,carryoutcoatingmake-upaccordingto
the coating status, for example, primer needs to be painted if it is grounded to the
materialsurface.Eachcoatingneedstobedriedfor6~8hoursbeforenextcoatingis
paintedtillthecoatingthicknessreachtheoriginalcoatingthickness.
The repair primer of offshore units should be epoxy zinc rich primer. It needs to be
paintedtwiceandthecoatingthicknessshouldbewithin90μm.
b) MaintenanceRequirementsforCoatingofHighTemperatureParts
MaintenancePosition:positionswherethecoatingisdamagedorrustedatpartssuch
as engine exhaust pipe, muffler, high temperature pipe clamps, and heater exhaust
pipe.
MaintenanceInterval:Spotcheckonceamonth.
Maintenance:De-oilandgrindthedamagedorrustedareascompletelyandgrindthe

edgestobeveledtomakesuretheloosecoatingandrustsareallremoved.Grindtothe
materialsurfaceandpainthightemperatureprimer.Makesurethefilmiscompletely
dry (it takes at least one day) and then pain one high temperature finishing coat or
primer.Thetotalfilmthicknessshouldbewithin50μm.
c) MaintenanceRequirementsforCoatingInsidetheTanks
MaintenancePosition:Insideofthedisplacementtanks,slurrymixingtanksandsand
blendingtubs.
MaintenanceInterval:Checkthecoatingonceaweek.
Maintenance:Completelycleanandgrindthepositionswherethecoatingisdamaged.
Grindtheedgestobeveledtomakesuretheloosecoatingandrustsareallremoved.
The surface should be coated with two films. The first coating needs to be dried for
more than 8 hours (the ambient temperature of 20℃) before the second coating is
paintedtillthecoatingthicknessreachtheoriginalcoatingthickness.
13.4.2.8.2 NON-COATING MAINTENANCE REQUIREMENTS
a) Plated Pieces (Such as pipe connectors, bracket, valve terminal and external
instruments)
Maintenance:Completelycleanandgrindthesurfaceoftheworkpieceandthenpaint
from the primer. The next coating can be painted only when the former coating has
beendriedfor6~8hourstillthefinishingcoating.Thepaintfilmthicknessshouldbe
thesamewiththatofotherworkpieces.
Theprimerofoffshoreunitsshouldbeepoxyzincrichprimer.Itneedstobepainted
twiceandthecoatingthicknessshouldbewithin90μm.
b) Bolts

1) Theboltsthatwon’tbedisassembledorreplacedforalongtime
Maintenance:De-oiltheworkpiecewithcleanercompletely,grindthesurfaceand
thenpaintfromtheprimer.Thenextcoatingcanbepaintedonlywhentheformer
coating has been dried for 6~8 hours till the finishing coating. The paint film
thicknessshouldbethesamewiththatofotherworkpieces.
The primer of offshore units should be epoxy zinc rich primer. It needs to be
paintedtwiceandthecoatingthicknessshouldbewithin90μm.
2) Boltsthatneedstobedisassembledandreplacedfrequently
MaintenanceInterval:Aftereachdisassemblyorreplacementorspotcheckoncea
week.
Maintenance:Grindtherustedpositiontothesubstrateandspray(brush)waxyfilm
orhardfilmrustpreventiveoil.
c) Gaps
MaintenanceInterval:spotcheckonceamonth.
1) Gapswithwidthlessthan5mm
Maintenance:Donappingtreatmenttotheedgesofthegasps,sealthegapwith
polyurethanesealantandthenpaintfinishingcoatonthesurfacewhenthesealant
isdry(elasticandnotsticky).
2) Gapswithwidthequaltoandmorethan5mm,andthedepthexceedingthe
paintingoperationcapability
Maintenance:Sprayrustpreventiveoilinsidethegap.
d) AluminiumParts(suchasladders,guardsandplatforms)andAluminumAlloyParts
1) AnodizedorRustedAluminiumPartsandAluminumAlloyParts
MaintenancePosition:Positionswheretheoxidationfilmisdamaged.

Maintenance:Grindandcleanthepositionwheretheoxidationfilmisdamagedor
wherethereisrust.Then,spraypaintofsimilarcolororspray(brush)waxyfilmor
hardfilmrustpreventiveoil.
2) UntreatedWorkPiece
MaintenanceInterval:Spotcheckonceaweek.
Maintenance: Clean the surface of the work piece and spray hard film rust
preventiveoil(filmisthickerthan50μm).
3) RustedWorkPiece
MaintenancePosition:Rustedarea
Maintenance:Grindandremovetherustoftherustedareacompletely,then,spray
paintofsimilarcolororspray(brush)waxyfilmorhardfilmrustpreventiveoil.
e) PlungerPumpDrawBarsandPlungers
Please refer to the Plunger Pump Operation and Maintenance Manual for detailed
maintenanceinformation.Coatdrawbarsandplungerswithgreaseorrustpreventive
oilaccordingtothismanual.
f) Shafts(ElectricMotor,CentrifugalPumpandDriveShaft)
Maintenance:Cleanthesurfaceofshaftstocompletelycleanwithoutanydustorother
stuff,andthencoattheshaftsurfaceswithgreaseorrustpreventiveoil.
g) PinsandPinHoles
Maintenance:
1) Iftheclearancebetweenthepinandthepinholeisbiggerthan1mm:Thepinhole

