Cement Batch Mixer

BMR-100 Batch-Mixer Trailer
Operation and Maintenance Manual
Part No. 101605800

All information contained in this publication is confidential and proprietary property of
Halliburton Energy Services, Inc. Any reproduction or use of these instructions, drawings,
or photographs without the express written permission of an officer of Halliburton is for-
bidden.
© 2008 Halliburton
All Rights Reserved. Printed in the United States of America.
Part No. 101605800
Printed January 2008

Contents
Section 1—Introduction
Overview .................................................................................................. 1-1

Features of the BMR-100 Batch-Mixer Trailer ......................................... 1-2
Section 2—Major Components and Systems
Trailer Chassis ......................................................................................... 2-1

Deck Engine Module ............................................................................... 2-1
Centrifugal Pump Module ........................................................................ 2-3
Batch-Tank Modules ................................................................................ 2-5
Non-Radioactive Densometer ................................................................. 2-8
Operator Control Stand ........................................................................... 2-10
Section 3—Pre-Trip Inspection
Section 4—Operation
Introduction .............................................................................................. 4-1

Operating Procedures ............................................................................. 4-1
Section 5—Test and Setup Procedures
Introduction .............................................................................................. 5-1

Specification D00120521: Test for BMR-100 Batch Mixer Trailer
Specification D00113295: Unit Road Testing
Specification D00113918: Test for Final Inspection of Trailer
Appendix A—Unit Wiring Schematic
Appendix B—Hydraulic Piping
Appendix C—Air Piping
Appendix D—Component Repair and Service Manuals
i
ii
Section
1
Introduction
Overview
The BMR-100 batch-mixing trailer is a 100-barrel capacity batch-mixer trailer designed by
Halliburton for mixing oilfield slurries for use in a wide variety of purposes, including
drilling muds and spacers. Figure 1.1 shows an isometric view of the BMR-100 batch-mixer
trailer.
Figure 1.1—Isometric view of the BMR-100 batch-mixer trailer from the passenger's
side of the trailer
These units are built with a single-engine power pack, either one or two centrifugal pumps,
two 50-barrel batch tanks with agitators, and an operator's platform with control stand. Batch
tank agitators and centrifugal pumps are powered hydraulically and all power comes from the
single-engine power pack.
January 2008 Page 1-1 of 4 Sec. 1—Introduction

This manual provides information on the major components and systems of the BMR-100
batch-mixer trailer. Operating procedures, descriptions of major components, and basic
maintenance information will be covered in a task-oriented manner. An operator can best
use this manual for operation theory, training, basic setup of the unit, and preventative or
periodic maintenance. If maintenance and repair for major components is needed, see the
referenced repair manuals. A list of maintenance and repair manuals for other components
is included in this manual.
Features of the BMR-100 Batch-Mixer Trailer

The BMR-100 batch-mixer trailer was designed to incorporate an emission-certified engine
and to include safety and ergonomic features for improved use at the wellsite. This design
can provide the following benefits:
• The engine package is mounted on the gooseneck portion of the trailer, resulting in less
noise and maintenance access to both sides of the engine.
• Personnel can safely stand and work on top of the 50-barrel batch tanks. The top surface
of the batch tanks is equipped with handrails built to OSHA specifications.
• The trailer has the same 344-in. wheelbase and configuration as that used on the 75TC4
and Elite cementing trailers.
• The recirculation/booster pump is hydraulically operated for better speed control. The
hydraulic system is identical to that of the Elite cementing trailers and ISO Advantage
cementing skids.
• The trailer has an overall lower center of gravity.
• The eductor hopper and elbow assembly for the blower hose can remain permanently
mounted on top of the tank. These items are lower than the 13-ft, 6-in. height restriction
that is used as a design standard for land equipment.
• The trailer includes an arrangement for the bulk blower hoses wherein each elbow
assembly can be teed together in a Y configuration so that a single bulk hose from the
bulk truck can feed either batch tank.
• The low-pressure manifold has been designed to allow the suction lines from each
batch tank to be pressurized and washed out using the 6 × 5 centrifugal pump.
• The engine package is mounted on rubber isolators to reduce noise and vibration.
• Each batch tank includes two clean, in-place spray nozzles to assist in scrubbing and
washing the tanks after the job is complete.
• The fuel tank is mounted to allow the unit to be refueled at ground level.
• The batch tanks include large center opening hatches with removable lids to allow
access to the inside of the tank.
Sec. 1—Introduction Page 1-2 of 4 January 2008

• Each batch tank includes four paddle-type, unsupported agitators instead of one. Four agitators
provide equivalent fluid movement and mixing, and eliminate maintenance of the previously
used bottom bearing.
• The design includes a 30° stair-type ladder that provides a very safe approach for boarding and
deboarding the unit.
• The unit includes a standard non-radioactive densometer and includes a 19-in. spool in the
discharge manifold for a conventional nuclear densometer, if required.
• The unit includes a 1-in. air diaphragm pump to be used for pumping chemicals from a drum at
ground level into each batch tank.
• The unit is designed to be manufactured with two 6 × 5 × 11 × 11 centrifugal pumps.
• Flat-topped tanks allow for material in sacks or buckets to be placed on top of the tank.
• The unit is equipped with an emission-certified engine that produces lesser quantities of pollu-
tion and smoke.
• The unit includes storage for up to 100 feet of suction hose and/or bulk hose, along with storage
capacity for loose iron and high-pressure rotary hoses.
January 2008 Page 1-3 of 4 Sec. 1—Introduction

Notes
Sec. 1—Introduction Page 1-4 of 4 January 2008

Section
2
Major Components and
Systems
Trailer Chassis
The trailer chassis wheelbase is 344 in. long when measured from the kingpin to the center of
the bogie. The trailer frame is manufactured from high-strength, low-alloy (HSLA) steel. The
trailer chassis is equipped with the following items:
• Hendrickson-Turner 44,000-lb air-ride suspension

• Spicer axle assemblies
• 11R × 22.5-in. tires, load-range G
• Rockwell antilock brakes
Deck Engine Module

The deck engine on the BMR-100 batch-mixer trailer is a Cat C7 engine. This engine is Tier
III emission certified and is rated at 300 bhp at 2,200 rpm and supplies all power requirements
on the trailer. This engine is electronic, and control and diagnostic functions involving the
engine are performed through the engine control module (ECM). The engine package is
mounted on rubber isolators to reduce transmitted vibration through the trailer. The engine is
started by an electric starter that is tied into two 12-volt batteries.
The deck engine is equipped with a gear-type 13.2-cfm air compressor. This air compressor
supplies air for the 3-position valves in the control stand that are used to open and close
butterfly valves on the trailer. The engine also includes a 12-volt 100-amp alternator that
charges the two batteries on board the trailer. The batteries are located next to the engine on
the maintenance platform on the driver's side of the trailer.
Attached to the engine is a pump drive with built-in clutch. The pump drive can include up to
four hydraulic pumps. All four of these circuits are closed loop, and speed is controlled by a
joystick controller within the control stand of the unit. The four hydraulic pumps are:
January 2008 Page 2-1 of 12 Sec. 2—Major Components and Systems

• One or two Eaton ACL064 Closed-Loop Pumps—This pump is used to power the hydraulic
motor on the 6 × 5 pump that supplies fluid to the prehydrators.
If the trailer is equipped with two 6 × 5 centrifugal pumps, it will also include a second Eaton
closed-loop pump to power the hydraulic motor for the second 6 × 5 pump. This second 6 × 5
pump is capable of boosting or recirculating the batch tanks.
Note The second 6 × 5 centrifugal pump is optional and not all trailers are equipped to
include it. If the second pump is not included, one of the pads of the pump drive will
be covered with a blanking plate.
• Two RexRoth AA10VG45 or Sauer-Danfoss Series 90 Closed-Loop Pumps—These pumps

supply hydraulic oil to the front and rear tank agitators.
The engine includes one additional hydraulic pump that is mounted to the back of the air
compressor. This pump supplies hydraulic fluid to the motor powering the fan that cools hydraulic
fluid for the unit. The hydraulic circuit is set up to supply the appropriate amount of fluid to the fan
motor so that it turns at a fixed and constant speed.
Sec. 2—Major Components and Systems Page 2-2 of 12 January 2008

Centrifugal Pump Module

Whether the batch-mixer trailer is equipped with one or two centrifugal pumps, both pump modules
are identical. The trailer will be equipped with a Halliburton 6 × 5 × 11 × 11 centrifugal pump and
an Eaton fixed-displacement piston motor. The material numbers for the centrifugal pump and
hydraulic motor are listed in Table 2.1.
Table 2.1—Material Numbers for the Centrifugal Pump and Hydraulic Motor
Material No. Description

100011795 Pump assembly, centrifugal, 6 × 5 × 11, 11 in. impeller, lip seals,
Halliburton
100032530 Motor, hydraulic, axial piston, 4.59 cubic inch displacement, 14
teeth 12/24 pitch spline shaft, SAE 4-bolt C flange, SAE 1 inch
6000 psi split flange ports, with spec 70.77566 protective coating,
P/N HHD463314BG1H00A
Similar to previous hydraulic-powered centrifugal pumps on other units, the centrifugal pump and
motor are direct coupled via a Woods-type coupling. Speed control of the centrifugal pump will be
accomplished by the joystick-type controller in the control stand. With the engine running at the
fully loaded speed of 2,200 rpm, each centrifugal pump should have a top speed of approximately
1,710 rpm while loaded and circulating water. This speed is a designed speed and is dependent on
several factors, including volumetric efficiency of the hydraulic system and age of the unit. The
speed of the centrifugal pumps may be +/- 50 rpm of the calculated speed.
Figure 2.1 shows the 6 × 5 recirculating pump.

Figure 2.1—6 × 5 recirculation/booster pump
An air-pressured oiler tank is included on the handrail of one of the batch tanks. This tank assembly
includes a 1/4-in. air ball valve with vent and an air-pressure regulator. The air regulator pressure
should be set between 3 to 6 psi.

Batch-Tank Modules
Table 2.2 lists the subcomponents included in each 50-barrel batch-tank module. The front 50-
barrel batch tank is shown in Figure 2.2.
Table 2.2—Subcomponents of Each 50-bbl Batch-Tank Module
Qty. Component
4 24-in. Diameter agitator
4 Parker/Ross 24.7-in.³/rev motor
1 Haldex-Barnes flow divider
1 Prehydrator with single built-in jet
1 5-in. Elbow assembly
2 Internal tank-washing nozzles
2 Handrail gates for loading bulk material
1 Inspection hatch near platform
1 Center service hatch
Figure 2.2—Front 50-barrel batch tank

Each of the four agitators is equipped with two rows of blades. The bottom rows of blades are posi-
tioned so that they are at a 90° angle to the fluid surface. The upper rows of blades are positioned
so that the blades are at a 45° angle to the fluid surface. Two of the agitators have the upper row of
blades mounted at a 45° angle so that the fluid is directed downward into the tank when the agitators
are rotated clockwise (CW). The other two agitators have the upper row of blades mounted at a 45°
angle so that the fluid is directed downward into the tank when the agitators are rotated counter-
clockwise (CCW). The rotation and placement of the four agitators is shown in Figure 2.3. The
agitators are placed and rotated in a way that helps ensure that fluid is moved around the tank and
towards the center of the tank for more thorough mixing and delivery to the suction of the centrif-
ugal pump(s). The velocity of the fluid mixed will be greatest near the walls and corners of the tank.
Figure 2.3—Batch-tank agitator rotation diagram

Each tank has four agitators that are capable of variable speed control up to 135 rpm. All four agita-
tors on each tank are rotated at the same speed and are controlled by a single joystick controller
within the control stand.
Similar to previous batch mixers, each batch tank is equipped with a dry-material jet prehydrator,
which helps enable thorough mixing of the base fluid with dry ingredients as they flow together into
the mix tank. Flow of bulk cement can be throttled and regulated using the 5-in. butterfly valve in
the elbow assembly mounted directly above the jet prehydrator. Flow of fluid from the discharge of
the 6 × 5 pump can also be throttled and regulated using the 3-in. butterfly valve mounted on the
discharge manifold of the 6 × 5 pump before entering the prehydrator. The bulk inlet connections
for both the front tank and rear tank prehydrator are tied together and piped with flexible hoses
below the walkway of the trailer so that the hose from the bulk truck can be tied into the trailer at
ground level.
Each batch tank is equipped with a large service hatch in the center and a small inspection hatch
near the operator's platform. The service hatch can be used as an access point to wash the inside of
the tank after completing a job. Two levels of protection are present to help prevent items from inad-
vertently entering the hatch. Each hatch has fiberglass screening to prevent items such as tally
books, hardhats, and clipboards from falling into the tanks. This screening is not attached and can
be easily removed to allow better access to the inside of the tanks if necessary. Underneath the
screening, bolt-in sheet metal bars are spaced in such a way to help prevent a person from inadvert-
ently falling into the tank.
Inside each tank are two internal tank spray nozzles. These spray nozzles are plumbed to the
discharge manifold of the centrifugal pump(s) and include isolation valves to prevent cement slurry
from being pumped through them.
Caution Ensure that the 1-in. isolation valves are closed at all times during pumping or
recirculation. These valves should be used after the cement fluid has been
removed from the tank during washup, when the centrifugal pumps are pumping
water.
During washup of the tanks, the 1-in. isolation valve to the spray nozzles can be opened, allowing
water to flow through the spray nozzles. The spray nozzles spray water in a 270° spherical pattern,
thereby assisting in spraying the sides of the batch tank, top of the batch tank, and the agitator
paddles.
Remove and clean the nozzles on a regular basis to help prevent cement buildup. Each of the four
spray nozzles is attached with a 1-in. low-pressure Weco® union, which enables easy removal for
cleaning.
Figure 2.4 shows one of the spray nozzles in relation to the agitators and the inside of the tank.

Figure 2.4—Inside view of 50-barrel batch tank with tank-washing nozzle
Non-Radioactive Densometer
The BMR-100 batch mixer is equipped with a Micro Motion DL200 mass flowmeter. A mass flow-
meter is an instrument that can be configured to provide density of a fluid as an output parameter.
The Micro Motion DL200 mass flowmeter includes two 2-in. diameter inlet and outlet connections.
The inlet to the mass flowmeter is attached to the discharge piping of the centrifugal pump near the
centrifugal pump volute. The outlet of the mass flowmeter is attached to the top of the batch tank.
Fluid from the centrifugal pump is slip-streamed from the discharge of the centrifugal pump,
through the mass flowmeter, and into the top of the batch tank. Density of the fluid from the mass
flowmeter is read from a 4-20 mA display mounted in the control stand.
Calibration of the mass flowmeter should not be required after it is calibrated with water. If calibra-
tion is required, refer to the Micro Motion literature or website for instructions.
Take care to keep the mass flowmeter clean and free of cement buildup. If the meter plugs during
the job while the fluid is circulating, close the 3-in. throttling valve from the centrifugal pump to
the batch tank to force all flow of the centrifugal pump through the mass flowmeter. This action
should remove the obstruction. After the job, perform this same procedure to remove any cement
residue in the meter and adequately clean the meter. Also following the job, open the ½-in. ball
valve mounted to the volute of the centrifugal pump to drain washup water from the meter.

The DL200 mass flowmeter is mounted in a horizontal position underneath the operator's platform
(Figure 2.5). The mass flowmeter is self-draining, and fluid will drain from it into the centrifugal
pump and through the ½-in. ball valve in the volute of the centrifugal pump. The 4- to 20-mA
readout for the DL200 mass flowmeter is mounted inside the control stand (Figure 2.6).
Figure 2.5—DL-200 mass flowmeter
Figure 2.6—The 4- to 20-mA readout for the DL200 mass flow-

meter

Operator Control Stand

The control stand is located on the main work platform between the two batch tanks. Figure 2.7
shows a batch-mixer trailer twin centrifugal pump control stand.
Figure 2.7—Batch-mixer trailer twin centrifugal pump

control stand
Controls for the air actuators for the butterfly valves are located on the control stand along with
joystick speed controls for the centrifugal pumps and batch-tank agitators. Engine control functions
such as start, stop, throttle, engine speed, and emergency kill are included in the control stand.
Analog gauges for engine oil pressure, engine coolant temperature, voltmeter, and hydraulic oil
temperature are also included.

In addition to the analog gauges, the Murphy Powerview display is included for reading basic
engine parameters along with other engine parameters necessary for diagnostic and maintenance
purposes. The Murphy Powerview displays the following parameters:
• Engine rpm
• Engine hours
• Machine hours
• System voltage
• % Engine load at the current rpm
• Coolant temperature
• Oil pressure
• Fuel economy
• Throttle position
• Engine manifold air temperature
• Current fuel consumption
• Transmission gear oil pressure (not used)
• Transmission gear oil temperature (not used)
• Active service codes
• Stored service codes from the engine
• Set units for display (English or metric)
• Engine configuration parameters
A copy of the Murphy Powerview display manual is included in the appendix of this manual
detailing operation of this instrument.
System and charge pressure gauges for each of the hydraulic circuits are also included in the control
stand.
In the center of the control stand is a process and instrument (PI) diagram for the valve actuators for
the low-pressure manifold detailing which valve opens a specific actuator. This diagram can help
personnel develop confidence as they operate the unit.
The 4 to 20 mA readout for the mass flowmeter is also included in the control stand. The transmitter
for the DL200 mass flowmeter is either mounted inside of the control stand or very near to the
control stand. The 4- to 20-mA readout for the mass flowmeter is wired into this transmitter.
Light switches for lighting on the truck are also included in the control stand. Toggle switches for
halogen lights on the trailer are included for the front batch tank, rear batch tank, and control stand.


Section
3
Pre-Trip Inspection
Before using the BMR-100 batch-mixer trailer on a cementing job, perform the following
steps before the trailer leaves the yard to help ensure that the unit is ready to perform a
cementing job. Verifying these basic prejob inspection items will, in most cases, diagnose a
component that is in danger of failure.
1. Check the engine water filters for signs of leakage before and after the engine is started.
2. Inspect the radiator hoses and connections for leaks. Check the coolant level in the radi-
ator. The fluid level should be 1 1/2 to 2 in. below the filler neck in the top tank.
Caution Do not remove the cap from a hot radiator. Major burns could result from
this action.
3. Check the crankcase oil level on the engine.

4. Check the restriction indicator on the engine air filters. As restriction increases, an indi-
cator moves from green through yellow to red. Change the filter before the indicators
reaches red. Reset the indicator after each time you check it.
5. Remove or open the fan guard and check the alternator belt for alignment, wear, general
condition, and tension.
6. Check the water pump and fan belt for alignment, wear, general condition, and tension.
7. At the front of the trailer, check the air and electrical connections for the tractor. Air-
brake connections are necessary for regular service and for emergency backup. The
brake lights and running lights are powered through the electrical connection.
8. Check the fuel level. Verify that the gauge is working properly.
9. Check the gearbox oil level.
10. Check the hydraulic hoses for leaks. Verify that sharp edges are not rubbing through the
hoses.
11. Check the hydraulic tank oil level.
January 2008 Page 3-1 of 2 Sec. 3—Pre-Trip Inspection

12. Check the hydraulic pumps for leaks.

13. Check the hydraulic oil filters. Verify that the indicators are not in bypass mode.
14. Check the centrifugal pumps. Verify that the seals are good and not leaking.
15. Check the oil level of the lube tank for the centrifugal pump, and verify that the regulator is
working and set correctly. The air-pressure regulator should be set between 3 and 6 psi.
16. Check that the air dryer is working properly and that the canister does not need to be replaced.
17. Check all hydraulic gauges in the control stand to verify that they are not broken or leaking oil.
18. Check that the 4 to 20 mA panel readout for the mass flowmeter powers up and is reading
correctly.
19. Check the tire pressure and examine each tire carefully for wear, tread loss, bulges, and cracks.
20. Before every trip, drain moisture from the two airlock-brake tanks located at the rear of the
trailer. Open a petcock or quick-latch valve on each tank until all moisture is discharged.
21. Ensure that all trailer lights are working properly. Replace broken lights if necessary.
22. Ensure that the work lights aboard the unit are functioning.
23. Verify that the bulk cement hoses are clear of dry-cement buildup and that cement can be
pneumatically conveyed.
24. Check the prehydrator, and verify that no cement buildup exists in the mixing bowl.
25. Start the engine. Verify that the battery is charged.
26. After starting the engine, check all hydraulic gauges, and verify that the charge and system
pressure gauges are functioning and reading correct pressures.
27. After starting the engine, verify that the air compressor is working and the air tanks will air up
to a system pressure of 90 to 100 psi.
28. After starting the engine, verify that the alternator is charging. The voltmeter should read
between 13 and 14 volts.
29. After starting the engine, verify that the oil pressure and water temperature gauges are
working.
30. Open and close each butterfly valve and verify that no butterfly valves are stuck. Verify that
no air leaks from the air system between the control stand and each air actuator.
31. Ensure that the cooling fan for the hydraulic cooler is working properly.
32. Ensure that all suction hoses and discharge iron are properly secured for roading purposes.
Verify that the contents of the nipple boxes are secure and cannot be lost during roading.
33. Verify that the ladder is properly secured. Both latches should be attached to each side of the
ladder. The safety chain under the ladder should also be attached.
34. Verify that the lids and work gates on top of the batch tanks are secure and latched.
Sec. 3—Pre-Trip Inspection Page 3-2 of 2 January 2008