shouldbecoatedwithprimer;theexposedpartofthepinshouldbecoatedtillfinishing
coatandotherpositionsshouldbecoatedwithprimer;thefilmthicknessshouldbethe
samewiththatofotherworkpieces.
2) Iftheclearancebetweenthepinandthepinholeissmallerthan1mm:boththepin
andpinholeshouldbecoatedwithrustpreventiveoil.
13.5 LIST OF UNIT MAINTENANCE
Check
Frequency 3 6 12 18 24 30 36 42 48 54 60 72
(Month)
Working
50 100 300 450 600 750 900 1050 1200 1350 1500 2000
Hours (h)
CoolingSystem △ △ △ △ △
Turbocharger △ △ △ △ △ △ △ △ △ △ △
AirCompressor △ △ △ △ △ △ △ △ △ △ △
AirFilter △ △ △ △ △ △ △ △ △ △ △
Generator △ △ △ △ △ △ △ △ △ △ △
FuelFilter ★ ★ ★ ★ ★
WaterPump △ △ △ △ △ △ △ △ △ △ △
AirIntake
Engine
△ △ △ △ △ △ △ △ △ △ △
System
ExhaustSystem △ △ △ △ △ △ △ △ △ △ △
WaterTank
△ △ △ △ △
Radiator
Connection
andInstallation △ △
Parts
Thermostat
△
andSeals
EngineLubeOil Replaceevery250hoursofoperationoreveryyear.

EngineLubeOil
Replacethefilterelementwhenreplacingtheenginelubeoil.
Filter
Pump ChangeLube
★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★
Drive Oil
HydraulicOil ★ ★ ★ ★ ★ ★
SuctionOil
★ △ ★ △ ★ △ ★ △ ★ △ ★ △
FilterElement
Hydraulic
ReturnOilFilter
System ★ △ ★ △ ★ △ ★ △ ★ △ ★ △
Element
Hydraulic
△ △ △ △ △
Pipelines
Pressure
△ △ △ △ △
ReducingValve
Drainwater
fromtheair △ △ △ △ △
Pneumatic bottle
System
AirPipeline △ △ △ △ △
DirectionValve △ △ △ △ △
Pneumatic
△ △ △ △ △
Cylinder
Battery △ △ △ △ △ △ △ △ △ △ △
Cable
Electric △ △ △ △ △ △ △ △ △ △ △
Connection
System
Wiringwearor
△ △ △ △ △ △ △ △
aging
MotorCoupler △ △ △ △ △
Centrifugal Bearing
△ △ △ △ △
Pump Lubrication
Impeller △ △ △ △ △
Acid
Mixing MixerCoupler △ △ △ △ △
System
★ Change △ Check

13.6 MAIN VULNERABLE PARTS LIST
Location Item P/N Description Qty.
1 P070001208 EngineOilFilterElement 2
DDCS60 2 P070001181 DieselOilFilterElement 1

Engine 3 P070001182 GeneratorBelt 1set
4 P070001126 EngineAirIntakeFilterElement 1
Hydraulic 1 P200004115 ReturnOilFilterElement 2

System 2 P200004124 SuctionOilFilterElement 2


CHAPTER 14 TROUBLESHOOTING
DECLARATION ..................................................................................................................... 1
14.1 ENGINE TROUBLESHOOTING ................................................................................... 1
14.2 MANIFOLD SYSTEM TROUBLESHOOTING .............................................................. 3
14.3 SAND TRANSMITTING SYSTEM TROUBLESHOOTING .......................................... 4
14.4 BLENDING SYSTEM TROUBLESHOOTING ............................................................... 5
14.5 LIQUID ADDITIVE SYSTEM TROUBLESHOOTING ................................................... 6
14.6 CHASSIS TROUBLESHOOTING .................................................................................. 7
14.7 PNEUMATIC SYSTEM TROUBLESHOOTING ............................................................ 7
14.8 HYDRAULIC SYSTEM TROUBLESHOOTING ............................................................. 8
14.9 ELECTRIC SYSTEM TROUBLESHOOTING................................................................ 10

CHAPTER 14 TROUBLESHOOTING
DECLARATION
Thischapterisageneralsummarizationofthecommonfailurethatmayoccurtothe
sandblendersanditisonlyforreference.Pleasesubjecttotheactuallydeliveredunits
forthedetailedconfigurationandfunctions.Donotcomparetheconfigurationofyour
unitswiththosementionedinthischapter,andnorequirementsbasedondifference
betweenthemwillbeaccepted.
14.1 ENGINE TROUBLESHOOTING

Measurebatteryvoltage,thevalueshall
Insufficientvoltage behigherthan24V.Ifthevalueislower
(electricityquantity) than18Vduringstartup,chargethe
battery.
Emergencykillshutoff Reset
Enginecannotbe Checktoverifyfuelsupplypressurecan
started. Fuelsystemfails. meettherequirementsandairinthefuel
systemhasbeenreleasedthoroughly.
PressPowerViewtoremovethe
Enginewarns.
warning.
Checktheelectricorpneumaticcontrol
Startingmotorfails.
systemandremovethefailure.
Enginegoesback Airfilterblocked Replace

toidlespeed Fuelfilterblocked Replace
suddenlyorits Badcontactofthrottle
speeddecreases. Re-installtheplug.
controlwiringharnessplug
HSC16 Chapter 14 Troubleshooting 1

Checkwhethertheenginegetspower
Enginegetsnopower
Engineparameter supplynormallyaccordingtothe
supply.
display drawings.
instrumentswarn CANbusisopencircuitor MeasurewhethertheCANbushasa
ordisplayno shortcircuit. resistanceof60Ωor120Ω.Ifithasnot,
data. pleasecheckthebreak-makeoftheCAN
ECMfails.
bus.
Throttlewiringharnessis Measurewhetherthereisshortcircuit
shortcircuitoropencircuit. amongthethreewiringsofthethrottle,
andthensupplypowertotheengine.
Measurecorrespondingterminalto
checkwhetherthevoltagerangeis0.5
Throttlefails. V~4.5V.Ifthevoltagevarieswithinthe
Throttledamaged normalrange,pleasecheckthe
break-makeoflinesbetweentheengine
ECMandtheterminal.Ifthevoltage
remainsthesame,itindicatesthatthe
throttleisdamaged.
Measurewhetherthevoltageatthe
generatorwiringendisabout27Vwhen
Generatorisdamaged.
theengineisrunning.Ifthevoltageis
about24V,pleasecheckthegenerator.
Pleasecheckthetensionofthebeltand
Thebeltistooloose.
adjustproperly.
Insufficient
Scalesaredesignedattwosidesofthe
voltage
battery.Theelectrolytelevelcannotbe
(electricity
Electrolyteinsidethebattery lowerthanthelowlimit.Ifthelevelis
quantity)
isinsufficient. lowerthanthelowlimit,pleasefeedthe
batterywithelectrolytebutdonot
exceedthehighlimit.
Checkwhetherthecounterelectrodeof
Batteryisdamaged. thebatteryisvulcanized.Ifitis,please
replacethebattery.
Fuellevelisnot Wiringsareshortcircuit. Pleasechecktheresistanceofthe

displayedortoo Sensorsaredamaged. sensors,andtheresistanceshallbe
2 Chapter 14 Troubleshooting HSC16

full. within30~240Ω.Iftheresistanceisfar
morehigherthan240Ω,pleasemeasure
thebreak-makeofthewirings.Ifthe
wiringsarenormal,pleasereplacethe
sensors.Iftheresistanceistoosmall,the
wiringsareshortcircuitandplease
replacethewirings.
Shutdowntheengineimmediately,
Emergencyshutoffvalves
openallemergencyshutoffvalvesto
arenotfullyopened.
Heavyengine ensuresmoothairintake.
smoking Checkignitioncoilandcontrolwiringfor
Poorignitionofthecylinder.
failure.
Airinfuelpipesystem. Dischargetheair.
14.2 MANIFOLD SYSTEM TROUBLESHOOTING

Thehydraulic Thepressureofthebutterfly
Adjustthepressureofthehydraulic
butterflyvalves valvehydraulicsystemisset
systemtoabout1,450psi.
cannotbe toolow.
openednormally
afterseveraldays Butterflyvalvesarestuck. Checkandremove.
ofclose.
Thebutterflyvalvesaretitled
Loosethefixboltofthevalveand
toonesideduring
re-adjustthevalveposition.
installation.
Butterflyvalves
Butterflyvalvesareblinded. Cleantheimpurities.
arestuck
Adjustthepressureto0.65Mpahigher
sometimes. Insufficientairsupply
thanthesetpressure
Butterflyvalveandflangeare Loosethefixingboltofthebutterfly
installedtoofirmly. valveandreadjust.
Levelautomatic Thesuctionbutterflyvalveis Adjusttheresponsetimeofthebutterfly
controlis notsensitive. valves.

abnormalandthe Valvepositionmonitoring
Replace
fluctuationis sensorisdamaged.
serious. Proportionalvalvesare
Replace
damaged.
Levelsensorscannotdisplay
Re-calibrateorreplace
accurately.
Sensorsaredamaged. Replace
Impellersarewornout. Checkandreplace
Pressureofthe Workingpressureofthe
suctionpumpis Adjust
hydraulicsystemistoolow.
low. Checkthemanifoldprincipleonthe
Suctionflowrateislow. controlpanelorincreasethequantityof
thesuctionmanifold.
14.3 SAND TRANSMITTING SYSTEM TROUBLESHOOTING
Basebearingsaredamaged. Replace
Repairtheopencircuitpositions,
PLCdoesnotoutputcurrent.
replacePLCoradjusttheprogram
Potentiometerisdamaged Replace
Powersupplyswitchis
Replace
damaged.
Augersdonot
Hydraulicmotoris
rotate. Repairorreplace
damaged.
Hydraulicpumpsare
Repairorreplace
damaged.
Badcontactofplugsonthe
Checkandrepair
hydraulicpumps
Augersarestuck. Cleantheimpurities.