Section
4
Operation
Introduction
Before operating the unit, the operator should become familiar with the BMR-100 batch-
mixer trailer by reading the manual and operating the unit in the yard's wash rack before using
the unit on location.
Operating Procedures
To operate the unit, perform the following steps:
1. Verify that the mass flowmeter is working correctly on the unit and is calibrated
correctly. The ideal way to verify is to circulate water through the mass flowmeter. With
water, the meter should read 8.2 to 8.3 lb/gal.
2. Verify that the ball valve for the cleanup nozzles is closed.
3. Run a suction line from the mixing water source to the suction side of the centrifugal
pump.
4. Open the correct butterfly valves and prime the centrifugal pump(s).
5. Engage the centrifugal pump to full speed and begin filling one of the batch tanks
through the prehydrator.
6. Check the jet pattern of the water jet.
7. Check the mixing bowl and elbow assembly for dry-cement buildup and clean out if
necessary.
Note Ensure that water in the batch tank from this procedure is either mixed with the
slurry or pumped off the unit before mixing.
8. If the water pattern is satisfactory and the bowl is clean, take on a premeasured amount
of water in each tank. To take on the water, either use the centrifugal pump or have the
water pumped into the tanks through the high-pressure fill line. If the unit is equipped
January 2008 Page 4-1 of 4 Sec. 4—Operation

with a second centrifugal pump, this pump can also be used to fill the tank with the premea-
sured amount of water.
9. Attach the bulk delivery hose. If the material used is in sacks, attach the hopper to the prehy-
drator.
10. To begin mixing, open the appropriate discharge valves on the centrifugal pump connected to
the prehydrator and begin recirculating the water in the batch tank.
11. Turn on the batch-tank agitators.
12. Ensure that the bulk equipment operator is ready to provide a steady delivery of dry material.
13. When the operator is ready, open the master cement valve to begin adding cement or other dry
material. The slurry will be circulated through the centrifugal pump, through the mass flow-
meter, and into the batch tank. Slurry from the mass flowmeter will be circulated directly into
the batch tank. The remaining slurry will be circulated into the tank through the prehydrator.
As the slurry is circulated through the prehydrator, more dry material will be added. This
procedure will continue until the slurry is near the desired density.
14. After all cement has been mixed and pumped to a pumping unit, put at least 10 barrels of water
into the tank and circulate through the low-pressure manifold and the prehydrator to help
ensure that no cement remains.
15. Open the ball valve to the cleanup nozzles so that the nozzles can help wash the inside of the
tanks. Thoroughly rinse the agitator paddles and the inside of the tanks as well as any cement
that may be have accumulated on the outside of the unit.
The low-pressure suction manifold can be pressurized and flushed using the centrifugal pump(s).
Each length of suction manifold from the tank to the centrifugal pump is equipped with a 4-in.
discharge manifold tied into the suction manifold just after the tank outlet valve. To flush the
suction manifold, draw fresh water from one of the batch tanks with the centrifugal pump(s).
Discharge the water through the 4-in. discharge manifold. Close and open the appropriate valves to
direct water into the opposite suction manifold for the other tank and then through the pit connec-
tion, and ultimately into the waste pit.
After the suction manifold for one tank is flushed, reverse the process for the second tank. Flushing
suction lines in this manner was not possible with the previous trailer design. Flushing the lines in
this manner after each job can greatly reduce the likelihood of cement buildup in the suction lines.
The cleanup water can be discharged from the unit at the pit connection of the trailer. The pit
connection of the trailer is shown in Figure 4.1.
Sec. 4—Operation Page 4-2 of 4 January 2008

Figure 4.1—Pit connection for washup water
January 2008 Page 4-3 of 4 Sec. 4—Operation

Notes
Sec. 4—Operation Page 4-4 of 4 January 2008

Section
5
Test and Setup Procedures
Introduction
This section includes three test and setup procedures for the BMR-100 batch-mixer trailer.
The specifications and procedures can also be found on Matrix.
Important Always use the latest version of all specifications.
This section contains the following specifications:
• Specification D00120521: Test for BMR-100 Batch Mixer Trailer

• Specification D00113295: Unit Road Testing
• Specification D00113918: Test for Final Inspection of Trailer
January 2008 Page 5-1 of 2 Sec. 5—Test and Setup Procedures

Notes
Sec. 5—Test and Setup Procedures Page 5-2 of 2 January 2008

Halliburton Energy Services Specification D00120521 Revision D
Tested Unit: BMR100,Batch Mixer Trailer, Twin
Duncan, OK Centrifugal Pump, CAT C7
Date: 07/06/2007
The information contained hereon shall be considered the sole property of Halliburton Energy Services (HES) and the recipient thereof agrees not to
disclose said information to parties outside the recipient’s organization and not to use or duplicate said information for any purpose except as specified
by HES with the written permission of HES.
1. TEST INFORMATION
a. Instructions for use
i. This test procedure is intended to identify the minimum requirements for the testing of a
Batch Mixer Trailer (2003) with 2ea 50 bbl mixing tanks, twin Halliburton 6x5x11x11
centrifugal pumps, CAT C7 300 hp engine, Funk pump drive, Micromotion DL200
densometer with RFT9739 transmitter, Precision Digital loop-powered meter, and
Murphy PowerView.
ii. This test assumes the work will be performed by qualified technicians familiar with the
operation of the tested unit, the associated tools, and the equipment used in performing
the test. The test technician should read the entire procedure prior to starting. If there
are any questions concerning the test, please contact the Duncan Technology Center.
iii. This work is to be documented on test data sheet(s) at the end of this procedure by the
test technician(s) performing the work. Items in this test procedure that do not apply to
the unit being tested shall be indicated as being not applicable, “n/a”, in appropriate
locations on the test data sheet(s). This procedure is available in electronic format
through the Halliburton network and has been designed to enable manual or electronic
data entry.
b. Use the latest revision of the test
i. Retrieve latest version of the test procedure from matrix by the following procedure:
1. Open matrix checker and find the spec number of this document.
2. Open the latest revision to the specification that is in production release and print the specification.
3. Use the specification (test procedure) as a checklist to complete this testing.
2. UNIT INFORMATION
a. Operating and service standards for this unit.
MANUAL DESCRIPTION REF. NO.
Lubrication Standard 278.90538
Caterpillar C7 Service Manual 101502885
Caterpillar C7 Parts Manual 101502860
Funk Pump Drive Service Manual 100032617
Halliburton Centrifugal Manual 100003124
Alternator Service Manual 100047095
Alternator Parts Manual 100047096
Murphy PowerView Installation and Operations Manuel D00118626
Precision Digital Loop-Powered Meter Operations Sheet D00120037
b. General operating parameters for this unit.
Deck Engine - Cat, C7, 300 Bhp, 2100-2200 Rpm, Industrial, SAE 1 Flywheel Housing, ADEM 4, Dry Exhaust
Manifold, 13.2 CFM Air Compressor, EPA And CARB Tier 3 And EC Stage 3A Non-Road Emission
Certified
Description Min Typ Max

Low Idle Speed (Rpm) 690 700 710
Rated Engine Speed (Rpm) 2200
Top No Load Speed (Rpm) 2210 2220 2230
Overspeed Setting (Rpm) 2495
Coolant Temperature (F) 160 190 219
Oil Pressure At Rated Speed (psi) 36 47.9 87
Oil Pressure At Low Idle (psi) 5.9 23 87
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Max Fuel Supply Line Restriction (In. Hg) 4.1

Max Fuel Return Restriction (In. Hg) 20.7
NORMAL FUEL PRESSURE-CLEAN SYSTEM (PSI) 72.5
Max Air Cleaner Restriction Clean (In. H2O) 14.9
Max Air Cleaner Restriction Dirty (In. H2O) 30.1
Exhaust Restriction (In. H2O) 40.2
System Voltage (V) 9 14.5
Start Requirements (RPM) 150
Service Manual - Binder RENR9800 101502885

Parts Manual - Paperback SEBP4436 101502860
Engine S/N Prefix JTF
Hydraulic System Min Typ Max

Hydraulic Tank Capacity (gal) 30
Hydraulic Oil Temp (F) 160 180
RexRoth Pumps Charge (psi) 325 Stroked 350 Neutral
RexRoth Pumps Circuit (psi) 800 1600 3000
Eaton Pumps Charge (psi) 335 Stroked 360 Neutral
Eaton Pumps Circuit (psi) 2000 3500
Parker Gear Pump (psi) 1500
Hydraulic Cooler Fan (rpm) 2000
6x5 Pump Speeds (rpm) 1500 1900 Max on curve
Agitator Speed (rpm) 120
3. LUBRICATION PROCEDURE
a. Lubricate the unit and complete the lubrication table on the test data sheet.
b. Engine oil
i. Fill engine crankcase(s) to appropriate level on dipstick
ii. Four cycle engine oil, 15W-40, Halliburton part No.100001834 per lubrication standard,
Part No. 100053807
c. Fuel tank
i. Fill fuel tank(s) for testing
ii. Fill the fuel filter and purge all air from the system up to the inlet of the fuel pump.
iii. Off-road diesel, Part No. 100001739
d. Radiators
i. Fill Radiator(s) to the bottom of filler neck tube.
ii. The cooling systems for all units except those for Alaska and the North Slope are to be
filled with a 50% ethylene glycol / 50% water coolant mixture with freeze protection to
–34°F (-37°C) per Specification 70.85228. Add antifreeze to trailers for the North
Slope and Alaska to protect to –60°F (-51°C).
e. Hydraulic pump drive/Gear Box
i. Fill Pump Drive Gear Box to full level.
ii. SAE 90 gear lube, Halliburton Part No. 100026248 per lubrication standard, Part No.
100053807
f. Hydraulics
i. Fill hydraulic reservoir to full level.
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Date: 07/06/2007
ii. Verify that high pressure filters are installed for correct direction of flow and fill with
ATF.
iii. Fill charge and loop filters with ATF and verify that they are properly installed for
direction of flow.
iv. Check all valves, filters, backflow preventers, hoses, etc... for correct installation and
direction of flow.
v. Fill inlet hoses, hydraulic pumps, and motor cases.
vi. Open all valves on suction lines to supply all pumps with fluid
vii. Purge air from main drive pump suction line.
viii. Remove upper case drain hoses or fittings if necessary and fill all hydraulic pump
and motor cases, (equipped with a case drain connection), with hydraulic fluid.
ix. Loosen suction hoses at all hydraulic pumps until oil is present, this will allow air to
escape from suction hoses.
x. Re-tighten all hoses, fitting, and plugs.
xi. Prime all hydraulic pumps driven by the pump drive.
xii. Automatic Transmission Fluid Halliburton Part No. 100001835 per lubrication standard,
Part No. 100053807
g. Halliburton centrifugal pumps (6x5)
i. Fill the pump lube tank(s) with Automatic Transmission Fluid Halliburton Part No.
100001835 per lubrication standard, Part No. 100053807
ii. Do not grease mechanical seal.
iii. If using an oil lubricant or grease system for a lip seal , be sure that the lubricating
system is connected to the pump and operating properly. The oil system should be
pressured at 5 to 7 psi.
iv. With a hand-operated grease gun (Part No. 70.24620 - Cartridge), grease the bearings
with five shots of Marine Lube “A” or an equivalent. Make sure that the pump turns
freely by hand.
v. Caution—If heat buildup is excessive, reduce the amount of grease. Grease expands
when heated, increasing pressure on the pump.
h. Axle hubs
i. Fill to site glass level if low.
ii. Lubricant per lubrication standard (Part No. 100053807).
i. Install all required grease zerks and fill with lithium grease, Part No. 100026247 (i.e.
pillow block bearings, flange block bearings, drive shafts, landing legs and leveling
jacks, discharge chutes, and belt tensioners, augers, Lo-Torq valves etc….).
4. PRE-START INSPECTION
a. Inspect overall unit to verify wiring and hoses are properly routed, secured, and
protected. Bend radii must not be less than minimum bend radii recommendations
for the particular material.
i. Wiring is secured at approximately 2-foot intervals.
ii. Hoses are secured at approximately 4-foot intervals.
iii. Wiring and hose are clear of rotating components.
iv. Wiring and hoses are armored at wear or pinch points.
v. Wire and hose bends exceed minimum bend radii
vi. Wiring and hoses are protected from hot spots
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Date: 07/06/2007
vii. Wiring and hoses are shielded when going over sharp corners, contacting other rub
surfaces, near hot surfaces, and near rotating shafts.
b. Pump primer on the fuel filter and prime fuel system.
c. Connect suction hose(s) to water supply and provide water with a centrifugal pump.
d. Inspect unit for general hazards that could endanger personnel when the unit is
started:
i. Leaks
ii. Missed welds
iii. Loose nuts or bolts, (including drive line bolts)
iv. Misaligned connectors or shafts
v. Loose wires, cables, or hoses
vi. Deformed or cracked components
vii. Covers, lids or guards that are not properly installed,
viii. Loose chains, belts, or idlers.
ix. Check woods coupling for proper alignment.
x. Hydraulic components that are improperly installed, routed, or reversed.
xi. Pneumatic components that are improperly installed, routed, or reversed.
e. Check all fluid levels.
f. Verify that the battery cables are labeled with a Pos and Neg nameplate or color coded
cables and connected correctly.
g. Verify that all suction valves on hydraulic lines/tank, fuel lines/tank, water lines/tank
are open.
h. Verify that all quick-disconnects are properly tightened and secured.
i. Open all hydraulic valves to purge air from system.
j. Connect data recording devices, as appropriate to record pump discharge pressure
and suction pressures. Identify recording device (unipro, gauges, DAS,
thermocouples, pressure transducers) and calibration information on Test Data Sheet
(serial Number, Description, Last Cal, Next Cal).
5. INSPECTION AND ADJUSTMENTS
a. Ensure the Loop Flushing Valve on each set of the RexRoth hydraulic piping is
partially open. There are two per unit, one on each agitator circuit.
b. Adjust pressure regulator to maintain 5-7 psi in centrifugal pump lube tanks.
c. Adjust pressure regulator to maintain 90-100 psi for control valves.
d. Connect water supply hose to suction manifold of driver side prehydrator pump.
e. Connect data recording devices, as appropriate to record pump discharge pressure
and suction pressures. Identify recording device (unipro, gauges, DAS,
thermocouples, pressure transducers) and calibration information on Test Data Sheet
(serial Number, Description, Last Cal, Next Cal).
f. Verify that the Loop-Powered meter is installed correctly and connected to the power
supply.
i. Turn on, set-up and calibrate the density measuring system .
ii. Calibrate the low side (4mA) to air (0 LB per gal).
iii. Calibrate the high side (20mA) by driving a 20mA signal from a portable computing
device to the Loop-Powered meter and setting this as 26 LB per gal.
iv. Check 9.1384 mA to flowing water (approx. 8.35 LB per gal) at the end of step 7.
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Date: 07/06/2007
g. Complete setup and test of the DL200 per Test Specification D00252345
h. Verify that all suction valves on hydraulic lines/tank, fuel lines/tank, water lines/tank
are open.
i. Pump primer on the fuel filter and prime fuel system.
j. Engage the engine clutch.
6. Startup
a. Safety
i. Verify that personnel and equipment are clear of potentially moving or rotating
components and that all guards and shielding are properly installed.
ii. Verify that all lubrication has been completed and that supply valves from tanks and
reservoirs (fuel, hydraulic fluid, pump lube, etc) are open.
iii. Verify that muffler is properly positioned with exhaust ventilation system, and that
exhaust ventilation system is running.
b. Setup and Adjustment
i. Connect CAT Engine Technician (ET) diagnostic software to Engine.
1. Turn the main power on and correct all engine faults
2. Set all customer parameters to appropriate values.
3. Confirm that run/stop control switch, engine throttle controls, and emergency kill switches are
working correctly.
4. Test over speed verify switch (if included on equipment).
5. Set over speed verify to off or disable.
c. Starting Procedure
i. Turn the main power switch on at the control panel of the enclosure.
ii. Crank engine with the run/kill switch in the kill position until engine oil pressure gauge
indicates 3 to 5 psi.
iii. Start the engine.
iv. Observe Unit for Major leaks and shut down immediately if necessary.
v. Observe the engine oil pressure gauge. If the oil pressure does not rise to above 5.9 psi
within 15 seconds after the engine starts, shut the engine down and determine the cause.
vi. Observe hydraulic oil pressure gauge and shut down the engine within 30 seconds if the
hydraulic oil pressure is low.
d. Engine Package
i. Verify the following items with engine idling at approximately 1000 rpm.
1. Engine oil pressure is acceptable.
2. Low Idle speed is correct.
3. Rated speed is correct.
4. Top No Load Speed is correct.
5. Hydraulic oil pressure is acceptable on all pumps
6. All leaks have been corrected.
7. The charging system is operating correctly.
8. The radiator fan is blowing air through radiator.
9. All engine faults have been corrected.
10. Main and remote throttle controls are operational.
11. Main Emergency shutdown controls and remote emergency shutdown controls are operational.
12. Murphy PowerView is initialized per D00118626 (PowerView operating instructions) and correct
any faults displayed.
e. Verify operation of the engine gauges and controls.
i. System voltage gauge
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Date: 07/06/2007
ii. Engine oil pressure gauge.