14.4 BLENDING SYSTEM TROUBLESHOOTING
Valuedisplayedonthe Controlthespeedoftheagitator
Toomanybubbles.
levelmeteris properly.
inaccurate. Wrongcalibration Re-calibrate
PLCdoesnotoutput Repairtheopencircuitposition,replace
current. PLCoradjusttheprogram.
Potentiometeris
Replace
damaged
Powersupplyswitchis
Replace
damaged.
Hydraulicmotoris
Repairorreplace
damaged.
Hydraulicpumpsare
Repairorreplace
Agitatorsdonotrotate. damaged.
Valvebanksare
Repairorreplace
damaged.
CheckwhetherportLsofthe
Theagitatorwillnot proportionalvalveisblockedorwhether
workwithoutpressure. thecontrolvalvesonthepumpare
stuck.
Agitatorsdonotwork
Checktheexternalload.
underhighpressure.
Agitatorsarestuck. Cleantheforeignobjects.

14.5 LIQUID ADDITIVE SYSTEM TROUBLESHOOTING

Frequency-to-current
Replace
moduleisdamaged.
Sensorsaredamaged. Replace
Badconnectionofthe
Replace
connectingwire.
Displacementofthe
Calibrationisnot
liquidadditive Re-calibrate
performed.
pumpsarenot
Threadfiltersareblocked. Clean
displayed,but
fluctuationisshown. Pleaseoperatethemanualhandleof
themulti-tandemvalve,andcheck
Theliquidadditive whethertheliquidadditivepumps
pumpsdonotact. willactornot.Ifthepumpsstilldo
notact,itindicatesthatthepumpsor
hydraulicsystemfailed.
Handletheairleakageparts(check
Airmixesintothesuction whetherthereisleakatthesuction
pipe. manifoldconnectionsandthepipes
Fluidsupplypump fordamages)andexhausttheair.
doesnotsupply Pressureregulatingvalve
Replace
fluid. releasespressure.
Pumpiswornout. Replacethewornaccessories.
Thesuctionpipeistoo Increasesuctionpipeorboosting
long. pump.

14.6 CHASSIS TROUBLESHOOTING

Levelofchassis Insufficientcoolant Addcoolant.
coolanttankislow
andthesystem Sensorsfail. Checkorreplace
warns.
14.7 PNEUMATIC SYSTEM TROUBLESHOOTING
Pipesaretwistedorsquashed. Correctorreplace
Themediumtemperatureorenvironment
Replacethe
temperatureistoolow,whichleadtothe
water-oilseparator.
Theairpressureof freezingofthemanifold.
thepneumatic Filterelementispluggedorfrozen. Replace
systemislow. Replacethefailed
Seriousairleak pipe/hoseor
connector.
AirCompressorfails. Check
Adjustthepressure
Theoutputpressureofthepressure
toworkingpressure
Insufficientair regulatingvalveistoolow.
of120psi.
supply
Pistonringoftheaircompressorisworn
Replace
out.

14.8 HYDRAULIC SYSTEM TROUBLESHOOTING
Emptyorlowoillevel Addoilandassurenoleaks.
Wronglubeoil Replace
Thehydraulic Filtersblocked Replace
systemcannot Checkwhetherthepipesaresqueezed,
worknormally. Oilwayblocked leakingorblocked,andremovethe
failures.
Checkwhetherthepumpdrivedeviceis
Pumpcannotwork.
damaged.
Checkleaksinsuctionofthepumpremove
Airinthesystem
Systemworks theleaks.
unsteadily Lowoiltemperature Leavewarmingtimeforthesystem
Lowoillevel Addwiththesameoil.
Enginespeedtoolow Keepenginespeedhigherthan1,800rpm
Highhydraulicoilviscosity
Systemworks duetolowambient Warmthesysteminadvance
slowly. temperature.
Checkforsqueezed,leakingorblocked
Oilwayblocked
hoses.
Lowoillevel Addwiththesameoil.
Hydraulicoil
Radiatordoesnotventilate
temperature Cleantheforeignobjects.
smoothly.
toohigh
Heavysystemload Decreasetheload.
Wronglubeoil Replace
Hydraulicoil
Lowoillevelor
foams Checkthesuctionportforleaks.
contaminatedoil,airleaks
Lowoillevel,wrongoilor
Noiseinpump Replaceoraddoil.
foaminoil
during
Suction&returnoilfilter
working. Replace
elementsareblocked.