iii. Tachometer
iv. System air pressure
v. Hydraulic oil pressure gauge.
vi. Engine water temperature gauge.
f. Calibrate tachometer(s) and set magnetic pickups if appropriate (for units with
programmable tachometers).
g. Warm-Up Period--Before applying a load or accelerating the engine to speeds above
1,000 rev/min, warm the engine up for at least 5 minutes at or below 1,000 rev/min.
The warm-up period allows the lubricating oil to circulate through the engine,
forming a protective film between the engine's moving parts. After the 5-minute
warm-up, increase the speed to 1,200 or 1,500 rev/min, and allow the engine to reach
an operating temperature of 170° to 195°F (77° to 91°C).
h. Over speed System Test--To test the over speed system on the Cat C7, engage the 75%
VERIFY OVERSPEED switch in the control stand. When the engine speed reaches
75% of the speed set in the ECM (approximately 1,650 rev/min), the engine should
stop. This test verifies that the over speed is working properly. Move the switch back
to its normal position to return the engine to the normal working mode and restart
engine and idle it.
i. An emergency kill toggle switch is included on the control stand for the auxiliary
engine. When engaged, the switch will kill the engine.
i. Warning--Do not use the emergency kill toggle switch except in emergency situations
or a situation in which the normal method of shutting off the engine fails. In certain
circumstances, using the emergency kill toggle switch can severely damage the engine.
j. At the control stand, be sure all air-actuated valves are working properly. Although
the controls are moving, the valves may not be. Have someone check the valves as you
open and close the control levers. You should be able to fully open and fully close the
valves.
i. Open and close the hand operated valves and ensure they function properly.
ii. Close all external valves.
k. Fill batch mixing tubs 1/2 full of water.
l. Turn on water supply line.
m. With the water supply hose connected and flowing and tanks 1/2 full, bleed air from
suction manifold and discharge manifold by manipulating valves in plumbing while
supplying water.
i. Close all external valves.
n. Check all work lights.
7. Hydraulic System Startup
a. Check oil level in hydraulic reservoir often and refill as needed.
b. At control panel, place all hydraulic systems in the off position.
c. With the centrifugal pumps and agitators in the off or neutral position, disengage the
clutch and allow hydraulic system to warm up.
d. Observe charge pressure gauges for prehydrator pump, recirculation pump, front
agitator, and rear agitator circuits for indication of charge pressure. Charge pressure
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Date: 07/06/2007
should start showing on the gauges within 30 seconds after disengaging clutch. If not,
shut down engine and check plumbing and pump rotation.
e. If charge pressure is indicated, leave at idle with stroke controls in the neutral or off
position until air is purged from the system indicated by a steady reading on gauge.
f. Verify that the oil pressure gauge on the engine is reading the appropriate oil
pressure. Allow the oil to circulate and the engine to warm itself for at least 10
minutes.
g. After 10 minutes, verify that the water temperature is adequate (minimum 170°F and
that the alternator is outputting the correct voltage.
h. Increase the throttle to full speed (2200 RPM).
i. The charge pressure for the centrifugal pump circuits should be within the following
ranges:
i. charge pressure in neutral (minimum) = 350 to 370 psi
ii. charge pressure in stroked position (minimum) = 325 to 345 psi
1. If the charge-pressure setting is not acceptable in neutral, adjust the charge relief in the pump. If the
charge pressure setting is not acceptable in the stroked position, adjust the pressure-relief in the
hydraulic motor.
j. Stroke the prehydrator pump slightly and check for proper rotation of the pump.
i. Prime centrifugal pump (run with water only during this testing, and do not operate
without water in the suction lines.)
1. Ensure water supply line is engaged and flowing.
ii. The proper orientation of the stroke control is forward to engage and back to neutral.
iii. Adjust the stroke-control neutral-position lock screw to prevent the valve from passing
the center position.
iv. If the centrifugal pump rotation is incorrect, determine the cause as per the engineering
drawing and correct the problem accordingly.
k. Stroke the recirculation pump slightly and check for proper rotation of the pump.
i. Prime centrifugal pump (run with water only during this testing, and do not operate
without water in the suction lines.)
1. Ensure water supply line is engaged and flowing.
ii. The proper orientation of the stroke control is forward to engage and back to neutral.
iii. Adjust the stroke-control neutral-position lock screw to prevent the valve from passing
iv. If the centrifugal pump rotation is incorrect, determine the cause as per the engineering
drawing and correct the problem accordingly.
l. To allow air to escape from the loop, stroke the pumps in gradual increments a few
times before reaching full stroke.
i. All air has been purged when the charge-pressure reading is steady.
m. The charge pressure for the agitator pump circuits should be within the following
ranges:
i. charge pressure in neutral (minimum) = 340 to 360 psi
ii. charge pressure in stroked position (minimum) = 315 to 335 psi
1. If the charge-pressure setting is not acceptable in neutral, adjust the charge relief in the pump. If the
charge pressure setting is not acceptable in the stroked position, adjust the pressure-relief in the
hydraulic motor.
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Date: 07/06/2007
n. Once air is bleed from the system fully close the Loop Flushing Valve on each set of
the RexRoth hydraulic piping. There are two per unit, one on each agitator circuit.
o. Stroke the front agitator pump slightly and check for proper rotation of the agitator.
i. The proper orientation of the stroke control is forward to engage and back to neutral.
ii. Adjust the stroke-control neutral-position lock screw to prevent the valve from passing
iii. Verify that the correct agitators are installed on the correct hydraulic motor. Each tank
contains two different configurations of agitators. Check agitator rotation and correct
installation of agitator to each motor. See engineering drawing D00100801, sheet 7 of
7. The correct rotation is clock wise as viewed from above looking down on the
agitator and the fluid should be pushed down.
p. Stroke the rear agitator pump slightly and check for proper rotation of the agitator.
i. The proper orientation of the stroke control is forward to engage and back to neutral.
ii. Adjust the stroke-control neutral-position lock screw to prevent the valve from passing
iii. Verify that the correct agitators are installed on the correct hydraulic motor. Each tank
contains two different configurations of agitators. Check agitator rotation and correct
installation of agitator to each motor. See engineering drawing D00100801, sheet 7 of
7. The correct rotation is clock wise as viewed from above looking down on the
agitator and the fluid should be pushed down.
q. To allow air to escape from the loop, stroke the pump in gradual increments a few
times before reaching full stroke.
i. All air has been purged when the charge-pressure reading is steady.
r. When the charge pressures are steady and while a technician watches the gauge,
slowly open the Loop Flushing Valve on each set of the RexRoth hydraulic piping till a
50 psi drop is seen in each charge pressure. There are two per unit, one on each
agitator circuit.
s. Check oil level in hydraulic reservoir and refill as needed.
8. Function Test
a. Ensure engine speed is set to 2,200 rev/min.
b. Engage the DS 6x5 centrifugal pump, circulate water at maximum speed and finish
filling the front mixing tank.
i. Record centrifugal pump system pressure on test sheet.
c. Record the discharge pressure of the centrifugal pump while circulating water.
i. The minimum acceptable performance at “open” conditions is:
1. 6 X 5 PUMP – 15-25 PSI.
ii. Measure bearing/seal temperature(s) on pump with infrared thermometer on 5 minute
intervals. Record measured values on test data sheet.
iii. After bearing/seal temperature(s) have stabilized for three measurements (10 minutes),
record full open flow rate, discharge pressure, bearing/seal temperature(s), engine rpm,
engine temperature, engine oil pressure and system voltage.
d. Close the valves on the discharge side of the centrifugal pump after the pressure
gauge, and record the closed-in pressure.
i. Caution: Do not operate the pump closed-in for more than one minute at a time.
ii. Open the discharge valves
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Date: 07/06/2007
iii. The minimum acceptable performance at “closed-in” conditions is:

1. 6 X 5 PUMP – 35-50 PSI.
iv. If the minimum closed-in pressure cannot be obtained contact the vendor for appropriate
adjustments to be made.
v. When pump performance requirements are met, record the “Open” and the “closed–in”
water pressures on the test data sheet.
e. Disengage the DS 6x5 centrifugal pump
f. Engage the PS 6x5 centrifugal pump, circulate water at maximum speed and finish
filling the rear mixing tank.
g. Record the discharge pressure of the centrifugal pump while circulating water.
1. 6 X 5 PUMP – 15-25 PSI.
ii. Measure bearing/seal temperature(s) on pump with infrared thermometer on 5 minute
iii. After bearing/seal temperature(s) have stabilized for three measurements (10 minutes),
h. Close the valves on the discharge side of the centrifugal pump after the pressure
1. 6 X 5 PUMP – 35-50 PSI.
i. With the engine speed at 2,200 rev/min, engage both centrifugal pumps fully and
increase the speed of the tub agitators to full rpm. Run the system under these
conditions for at least 30 minutes, and fully heat up the engine.
i. Caution: Observe For An Unusual Or Excessive Vibration. If present, shut down the
system.
ii. When beginning test record speed of the loaded engine on test sheet.
iii. Record stroked charge pressures on test sheet.
iv. Record all system pressures on test sheet.
v. Measure bearing/seal temperature(s) on pump with infrared thermometer on 5 minute
vi. Measure and record temperature of all tub agitator hydraulic motors.
1. Operating ranges:
a. 120-125 °F Winter
b. 140-145 °F Summer
vii. After bearing/seal temperature(s) have stabilized for three measurements (10 minutes),
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Date: 07/06/2007
viii. Record agitator speed of each of the four agitators in both the front tank and rear
tank. Record the speed of the agitators. Agitator speeds should not deviate by more
than 15% from the slowest to the fastest agitator. Observe system pressure gauge.
Observe system pressure gauge and note if the hydraulic system surges or hunts for a
system pressure. If this condition occurs, note the severity and compare to the
performance once the oil is heated to operating temperature.
j. System Test Precautions to Watch during the Fully Loaded 30-Minute Run
i. During the 30-min test run, take the following precautions to ensure proper operation.
1. Keep the hydraulic reservoir filled to the full mark, and continually observe the system connections
for leaks.
2. Watch and listen for cavitation noises at hydraulic pumps.
3. Tighten all hoses that appear to leak any hydraulic fluid. Hoses that are not sufficiently tightened will
loosen even more when delivered to location, resulting in serious leaks when received by the field
location.
4. Ensure that the hydraulic temperature does not exceed 180°F.
5. With the system warm, check the hoses at the heat exchanger to make certain that oil is not bypassing
the heat exchanger.
6. Make certain that the arrow on the cooler check valve points from the inlet to the outlet line.
7. Check the filter bypass indicators for the bypass condition and change the elements if the bypass is
indicated or a major failure occurs on the system.
8. Check all low-pressure piping on the suction and discharge side of the centrifugal pumps. Correct
leaks at valve, victaulic connections, or welded joints.
k. Record speed of agitators on test sheet. (min 120 rpm)
l. After operating the system for 30 minutes and while fully loaded, record the hydraulic
oil pressure, water temperature, engine speed, air pressure, and voltmeter reading for
the engine.
m. Record the hydraulic oil temperature from the gauges in the case drain lines of the
hydrostatic pumps and the temperature of the oil in the reservoir.
n. Unload the engine and record speed on test sheet.
o. Follow proper system shutdown procedures.
p. Check the following fluid levels.
i. Engine crank case
ii. Hydraulic tank
iii. Fuel tank
iv. Radiator
q. Grease all zerks with lithium grease, Part No. 100026247.
9. Performance Test
a. This performance test allow the thermal cycling of the system since shutdown prior to
the road test being completed.
b. Complete inspections, adjustments and startups as stated above.
c. After 10 minutes, verify that the engine water temperature is adequate (minimum
170°F and that the alternator is outputting the correct voltage.
d. Ensure the hydraulic system is warmed up prior to running test.
e. Ensure engine speed is set to 2,200 rev/min.
f. Engage the DS 6x5 centrifugal pump and circulate water at maximum speed.
g. Record the discharge pressure of the centrifugal pump while circulating water.
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Date: 07/06/2007

1. 6 X 5 PUMP – 15-25 PSI.
h. Close the valves on the discharge side of the centrifugal pump after the pressure
1. 6 X 5 PUMP – 35-50 PSI.
i. Disengage the DS 6x5 centrifugal pump
j. Engage the PS 6x5 centrifugal pump and circulate water at maximum speed.
k. Record the discharge pressure of the centrifugal pump while circulating water.
1. 6 X 5 PUMP – 15-25 PSI.
l. Close the valves on the discharge side of the centrifugal pump after the pressure
1. 6 X 5 PUMP – 35-50 PSI.
m. With the engine speed at 2,200 rev/min, engage both centrifugal pumps fully and
increase the speed of the tub agitators to full rpm. Run the system under these
conditions for at least 30 minutes, and fully heat up the engine.
i. Caution: Observe For An Unusual Or Excessive Vibration. If present, shut down the
system.
ii. When beginning test record speed of the loaded engine on test sheet.
iii. Record stroked charge pressures on test sheet.
iv. Record all system pressures on test sheet.
v. Measure bearing/seal temperature(s) on pump with infrared thermometer on 5 minute
vi. After bearing/seal temperature(s) have stabilized for three measurements (10 minutes),
vii. Measure and record temperature of all tub agitator hydraulic motors.
1. Operating ranges:
a. 120-125 °F Winter
b. 140-145 °F Summer
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Date: 07/06/2007
viii. Record agitator speed of each of the four agitators in both the front tank and rear
tank. Record the speed of the agitators. Agitator speeds should not deviate by more
than 15% from the slowest to the fastest agitator. Observe system pressure gauge.
Observe system pressure gauge and note if the hydraulic system surges or hunts for a
system pressure. If this condition occurs, note the severity and compare to the
performance once the oil is heated to operating temperature.
n. System Test Precautions to Watch during the Fully Loaded 30-Minute Run
i. During the 30-min test run, take the following precautions to ensure proper operation.
1. Keep the hydraulic reservoir filled to the full mark, and continually observe the system connections
for leaks.
2. Watch and listen for cavitation noises at hydraulic pumps.
3. Tighten all hoses that appear to leak any hydraulic fluid. Hoses that are not sufficiently tightened will
loosen even more when delivered to location, resulting in serious leaks when received by the field
location.
4. Ensure that the hydraulic temperature does not exceed 180°F.
5. With the system warm, check the hoses at the heat exchanger to make certain that oil is not bypassing
the heat exchanger.
6. Make certain that the arrow on the cooler check valve points from the inlet to the outlet line.
7. Check the filter bypass indicators for the bypass condition and change the elements if the bypass is
indicated or a major failure occurs on the system.
8. Check all low-pressure piping on the suction and discharge side of the centrifugal pumps. Correct
leaks at valve, victaulic connections, or welded joints.
o. Record speed of agitators on test sheet. (min 120 rpm)
p. After operating the system for 30 minutes and while fully loaded, record the hydraulic
oil pressure, water temperature, engine speed, air pressure, and voltmeter reading for
the engine.
q. Record the hydraulic oil temperature from the gauges in the case drain lines of the
hydrostatic pumps and the temperature of the oil in the reservoir.
r. Unload the engine and record speed on test sheet.
s. Follow proper system shutdown procedures.
t. Check the following fluid levels.
i. Engine crank case
ii. Hydraulic tank
iii. Fuel tank
iv. Radiator
u. Grease all zerks with lithium grease, Part No. 100026247.
10.COMPLETE ROAD TEST PROCEDURE (Specification D00113295)
11.COMPLETE FINAL INSPECTION TEST PROCEDURE (Spec D00113918).
12.ACCEPTANCE CERTIFICATION
a. Review Recent Service Bulletins for this unit type and verify that all known issues
have been corrected on this unit.
b. Identify any components or systems of this unit that were not accepted, tested or
corrected or that did not meet the performance requirements identified in this
procedure or otherwise known as exceptions in the Acceptance Certification Section.
c. Fill in Signatory fields of the Acceptance Certification.
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Date: 07/06/2007
WARNING: THIS IS A NON-CONTROLLED DOCUMENT

ENSURE VIA MATRIX THE USE OF CURRENT DOCUMENTATION!
Unit Serial Number Part Number

Production Order Number Material Number
Equipment Number Batch Number
Model Number Date
Service: Offshore Land Both
Trailer Duty: Standard Severe Specific Other
3 Lubrication (Ensure the following are lubricated/filled properly)

Engine
Fuel
Radiator
Funk pump drive
Hydraulic reservoir
Hydraulic pumps, motor cases, lines, coolers, filter housings
Centrifugal pumps
Axle hubs
Grease zerks
4 Pre-Start Inspection
Wiring is secured at approximately 2-foot intervals.
Hoses are secured at approximately 4-foot intervals.
Wiring and hoses are clear of rotating components.
Wiring and hoses are armored at wear or pinch points.
Wire and hose bends exceed minimum bend radii.
Wiring and hoses are protected from hot spots
Wiring and hoses are shielded when going over sharp corners, contacting other rub surfaces,
near hot surfaces, and near rotating shafts.
Inspect for the following hazards
Leaks
Missed welds
Loose nuts or bolts, (including drive line bolts)
Misaligned connectors or shafts
Loose wires, cables, or hoses
Loose chains, belts, or idlers.
Deformed or cracked components
Covers, lids or guards that are not properly installed
Check woods couplings for proper alignment.
Battery cables properly labeled
5 Inspection And Adjustments

Packing lube tank pressure (psi)
Control valve pressure (psi)
Complete setup and test of the DL200 per Test Specification D00252345
Loop-Powered meter reading for air
Loop-Powered meter reading for water (complete when water is flowing through system)
Densometer on/off switch works
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Date: 07/06/2007
TEST INSTRUMENTS
TI # Description (DAS, Gauge, Unipro) Serial No. Last Cal Cal Due
1
2
3
4
6 STARTUP, INSPECT, ADJUST