Highhydraulicoilviscosity
atstartingduetolow Preheat
ambienttemperature
Hydraulicpumpbodyfails. Checkandeliminateorreplace
Reliefvalvefails. Checkandeliminateorreplace
Insufficientrefrigerant Add
Ballvalveontheheating
systemcoolantwayisopen Close(Insummer)
(badrefrigeratingeffect)
Checkandrepairaccordingtothe
Bloweroftheairconditioner
instructions,payattentiontothepower
doesnotwork.
supplyoftheblower.
Airconditioner Cutoffthepowersupplytothe
doesnot proportionalsolenoidvalve,thencontrol
refrigerateor thecontrolrodofthevalvemanuallyto
heat. Proportionalsolenoidvalve observewhetherthecompressorworks.If
fails. thecompressorworks,pleaseremovethe
failure;ifthecompressordoesnotwork,
repairitaccordingtotheairconditioner
instructions.
Ballvalveisnotopen
Checkwhethertheballvalveontheengine
(heatingcannotbe
coolantwayisopen.
achieved)

14.9 ELECTRIC SYSTEM TROUBLESHOOTING
Potentiometerthat Appliedoperationforceis
Operateitslowlyandgently.
controlstheaugers toobig.
andsuction Watergoesinside. Payattentiontowaterproof.
centrifugalpumps Otherchemicaladditives
getdamaged enterthepotentiometer, Payattentiontoprotection.
easily. whichcausedjelly.
Sensorsareopencircuitor Checkthecircuitofsensor
Operationdataare
thecommunicationfails. correspondingtothefailedvariable.
displayedas#on
Thedigitsofthevalue Wrongcalibration.Re-calibrate
theHMI
exceedthelimit. accordingtotheoperationinstructions.
CheckwhethertheplugsoftheMPI
communicationcableandEthernetare
Communicationfailed connectedfirmly.Measurethestitches
ofthecommunicationcablesoneby
onetocheckthecommunicationline.
1)Checkwhethertherunningstatus
indicatoroftheCPUmoduleisgreen.
Ifitisyellow,pleasecheckwhetherthe
dialswitchisatSTOPpositionandthen
turnittoRUNposition.
AlldataontheHMI
2）CheckwhethertheSFindicatorofthe
aredisplayedas#.
CPUmoduleisred.Ifitisred,itindicates
thattheCPUmodulefails.Normally,this
CPUfailed
failureiscausedbyfailureofPLC
module.Pleasecheckwhetherthereis
redindicatorilluminatinginthePLC
module.Ifthereis,pleasecheckthe
powersupplyoftheCPUmoduleand
thefastenessoftheconnector.Ifthe
powersupplyisnormal,connectionof
theconnectoristight,buttheSFisstill

red,pleasecontactJereh.
Cutoffthepowersupplytothe
proportionalsolenoidvalve,adjustthe
controlrodoftheproportionalvalve
manuallyandobservewhetherthe
pump,agitatorandairconditioner
compressorwork.
Hydrauliccircuitsorpump
1)Ifthepump,agitatorandcompressor
cannotworknormally.
workandgetnormalpowersupply,
pleasecheckwhetherthemulti-tandem
valvefails.
2)Ifthepump,agitatorandcompressor
donotwork,pleasecheckwhetherthe
hydrauliccircuitandpumparestuck.
Hydraulicallydriven
Observethestatusofproportional
components,such
solenoidvalveindicators.Iftheindicator
asliquidadditive
isredorisnotonaftergettingpower
motor,dryadditive
supply,pleasesupplypowertothe
motor,agitator Thepowersupplyofthe
proportionalsolenoidvalveagain.Then
motorandair proportionalsolenoidvalve
iftheindicatorisgreen,itindicatesthat
conditionermotor fails.
thevalveisnormal;iftheindicatoris
cannotwork
red,pleasecheckit.(Thecontrolsystem
normally.
shallunderoperationbeforesupplying
powertothesolenoidvalve).
Checkwhethertheredindicatorofthe
fuseholderison.Iftheyareon,please
replacewithfusesofcorresponding
capacity.Afterthesystemgetspower
supply,ifthegreenindicatorofthe
Circuitsareshortcircuitor
solenoidvalveison,itindicatesthatthe
thefusesaremelting.
systemisnormal.Afterthefusesare
replaced,ifthefusesaremeltwhen
supplyingpower,pleasemeasurethe
resistanceofthecircuit.Iftheresistance
issmall,itindicatesthatthecircuitis

shortcircuit,pleaserepairit.
Checkwhethertheredindicatorsofthe
fuseholderareon.Iftheyarenot,please
checkthebreak-makeofthecircuit
signals,powerandpublicnegativepole
Circuitisopencircuit. withmultimeter.Measurethevoltage
betweenstitch1and3,betweenstitch2
and3attheplugendofthe
proportionalvalveafterthePLCand
proportionalvalvegetpowersupply.
Afterconfirmingthatthecircuitis
normal,changethisvalvewithother
Proportionalsolenoidvalve
proportionalvalvestocheckwhetherit
fails.
canworknormally.Ifthevalvedoesnot
workafterthechange,pleasereplaceit.
Checkwhetherthethermostatthat
installedontheradiatorcanwork
normally.Whentheoiltemperature
reaches45°C,buttheindicatorofthe
Thermostatfails.
temperaturecontrollerdoesnot
illuminate,pleasecheckwhetherthe
thermostatpowersupplycircuitis
normal.
1)Pleasecheckwhetherthevoltage
Hydrauliccooling betweenthecoilterminalsA2andA1of
fandoesnotwork. therelaythatrelatedtothethermostat
is24Vaccordingtothedrawings.Ifthe
indicatorsofthethermostatandrelay
illuminatesimultaneously,itindicates
Relayfails.
thattherelayfailsorthewiringsare
opencircuit.
2)Shortconnectpoint11and14ofthe
relayafterthepowersupplyiscutoffto
observewhetherthefanworks(or
testingafterreplacingtherelaydirectly).