Inspect engine gauges, control stand gauges and controls for proper operation
All engine faults corrected
All customer parameters set
Run/Stop control switch functions
Engine throttle controls function
Emergency kill switches function
Over speed switch functions
At 1000 RPM check and record the following
Control Stand
Engine Oil Pressure psi
Engine Water Temp °F
Charging System Volts
System air gauge
Tachometer
Engine idle speed rpm
Hydraulic Oil pressures gages
Engine over speed is Set/Functions
Engine maximum no load speed is set
Throttle linkage and over speed kill linkage connected
Unit Void of Oil Leaks
Air Operated valves work correctly and position matches that on the control panel
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
Hand operated valves operate correctly
1 2 3 4 5 6
Tank and Work lights operate correctly
1 2 3 4 5 6 7 8 9 10 11 12
7 SETUP AND ADJUST HYDRAULICS/AGITATORS

Air Bleed Off
PS 6x5 Pump charge pressure set (psi)
DS 6x5 Pump charge pressure set (psi)
Pumps Primed
DS Pump Speed Set (rpm)
PS Pump Speed Set (rpm)
PS 6x5 Pump system pressure (psi)
DS 6x5 Pump system pressure (psi)
Agitators are correctly configured in each tank.
Agitators are rotating in a clockwise direction as seen from above looking down
Front agitator neutral charge pressure (psi) prior to opening loop flushing valve
Rear agitator neutral charge pressure (psi) prior to opening loop flushing valve
14 of 20
Date: 07/06/2007
Front agitator neutral charge pressure (psi) after opening loop flushing valve
Rear agitator neutral charge pressure (psi) after opening loop flushing valve
Front agitator stroked charge pressure (psi) after opening loop flushing valve
Rear agitator stroked charge pressure (psi) after opening loop flushing valve
8 Function Test
PUMP TEST RESULTS DS
Record average values for listed parameters during each run in the spaces provided below.
Flow Condition Full Flow Closed In
Bearing/Seal Temp (°F)
Discharge Rate ( GPM )
Discharge Pressure (psi)
Charge pressure (psi)
System pressure (psi)
Engine Speed (rpm)
Engine Temperature (°F)
Engine Oil Pressure (psi)
System Voltage (V)
PUMP TEST RESULTS PS
Engine Speed (rpm)
System Voltage (V)
8 Function Test
Start of 30 Minute Test Run
Engine speed unloaded (rpm)
Engine speed loaded (rpm)
DS Centrifugal stroked charge pressure loaded (psi)
PS Centrifugal stroked charge pressure loaded (psi)
Front agitator stroked charge pressure loaded (psi)
Rear agitator stroked charge pressure loaded (psi)
DS Centrifugal system pressure loaded (psi)
PS Centrifugal system pressure loaded (psi)
Front agitator system pressure loaded (psi)
Rear agitator system pressure loaded (psi)
DS Centrifugal pump speed loaded (rpm)
PS Centrifugal pump speed loaded (rpm)
Maximum tub agitator speed (rpm) Front #1
Maximum tub agitator speed (rpm) Rear #1
15 of 20
Date: 07/06/2007

Tub agitator motor Temperature (F) Front #1
Tub agitator motor Temperature (F) Rear #1
Full Flow Flow Condition
Engine Speed (rpm)
System Voltage (V)
End of 30 Minute Test Run

DS Centrifugal circuit pressure loaded (psi)
PS Centrifugal circuit pressure loaded (psi)
Front agitator circuit pressure loaded (psi)
Rear agitator circuit pressure loaded (psi)
16 of 20
Date: 07/06/2007

System Voltage (V)
9 Road Test
Road Test (D00113295) completed.
10 Performance Test

Engine Speed (rpm)
System Voltage (V)
17 of 20
Date: 07/06/2007
Engine Speed (rpm)

System Voltage (V)
8 Function Test
Start of 30 Minute Test Run
DS Centrifugal system pressure loaded (psi)
PS Centrifugal system pressure loaded (psi)
Front agitator system pressure loaded (psi)
Rear agitator system pressure loaded (psi)
Engine Speed (rpm)
18 of 20
Date: 07/06/2007

System Voltage (V)
End of 30 Minute Test Run

DS Centrifugal circuit pressure loaded (psi)
PS Centrifugal circuit pressure loaded (psi)
Front agitator circuit pressure loaded (psi)
Rear agitator circuit pressure loaded (psi)
System Voltage (V)
19 of 20
Date: 07/06/2007
11 Final Inspection
Final Inspection (D00113918) completed.
ACCEPTANCE CERTIFICATION
I certify by signature below:
The above testing has been completed and this unit performed in accordance with established criteria described
herein and/or known to me with exceptions as noted below.
I have reviewed recent Service Bulletins for this unit type and have corrected all known issues on this unit.
I have identified all components or systems of this unit that were not accepted, tested or corrected or that did not
meet the performance requirements of this procedure or otherwise known to me as exceptions below.
Exceptions: Reason Accepted:
Printed Name Signature Date

Test Tech 1
Test Tech 2
Test Tech 3
Test Tech 4
20 of 20
Halliburton Energy Services Specification D00113295 Revision A
Tested Unit: Unit Road Testing
Duncan, OK Date: 7/29/03
1. TEST INFORMATION
i. This test procedure is intended to identify the minimum requirements for the Road
Testing of a unit. This test assumes the work will be performed by qualified technicians
familiar with the operation of the unit and the tools and equipment used in performing
the test. The test technician should read through the entire procedure prior to starting.
If there are any questions concerning the test, please contact the Duncan Technology
Center.
ii. At any time during the performance of this test, should the operator of the pulling
vehicle feel or see an item of safety concern, this test is to be immediately terminated
and the vehicle pulled off the road and proper safety precautions taken.
iii. This testing is to be completed prior to the performance testing being completed. The
driver should be aware of and obey all laws, rules, and regulations applicable to this
testing. The purpose of this testing is to:
1. Verify the proper installation and operation of lighting.
2. Verify that the trailer is road worthy.
3. Confirm that all components are properly secured so that normal loads incurred while roading the
unit will not prevent the unit from catching a job.
iv. This work is to be documented on test data sheet(s) at the end of this procedure by the
test technician(s) performing the work. Items in this test procedure that do not apply to
the unit being tested shall be indicated as being not applicable, “n/a”, in appropriate
locations on the test data sheet(s). This procedure is available in electronic format
through the Halliburton network and has been designed to enable manual or electronic
data entry.
2. UNIT INFORMATION
MANUAL DESCRIPTION PART NO.
3. LUBRICATION PROCEDURE
a. Trailer Axles
i. Fill to site glass level if low.
ii. Lubricant per Lubrication Standard (Part No. 100053807).
b. Install grease zerks and fill with lithium grease, Part No. 100026247
i. Slack adjusters.
ii. Walkway support bearings.
iii. Manifold supports.
iv. Trailer jacks.
v. Any other zerks called out in the appropriate drawings.
4. Test setup
a. Connect trailer to tractor.
b. Remove any test equipment, tools, and etc.
1 of 8
c. Verify that the wheel bearings lubricant level is at the oil level mark on the hubcap
sight glass.
d. Verify that the trailer is equipped with a hub odometer.
e. Verify brake chamber rod travel less than 2 inches.
f. Verify that air is exhausted from air ride suspension air spring when spring brakes
are applied, if applicable.
g. Confirm dot brake hose has been installed.
h. Confirm anti-lock brake system (ABS) installed.
i. Check tire pressure. For standard tires, inflate to pressure listed on the fmvss tag.
For trailers equipped with 24R21 desert tires, inflate to 60 psi for highway operation
(40 mph maximum highway speed).
j. Verify ride height/leveling valve adjustment operation.
k. Re-torque lug nuts to appropriate torque for type of wheel.
l. Test landing gear operation.
m. Verify underide protection compliance.
n. Inspect trailer for loose items and etc and secure/remove as appropriate.
o. Assure that the fire extinguisher, first aid kit, and flare kit reported on the vehicle are
as required on the assembly drawing and stowed in an accessible location.
5. ADJUST BRAKES.
a. Manual type slack adjusters.
i. Wheel off the ground method (preferred method). Position wrench or socket over the
adjusting screw and disengage the locking sleeve by depressing the lock sleeve. Turn
the adjusting screw with the locking sleeve depressed until the brakes begin to drag.
Adjustment should then be backed off until the wheel turns freely. This will result in an
actuator stroke as short as possible without the brakes dragging. When the adjustment
is completed, the adjusting screw nut should be positioned so the locking sleeve engages
the adjusting screw nut, thus locking the adjusting screw in place. Do not attempt to
turn the adjusting screw without fully depressing the lock sleeve.
ii. Wheel on the ground method. Turn adjusting screw by using above procedure for
depressing the lock sleeve until the brake lining firmly contacts the brake drum. The
adjusting screw should then be backed off 3/4 of a turn.
b. Automatic type.
i. Apply and release the vehicle brake several times. Observe that the automatic slack
adjuster and its external components move freely and without binding.
ii. Observe the brake chamber stroke or the distance the brake chamber rod moves when a
service brake application is made. With the brake chamber push rod fully retracted, the
brakes must be completely released. In the applied position, the brake chamber stroke
should not exceed 2 inches.
iii. If automatic adjustor needs readjusting, it can be done manually.
6. CHECK FOR POSSIBLE SUSPENSION AND BRAKE CHAMBER
INTERFERENCE AND SUFFICIENT TIRE CLEARANCE.
a. Spring suspension.
i. Perform a visual inspection for loose bolts, nuts, and u-bolts. Also, check all welded
areas.
2 of 8
ii. On hutch suspensions, make sure all the alignment plates are welded located at the
spring seat/axle area.
b. Air suspension.
i. Check for interference between the air bag and the brake chamber clamp. Perform a
visual inspection of the shock bolts, air leveling valve, air connection and all welds for
loose or incorrect installation. Check the air system for leaks and the air suspension is
set at their proper ride height. Make sure that all of the adjustment collars on the frame
brackets are welded (four per suspension).
7. AIR SYSTEM
a. With trailer brake system air supply connected, check for air system leaks.
b. Check that air brake hose does not rub cross members or other components.
c. Brake systems checks
i. Place scotch blocks
1. Air compressor governor test with trailer connected
* Governor cut-in (approx. 98 psi)
* Release parking brake
* Governor cutout (approx. 118 psi)
2. Perform a brake leakage test with governor at its cut out setting and engine not running.
*Brakes off Allowable loss
Tractor-Trailer 3 psi/min. 6 psi/2 min.
*Brakes on
Tractor-Trailer 3 psi/min. 6 psi/2 min.
3. Emergency system test (start engine)

a. Tractor protection valve control (switch line to emergency-emergency line should go limp, then
switch line back to normal) if air loss is more than the allowable, isolate the cause and correct
the problems.
d. Brake performance test(pick up scotch blocks and idle off)
i. Spring brakes (set brakes and idle against them. Vehicle should not move.)
ii. Trailer hand brake (roll forward and stop vehicle with trailer brakes)
iii. Service brakes (roll forward and stop vehicle with service brakes)
8. INSPECT LIGHTING
a. Check trailer chassis lighting. Confirm all required lamps are present, correct color
and operational.
b. Complete light inspection section of test data sheet.
i. STOP, TAIL, AND TURN LAMPS - RED
ii. LICENSE PLATE LAMP - WHITE
iii. REAR SIDE MARKER LAMPS - RED
iv. REAR CLEARANCE LAMPS - RED
v. INTERMEDIATE SIDE MARKERS - AMBER
vi. FRONT SIDE MARKERS - AMBER
vii. FRONT CLEARANCE LAMPS - AMBER
viii. REAR IDENTIFICATION LAMP CLUSTER - RED
ix. REAR REFLEX REFLECTORS - RED
x. REAR SIDE REFLEX REFLECTORS - RED
3 of 8
xi. INTERMEDIATE SIDE RELEX REFLECTORS - AMBER