Ifthefanworks,pleasereplacetherelay.
3)Iftherelayandwiringsarenormal,
pleasecheckthehydraulicsolenoid
valve.
4)Presstherelaytocheckwhetherit
looses.
Shortcircuitpoint11and14oftherelay,
thencheckwhetherthepowersupplyof
thehydraulicsolenoidvalveis24V.Ifit
Hydraulicsolenoidvalve
is24V,pleasereplacethesolenoidvalve;
fails.
ifitisnot,pleasecheckthewirings
betweentherelayandthesolenoid
valve.
Iftheindicatorofthefuseholdersinside
thecontrolcabinetturnsred,please
checkwhethertheline-to-groundis
Fusesaremelt. shortcircuit.Ifitis,replace
correspondingfuses.Checkthecircuit,if
thefusesmeltimmediatelyafterthe
replacement.
Checktheresistancevalueofeachline.
Ifthevalueisfarmorehigherthan10Ω,
Lightsdonotwork. pleasereplacethelines.Tightenthe
Circuitfails. linesinsidethecontrolcabinetwitha
normalcircuit.Ifthelightsdonotwork
afterthetightening,pleasereplacethe
lights.
Observewhetherthebulbsareburnt
out.ForthoseLEDlights,theycanbe
Lightsfail. testedbyreplacingwithlightsafterthe
failureexistinginfusesandcircuitsare
removed.
Controlsystem Pleasecheckthevaluedisplayedonthe
Insufficientvoltage
getsnopower voltmeterattheoperationpanelafter
(electricityquantity)
supply. thebatterygetspowersupply.Ifthe

voltageislowerthan18V,pleasecharge
thebattery.
Turnontheswitch,checkwhether
voltagetoearthofeachbindingpostis
Powerswitchdamaged
about24V.Ifthevoltageisnot24V,
pleasereplacethemainpowerswitch.
Checkwhetherthebreakersinsidethe
controlcabinetareopencircuit.Ifitis
hardtodetermine,measurewhether
Breakersareopencircuit. thereisvoltageof24Vattheinputend
ofthepowermodulewithmultimeter.If
thereisno24Vvoltage,pleasecheckor
replacethebreakers.
Ifthereis24Vvoltageattheinputend
ofthepowermodule,pleasemeasure
Powermodulefails. whetherthereis24Vvoltageatthe
outputend.Ifthereisnot,please
replacethepowermodule.
Ifthereis24Vvoltageoutputbythe
powermodule,pleasecheckwhether
theindicatorsofrelatedfusesturnred.If
Lineslooseorfusesmelt
theyturnred,pleasereplacethefuses;if
theydonot,pleasecheckwhetherthe
powersupplylinesisloose.
Checkpoint1oftheAI/AOmodule,the
voltageshallbe24V(positive)andpoint
PLCmodulewarns Causedbyfailureofpower 20(40)shallbe24V(negative).Ifthere
andtheSF supplytotheAI/AO isno24Vvoltage,thesystemwillwarn.
indicatorisred. module. Ifthewarningisnotremovedafterthe
systemgetsnormalpowersupply,
pleasecontactJereh.
Thereisno Thestitchesofthesix-pinconnectorson
communication Opencircuit(badcontact bothendofthecablereelare
afterthedata ofdataline) correspondingtoeachother.Measure
acquisitionsystem theon-offbetweenthestitches.Ifthere

isconnectedwith isoff,pleasecheckaccordingtothe
theEthernet. correspondingrelationshipbetweenthe
wiringcolorandthestitches.A
(Orange-White),B(Green-White),D
(Orange),E(Green).
Measuretheon-offbetweenthechassis
socketandtheplug.A(Orange-White)-
B(Green-White)-3/D(Orange)-2/E
(Green)-5
Checkwhetherthepowersupplyswitch
Improperoperation
isturnedon.
Controltheoutputonthescreen
accordingtooperationinstructions.If
Outputsignalsfail. theoutputisnormal,thenthe
Potentiometerfails. potentiometerfails;ifthereisnooutput,
pleasechecktheoutputsignal.
Re-calibratethepotentiometerand
operateit.Iftheoutputisstillabnormal,
Potentiometerfails.
thenthepotentiometerorthecircuit
fails.
Iftheflowratesensordisplaysthat
systemisnormal,butthesystemis
abnormalactually,pleasecontactJereh.
Theoutputcurrentofthesystemunder
emptypipesisusuallyabout4mA.
Displacementof
Flowratesensororlinefails. Checkwhetherthecurrentis4mAwith
theliquidadditive
multimeter.Ifthereisnodisplay,please
cannotbe
checkthelinebetweentheinstruments
displayed.
terminals.Ifthelinesarenormal,please
replacetheflowmeterthentestor
contactJereh.
Proportionalsolenoidvalve
Checkorreplace
fails.
Displacementof Checkandremovethefailuresor
Flowratesensorsfail.
thedryadditive replacethesensor.

cannotbe Checkthedatalineforshortcircuitand
Datalinefails.
displayed. opencircuitorreplacethedataline.
Checkwhetherthepotentiometerworks
Augersdonotrotate.
normally.
Displacementof
Controlvariablepump Checkthebreak-makeofthecontrol
theaugerscannot
outputnosignals. lineofthevariablepumpsignal.
bedisplayed.
Approachswitchorrelay
Removethefailureorreplace
fails.
Relayfails. Checkwhethertherelayworkswhen
shiftingtherotationdirection(forward
Linesloose
andreverse)oftheaugersandobserve
whethertherearetwoindicators
flashingonthePLCmodule.Iftheyflash,
Augerscannotbe
buttherelaydoesnotwork,please
shiftedbetween
checkthelinesfromthePLCtotherelay
forwardand
coil.Replacetherelayifthelinesare
reverse. Toggleswitchesdamaged
normal.IfthePLCindicatorsdonot
work,pleasecheckthelinesfromthe
toggleswitchtothePLCmoduleor
whetherthepowersupplyvoltageis24
V.
Checkwhethertheoutputcurrentofthe
Thepressureofthe pressuresensoriswithin4~20mA.If
suctionand thereisnodisplay,pleasecheckthe
dischargecannot Lineslooseorsensors linesfromtheplugstotheterminals.
bedisplayedorthe damaged MeasurethevoltagebetweenpointA
pressuredisplayed andthenegativepole,itshallbe24V.If
ontheHMIis#. everythingisnormal.Pleasereplacethe
sensorsandthentestagain.
1)Checkwhetherthepowersupplyof
thelevelmeterisnormal.Thenormal
Levelmeterhasno Powersupplyfailsorthe
voltageis20V.Ifthereisnovoltage,
displayorHMI guidedwaveradarlevel
pleasecheckthepowersupplycircuit.
displays#. meterisdamaged.
2)Ifthepowersupplyisnormal,please
contactJereh.

1)Checkthepowersupplyofthe
Suctionflowrate electromagneticflowmeter.Thenormal
anddischarge Powersupplyfailsorthe voltageis24V.Ifthereisnovoltage,
flowratearenot flowmeterisdamaged. pleasecheckthepowersupplycircuit.
displayed. 2)Ifthepowersupplyisnormal,please
contactJereh.
Checkwhether"START"ontheHMIis
Unitcannotrun Autocontrolisnotstarted. pressed.Pleaserefertooperation
automatically instructionsfordetails.
underautocontrol. Parametersareset Resetonparameterinterfaceandstage
incorrectly. settinginterface
Checkwhetherthelinebetweenthefuse
terminalandtheinstrumentpower
terminalisnormalornot.Themeasuring
voltageis24V.Ifthevoltageis24V,
pleasecheckwhetherthefailureofthe
instrumentsiscausedbyloosepower
moduleinsidethesecondary
instruments.Checkwhether
correspondingfuseindicatorsturnred
Correspondingfusesare
Flowmeterand ornot.Iftheindicatorsareon,please
meltorcircuitandpower
densitometerdo replacewithfusesofsame
moduleofthesecondary
notwork. specifications.Iftheindicatorsturnred
instrumentsareloose.
againafterthereplacement,itindicates
thatthelowerlinesofthefusesfailed,
pleasecheckthelines.After
replacement,turntheindicatorsoffand
thenturnthemonagaintoseewhether
theycanbeturnedon.Iftheycannotbe
turnedon,checkthelinesorcheck
whetherthecorrespondingcomponents
aredamaged.

Clarification
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COPYRIGHT NOTICE

Petroleum Equipment and Technologies Co., Ltd.

authorizedagentofYantai Jereh Petroleum Equipment and Technologies Co., Ltd.

AnyattemptbyanypersonotherthananauthorizedagentofYantai Jereh Petroleum

Equipment and Technologies Co., Ltd. toalterthecontentsofthismanualinanyway

©Copyright2015byYantai Jereh Petroleum Equipment and Technologies Co., Ltd.

Yantai Jereh Petroleum Equipment and Technologies Co., Ltd.

Unit Conversion Between Metric Units and Imperial Units

CHAPTER 3…………………………………………………….……………………….BRIEF INTRODUCTIONS

CHAPTER 5…………………………………………………………………………………………POWER SYSTEM

CHAPTER 6…………………………………………………………….……………SAND BLENDING SYSTEM

CHAPTER 7……………………………………………..………………..…………..………HYDRAULIC SYSTEM

CHAPTER 8…………………………………………………………………………..………PNEUMATIC SYSTEM

CHAPTER 9…………………………………………………………………….….....…………ELECTRIC SYSTEM

CHAPTER 11……………………………………………………………………………SOFTWARE OPERATION

CHAPTER 13…………………………………………………………INSPECTION AND MAINTENANCE

1.1 GENERAL USE

CHAPTER 2—SAFETY AND HEALTHoutlinedherein.