xii. FRONT SIDE REFLEX REFLECTORS - AMBER
xiii. ABS INDICATOR LAMP – AMBER
9. FIFTH WHEEL TEST
a. Platform lock.
i. Place fifth wheel lock control in cab
1. To "unlock" position. Check for lock pins fully disengaged. Manually move fifth wheel platform
assembly full travel force and aft to check for free movement with no binding.
2. Place fifth wheel lock control switch to "lock" position and check platform lock pins for full
engagement.
b. Trailer brakes.
i. Apply hand control. Air will release from control hose according to amount of valve
applied.
ii. Apply foot brake. Air will release from control hose according to amount of pressure
applied.
10.Road Test
a. Road test must be conducted by person possessing appropriate valid driver’s license.
i. Pull trailer in yard and hard brake in yard at low speed (less than 10 mph).
ii. Verify ABS fault light is visible, operational, and that there are no ABS faults before
road testing.
iii. Pull trailer down designated route at normal speeds. Driver shall obey all traffic laws
and regulation during testing.
iv. Verify operation of service brakes.
v. Confirm that trailer off tracking is less than 1.50 inches.
vi. Hard brake at least two times after ensuring that there is no vehicles in the vicinity that
could be endangered by this action.
vii. Road approximately five (5) miles.
viii. Identify and record any unusual vibrations, noises, or conditions.
ix. Stop and complete 5 mile inspection
b. Five mile inspection
i. Verify operation of parking brakes.
ii. Check hub temperatures and brake drum temperatures with an infrared thermometer and
record on test data sheet.
iii. Check for wheel seal leaks on the inside and outside of each wheel.
iv. Inspect trailer for anything loose or out of the ordinary.
v. Pull trailer an additional 5 miles (minimum).
vi. Stop and complete ten mile inspection
c. Ten mile inspection
i. Inspect trailer for anything loose or out of the ordinary.
ii. Record hub and brake drum temperatures from the road test.
iii. Check for wheel seal leaks on the inside and outside of each wheel.
iv. Inspect trailer for anything loose or out of the ordinary.
v. Complete designated route and return trailer to test facility.
vi. Check for wheel seal leaks on the inside and outside of each wheel.
vii. Report any necessary repairs, unusual vibrations, noises, and or conditions to the test
technician responsible for this unit.
4 of 8
11.ACCEPTANCE CERTIFICATION
b. Identify any components or systems of this unit that were not accepted, tested, or
c. Fill in Signatory fields of the Acceptance Certification.
5 of 8


Model Number Date
3 LUBRICATION
QTY Component Lubricant Estimated QTY
Trailer Axle Lubricant SAE 90 Gear Lube, 100016248 Fill
Walkway Supports Lithium Grease, 100026247 Fill
Manifold Supports Lithium Grease, 100026247 Fill
Pump Mounts Lithium Grease, 100026247 Fill
Trailer Jack Lithium Grease, 100026247 Fill
4 ADJUSTMENT AND INSPECTION

Hub odometer is present
Brake chamber rod travel less than 2 INCHES.
Air is exhausted from air ride suspension air spring when spring brakes are applied.
DOT brake hose has been installed.
Anti-lock brake system has been installed.
Tire pressure is acceptable.
Ride height/level valve adjustment is operational.
Lug nuts are properly torqued
Landing gear is acceptable.
Underide protection is acceptable.
No loose items on trailer.
Trailer brakes correctly.
ABS Fault Light is visible and operational and there are no ABS faults.
Service Brakes are operational
Trailer off tracking is less than 1.5 inches.
No unusual noises, vibrations or conditions concerning the trailer roading performance.
Bumper marking conspicuity (reflective tape) treatment installed.
Side marking conspicuity (reflective tape) treatment installed.
Decals, labels and unit number applied
Vehicle certification nameplate properly attached to the trailer.
Nameplate visible without removing equipment.
The required data is stamped on the certification nameplate
7 AIR SYSTEM
No air leaks present
All lines clear trailer members
Brakes hold vehicle in place
8 TRAILER LIGHTS INSPECTION

Stop, tail, and turn lamps Red
License plate lamp White
Rear side marker lamps Red
Rear clearance lamps Red
6 of 8
Intermediate side markers Amber

Front side markers Amber
Front clearance lamps Amber
Rear identification lamp cluster Red
Rear reflex reflectors Red
Rear side reflex reflectors Red
Intermediate side reflex reflectors Amber
Front side reflex reflectors Amber
Abs indicator lamp Amber
9 FITH WHEEL TEST

Platform Locks.
Pins fully engaged.
10 HUB AND BRAKE DRUM TEMPERATURES (MEASURE WITH INFRARED THERMOMETER)

HUB TEMP DRUM TEMP TEST LOCATION
(F) (F)
FRONT DRIVER AT 5 MILE STOP
REAR DRIVER AT 5 MILE STOP
FRONT PASSENGER AT 5 MILE STOP
REAR PASSENGER AT 5 MILE STOP
FRONT DRIVER AT 10+ MILE STOP
REAR DRIVER AT 10+ MILE STOP
FRONT PASSENGER AT 10+ MILE STOP
REAR PASSENGER AT 10+ MILE STOP
11 ACCEPTANCE
No wheel seal leaks present.
Off road testing completed.
Problems Identified During the Road Testing.

1
2
3
4
5
6
7 of 8
1. The above testing has been completed and this unit performed in accordance with
established criteria described herein and/or known to me with exceptions as noted
below.
2. I have reviewed recent Service Bulletins for this unit type and have corrected all
known issues on this unit.
3. I have identified all components or systems of this unit that were not accepted,
tested, or corrected or that did not meet the performance requirements of this
procedure or otherwise known to me as exceptions below.

Test Tech 1
Test Tech 2
Test Tech 3
Test Tech 4
8 of 8
Tested Unit: Final Inspection
1. TEST INFORMATION
i. This test procedure is intended to identify the minimum requirements for a Unit’s Final
Inspection. This test assumes the work will be performed by qualified technicians
familiar with the operation of the unit and the tools and equipment used in performing
the test. The test technician should read through the entire procedure prior to starting.
If there are any questions concerning the test, please contact the Duncan Technology
Center.
ii. This testing shall be completed as the final step of all testing/painting processes. This
testing is to confirm that the unit has not been damaged during painting, all tape and
adverse overspray has been removed, any parts removed for painting or repairs were
properly reattached, and to install all required certifications and manufacturers labeling
for release to the field.
iii. This work is to be documented on test data sheet(s) at the end of this procedure by the
test technician(s) performing the work. As this is a general testing procedure, items in
this test procedure that do not apply to the unit being tested shall be indicated as being
not applicable, “n/a”, in appropriate locations on the test data sheet(s). This procedure
is available in electronic format through the Halliburton network and has been designed
to enable manual or electronic data entry.
2. UNIT INFORMATION
MANUAL DESCRIPTION PART NO.
3. INSPECT VEHICLE
a. General
i. Hoses protected from sharp edges.
ii. Hose end tie straps cut.
iii. Check overall appearance of paint.
iv. Confirm that all masking tape, paint shielding and etc. have been removed.
v. Confirm that all items removed for final painting were properly installed and operate
correctly.
vi. Confirm that all loose equipment has been installed and secured (see specific assembly)
i.e. walkways, ladders, high pressure iron, manifold caps, rain caps, etc.
vii. Confirm that all guards, shielding, and flaps are properly installed.
viii. Replace hydraulic filter elements.
ix. Confirm that all fluid levels are acceptable.
x. Confirm that unit is fueled.
xi. Confirm that there are no visible leaks.
xii. Confirm that manifolds and tanks are free of water.
xiii. Confirm that all wheel lugs are properly torqued.
1 of 4
b. Functional Test
i. Power up controller, start engine(s) and run through all gears (manifold does not need to
be connected for this testing).
ii. Verify that all components and controls work properly.
iii. Run Engine at high idle with transmission in neutral for approximately ten minutes to
cool down unit.
iv. Perform emergency shutdown test of each engine.
v. Reset ECM and ASO valves.
vi. Secure control panel lid.
4. INSPECT LIGHTING
a. Check chassis lighting. Confirm all required lamps are present, correct color and
operational.
b. Complete light inspection section of test data sheet.
i. STOP, TAIL, AND TURN LAMPS - RED
ii. LICENSE PLATE LAMP - WHITE
iii. REAR SIDE MARKER LAMPS - RED
iv. REAR CLEARANCE LAMPS - RED
v. INTERMEDIATE SIDE MARKERS - AMBER
vi. REAR IDENTIFICATION LAMP CLUSTER - RED
vii. REAR REFLEX REFLECTORS - RED
viii. REAR SIDE REFLEX REFLECTORS - RED
ix. INTERMEDIATE SIDE RELEX REFLECTORS - AMBER
5. DECAL AND MARKINGS
a. Install bumper marking conspicuity (reflective tape) treatment
b. Install side marking conspicuity (reflective tape) treatment
c. Apply decals, labels and unit number
d. Attach vehicle certification nameplate. Nameplate must be visible without removing
equipment.
e. Attach I.F.T.A. decal.
f. Attach proposition 65 warning label.
g. STAMP THE REQUIRED DATA ON THE CERTIFICATION NAMEPLATE (See
the incomplete vehicle nameplate or the incomplete vehicle documents.)
6. ACCEPTANCE CERTIFICATION
b. Identify any components or systems of this unit that were not accepted, tested or
c. If required, perform Pickling Procedure of Note 278.95008.
d. Fill in signatory fields of the Acceptance Certification.
2 of 4


Model Number Date
3 INSPECT VEHICLE
Hoses protected.
Hose tie straps cut.
Paint is acceptable.
All masking tape, paint shielding and etc. Have been removed.
All items removed for final painting were properly re-installed and operate correctly.
All loose equipment has been installed and secured.
All guards and shielding are properly installed.
All fluid levels are acceptable.
There are no visible leaks.
Manifolds and tanks are free of water.
Wheel lugs are properly torqued.
Engines started and run through all gears.
All controls and components operate properly.
Emergency kill operates correctly.
Control panel secured.
4 INSPECT LIGHTING
Stop, tail, and turn lamps Red
License plate lamp White
Rear side marker lamps Red
Rear clearance lamps Red
Intermediate side markers Amber
Front side markers Amber
Front clearance lamps Amber
Rear identification lamp cluster Red
Rear reflex reflectors Red
Rear side reflex reflectors Red
Intermediate side reflex reflectors Amber
Front side reflex reflectors Amber
Abs indicator lamp Amber
5 DECAL AND MARKINGS

Decals, labels and unit number applied
Vehicle certification nameplate properly attached to the trailer and DATA stamped on it.
Nameplate visible without removing equipment.
The required data is stamped on the certification nameplate
Y or N This unit was preserved for storage per pickling procedure (circle one)
3 of 4
1. The above testing has been completed and this unit performed in accordance with
established criteria described herein and/or known to me with exceptions as noted
below.
2. I have reviewed recent Service Bulletins for this unit type and have corrected all
known issues on this unit.
3. I have identified all components or systems of this unit that were not accepted,
tested or corrected or that did not meet the performance requirements of this
procedure or otherwise known to me as exceptions below.