EMERGENCYSHUTOFFVALVESOFTHEENGINEAREOPENED”inAIR INTAKE AND

EXHAUST SYSTEM of CHAPTER 5 POWER SYSTEM.Iftheoperatorsfailedtofollow

HSC16 Chapter 1 About This Manual 1

Yantai Jereh Petroleum Equipment & Technologies Co., Ltd.

2 Chapter 1 About This Manual HSC16

HSC16 Chapter 1 About This Manual 3

their uses, any advisory services and/or recommendations provided by

all express warranties，engineering drawings, samples, models, or actions with

4 Chapter 1 About This Manual HSC16

HSC16 Chapter 1 About This Manual 5

6 Chapter 1 About This Manual HSC16

HSC16 Chapter 1 About This Manual 7

8 Chapter 1 About This Manual HSC16

HSC16 Chapter 1 About This Manual 9

2.1 SAFETY AND HEALTH................................................................................................... 1

2.1.1 QUALIFIED PERSONNEL ........................................................................................ 1

2.1.2 PERSONAL PROTECTIVE EQUIPMENT ................................................................. 1

2.1.3 SAFETY PRACTICE .................................................................................................. 2

2.1.4 UNAUTHORIZED PERSONNEL .............................................................................. 2

2.1.5 HIGH PRESSURE ..................................................................................................... 2

2.1.6 UNAUTHORIZED MAINTENANCE ........................................................................ 2

2.1.7 LIFTING .................................................................................................................... 2

2.1.8 MOVING PARTS ..................................................................................................... 3

2.1.9 VISIBILITY ................................................................................................................ 3

2.1.10 PRE-START ............................................................................................................ 3

2.1.11 WORK AREA.......................................................................................................... 3

2.1.12 EQUIPMENT TRANSPORTATION ....................................................................... 3

2.2 SAFETY OPERATION GUIDELINE ................................................................................. 3

2.2.1 SAFE EQUIPMENT .................................................................................................. 4

2.2.2 SAFETY PROCEDURE .............................................................................................. 6

2.1 SAFETY AND HEALTH

2.1.1 QUALIFIED PERSONNEL

2.1.2 PERSONAL PROTECTIVE EQUIPMENT

HSC16 Chapter 2 Safety and Health 1

owner’s/operator’s responsibility to ensure that good safety practices, personnel

2.1.4 UNAUTHORIZED PERSONNEL

2.1.5 HIGH PRESSURE

2.1.6 UNAUTHORIZED MAINTENANCE

2 Chapter 2 Safety and Health HSC16

2.1.11 WORK AREA

2.1.12 EQUIPMENT TRANSPORTATION

2.2 SAFETY OPERATION GUIDELINE

HSC16 Chapter 2 Safety and Health 3

2.2.1 SAFE EQUIPMENT

4 Chapter 2 Safety and Health HSC16

authorizedagentofYantai Jereh Petroleum Equipment and Technologies Co., Ltd.

AnyattemptbyanypersonotherthananauthorizedagentofYantai Jereh Petroleum

Equipment and Technologies Co., Ltd. toalterthecontentsofthismanualinanyway

©Copyright2015byYantai Jereh Petroleum Equipment and Technologies Co., Ltd.

Yantai Jereh Petroleum Equipment and Technologies Co., Ltd.

CHAPTER 3…………………………………………………….……………………….BRIEF INTRODUCTIONS

CHAPTER 5…………………………………………………………………………………………POWER SYSTEM

CHAPTER 6…………………………………………………………….……………SAND BLENDING SYSTEM

CHAPTER 7……………………………………………..………………..…………..………HYDRAULIC SYSTEM

CHAPTER 8…………………………………………………………………………..………PNEUMATIC SYSTEM

CHAPTER 9…………………………………………………………………….….....…………ELECTRIC SYSTEM

CHAPTER 11……………………………………………………………………………SOFTWARE OPERATION

CHAPTER 13…………………………………………………………INSPECTION AND MAINTENANCE

CHAPTER 2—SAFETY AND HEALTHoutlinedherein.

EMERGENCYSHUTOFFVALVESOFTHEENGINEAREOPENED”inAIR INTAKE AND

EXHAUST SYSTEM of CHAPTER 5 POWER SYSTEM.Iftheoperatorsfailedtofollow

their uses, any advisory services and/or recommendations provided by

all express warranties，engineering drawings, samples, models, or actions with

owner’s/operator’s responsibility to ensure that good safety practices, personnel

2) Mobile communication devices on the same channel/frequency are required

equipment for the following personnel including site owner’s supervisor,

15 OperationPlatform Theworkingplatformoftheoperators.

Model Waukesha040 AS4197