Test Tech 1
Test Tech 2
Test Tech 3
Test Tech 4
4 of 4
Appendix
A
Unit Wiring Schematic
This section provides a wiring schematic for the BMR-100 batch-mixer trailer. Refer to
drawing number D00120079 for a larger version of this wiring diagram.
January 2008 Page A-1 of 2 App. A—Unit Wiring Schematic

LOOP POWERED DISPLAY

REF 101288595
DENSOMETER MICRO-MOTION
DL200 (S+) (S-)
(P,S)=PRESSURE SIGNAL TB3

(19,20)=TEMP WHT
WHT 1
11 REF 100021340 1-16GA TWISTED PR BLK
(17,18)=VISCOSITY BLK 2
3
(15,16)=FLOW
4
(26,27)=RS485 5
WHT
BLK
- +
P 20 19 18 17 16 15 14
MICRO-MOTION
TRANSMITTER
GRN/YEL
WHT
BLK
0 1 2 3 4 5 6 7 8 9
SINGLE POINT S 27 26 25 24 23 22 21
GROUND
ORANGE
BROWN
YELLOW
GREEN
BLACK
WHITE
GRAY
VIOLET
BLUE
RED
9 WHITE
8 GRAY
BLK 4 GA. 7 VIOLET
6 BLUE
5 GREEN
4
3
YELLOW
ORANGE
(TB4) ENG. WIRING
2 RED
1 BROWN TYP. WIRING
+12V BATTERY RED 10 GA. 1 ALERT

9
ON TRAILER BEFORE INSTALLATION, USE A FILE
9 CONDUCTOR CABLE (70.74750) SUPPLIED WITH SENSOR
TO REMOVE ALL + AND - SYMBOLS ON
THE TOP OF THE DIODE CASE. INSTALL
+
29A 29A 1 DIODES AND WIRE PER DIAGRAM ON THE
12 VOLTS
12 VOLTS
7 SIDE OF THE DIODE CASE.
9
TYPICAL THESE DIODES ONLY.
BLK 6 GA.
10 29B 29B
- - DIODE TERMINAL DETAIL

7
INLET AIR
100 AMP.WITH HEATER
130 AMP PEAK RELAY
INLET AIR AT 11 VDC
HEATER RELAY
80 AMP. CONNECTOR
70.54025 J501/P501 1 2 3 4 5 6 7 M
RED 6 GA. 1
8 70.05713 2-16 GA. POWER
2
INLET AIR
HEATER
8 9 10 11 12 13 14 M
J3/P3 40 PIN RECT. ECM CONNECTOR

REF. 70.84889
HYD. OIL DB1
4 AIR SHUTOFF SOLENOID RED POWER CHECK ENGINE STOP ENGINE ENGINE DIAGNOSTIC
5 SOLENOID COMMON BLK DIAGNOSTIC LIGHT
SW7 0N STOP ENG.
AIR INLET BLK 10 GA.
GROUND STUD 3 BLU
TB4-26 BLU SW10
2
BLU
RED/BLK 1 DB1-12 YEL LAMP TEST SWITCH
10 THROTTLE
ENGINE WIRING SW7-2 RED CB7 RED
6
BLU
TB4-25 YEL
DB1-11 YEL
DB1-M BLK
5 BLU
WHT TB4-52 BLK
1 +BAT. (UNSWITCHED) CB6 SW11-2 WHT ENGINE 4
BLK RED 10 GA. TACH
31 +BAT. (UNSWITCHED) CB7 OFF
RED 15 AMP.
32 +BAT. (UNSWITCHED) START 1 REF. 70.74988
BLK 35 AMP TB4-29 GRN
17 J1939 DATA LINK + - +
2 DPDT MOM.
18 J1939 DATA LINK -
WHT TB4 1 4 5 6 "B" "A"
3
HYD. OIL
TEMP
16 J1939 SHIELD HYD. OIL
4 SW8 WARNING LIGHT
GND
GRN/BLK BLK SHLD 1 RUN 5
22 ETHER START VALVE RELAY BLK
ENG TACH 2 BLK- TACH (-) 2 DB1-10 YEL
WHT STOP
WHT TB4-19 BRN NO C NC
WHT- TACH SIG. 3 6 BLU
ECM
RED
ORG/BLK TACH SENDER SHLD 4 TB4-20 BRN
27 GROUND LEVEL SHUTDOWN SW WHT +BAT (UNSWITCHED) RED TB4-51 BLK
5
BLK +BAT (UNSWITCHED) RED
6
RED +BAT (UNSWITCHED) RED
7 P1 J1
BLU +BAT (SWITCHED) CB8
8
CAT 3126B CONNECTOR 26 +BAT. (SWITCHED)
BLU
DENSOMETER 11
WHT (+) 9
15 AMP. RED
BLK
A
B
A
B
7 BRACKET BLK GND 10 TACH PWR THROTTLE
GND STUD +12V IGN. BRN WHT C C
GRN 11 5 102.00067
38 STARTING AID SW
ALTERNATOR 12 P1-A RED RED 1 MATING PARTS REQ'D
8 HOUR METER POWER
REF. 278.51300
ORG 13 "1" RED BLK 6 70.84879 RECEPTACLE
40 E-STOP VERIFY SW
2 14 "6" BLK YEL 2
VIEW 70.84883 CONTACT PINS
YEL BLK
J1939 LINK + 15 "2" YEL GRN 3
REG. RED WHT
RED J1939 LINK - 16 "3" GRN GRY 4
RED 10 CONDUCTOR 12 GA. 3
WHT 1 SHLD 17 "4" GRY TB4-28 BLK
3 1 RED/BLK 120ê 2
THROTTLE 18 P1-C WHT TB4-24 BLK
WHT
BLK 24 DIAGNOSTIC LAMP SW11-6 BRN
AUX. BLK 3 ORG/BLK 19
14 GA. 25 WARNING LAMP ENGINE STOP SW8-6 BRN N.O. PROTECTED
BAT. 20 SW8-5 BRN
SW9 TOGGLE SWITCH
(FOR 75% TEST
21 CIRCUIT)
GRN
STARTING AID SW 22
4 2 BLK GRN/BLK
STARTING RELAY VALVE 23
AIR INLET SOLENOID BLK ORG
PRESS E-STOP VERIFY SW 24 SW9-2 BLK DIODE
SWITCH 4N3889 WHT
DIAGNOSTIC LAMP 25 CHK ENG. TRANSZORB
RED 14 GA. C RED BLK
WARNING LAMP 26 STOP ENG. 70.74764 ENGINE BLOCK
HEATER
RED 14 GA. 27
BLK 14 GA. 28
4
9-PIN DEUTCH WHT 29A GRN AUX. START HEATER SWT.
CONNECTOR 3 START
BLK 29B 85 86
REF 70.84874 SOCKET SEE DIODE TERMINAL DETAIL 31 CR1-86 BLK 14 GA.
SW12
WHT 10 GA. 70.84875 RECEP. REF 70.18167 SW7-6 GRN TB4-31 BLK OFF ON
BRN 14 GA. 32 CR1-30 RED 14 GA.
+ G G BLK 14 GA.
BLK 10 GA. GRN 14 GA. 33 SW12-1 BLU 14 GA. 87A
3 1
WHT H H BLK 14 GA.
BLU 14 GA. 34 NOT USED
CR1
START 2
BLK 30
- S
SOLENOID
WEBASTO THERMO 90 E E RED 14 GA.
VIO 14 GA.
ORG 14 GA.
35
36
NOT USED
NOT USED TB4-32 RED
RED 10 GA. 87
RED 10 GA. F F RED 14 GA.
YEL 14 GA. 37 NOT USED
B B GRN 14 GA.
MODEL THERMO 90 D (DIESEL) BLK 10 GA. 38 HEATER LAMP BLK
WHT
A A BRN 14 GA.
39 BLK 10 GA.
C C BLU 14 GA. TB4-33 BLU
COOLANT HEATER RED 10 GA. 40 RED 10 GA.
J J VIO 16 GA.
41 TB4-38 BLK 14 GA.
RED 6 GA. REF. 70.97407 (TWISTED PAIR NOT USED) 42
43
WHT 44 SW11-3 WHT
3 E-KILL
BLK 45 P1-B BLK
LIGHT SWITCH 46 SW11-5 BLK
REF 70.77658
47
48
STARTER FRONT BATCH TANK REAR FRONT
CONTROL
STAND
BLU CONTROL STAND LAMPS 49
PLATFORM 50
FRAME (REF D00000951) BATCH TANK BATCH TANK SW1
1 SW4
GROUND 3 SW3 SW2 51 HYD OIL TEMP GND BLK
GRN 2 GRN
OFF ON OFF ON OFF ON OFF ON 52 SWT10-C LAMP TEST BLK EMERG KILL
3
YEL 3 YEL BLU SW11 0N
3 1 3 1 3 1 3 1 53 CASE DRAIN HYD OIL TEMP BLK
GRN 4
3
54 CASE DRAIN HYD OIL TEMP BLK
YEL 5 2 2 2 2 CB1 2 TB4-44 WHT
35 AMP WHT
GRN
YEL
6
1
HEATER
J-BOX (REF 278.96327) SW6 6
TB4-19 BRN CABLE LEGEND
(REF 70.11178)
HIGH TB5 TB4-46 BLK
5
RED CB9 4
+12V 15 AMP 1 REF 70.41253 10-#12 7 REF 70.12341 1-#2/0
OFF OFF
3 RED RED 10 GA. TB3-40 RED
RED 10 GA.
HEATER BLK 2 REF 70.71011 2-#16 8 REF 70.12201 1-#6 RED
LOW
FAN
GRN
YEL
(70.51968)
3 REF 70.12335 2-#14 9 REF 70.04625 1-#10 RED
TB1 1 CB5 BLK TB3-39 BLK

RED 10 GA. 4 REF 70.12221 6-#14 10 REF 70.12203 1-#6 BLK
2 8 AMP WHT N.C.
CIRCUIT
3 BREAKER 5 REF 70.71013 6-#18 11 REF 70.05713 2-#16
TB2 4 CB1 RED (70.90363)
5 CB5 RED 6 REF 70.71012 4-#16
6
7
REAR BATCH TANK 8
(REF D00000951)
1 9
3
GRN 2 GRN YEL 10 CB2
3 CB3
YEL 3 YEL GRN 11 CB4 RED 10 GA.
RED 10 GA.
GRN 4 YEL 12
PLATFORM GRN 13 35A DIODE 35A
YEL 5 DIODE
GRN
(REF D00000951) 35A TRANSZORB

YEL
YEL 14 DIODE TRANSZORB

6 1 3 70.74764
TRANSZORB 70.74764
J-BOX GRN 2 GRN GRN 15 70.74764
3
(REF 70.11178) YEL 3 YEL
GRN 4
YEL 5 CR4
GRN
CR3
YEL
3 6 CR2
J-BOX
RED 10 GA.
GRN
(REF 70.11178)
YEL
86 85
86 85
86 85
RED 10 GA.
3
RED 10 GA.
30
GRN
YEL
30
30
87
87
87
RED
A
REF 70.92785 3-#8 GA. 70.92785 3-#8 GA.
RED B
BLK
+
+
12 VOLTS
12 VOLTS
+12V BATTERY
ON TRACTOR
WEBASTO BLOCK HEATER WIRING

BLK
- -
(REF. 278.02357)
D00120079 Rev. A—Master wiring, batch mixer trailer (1 of 1)
January 2008 Page A-2 of 2 endix A—Unit Wiring Schematic

Appendix
B
Hydraulic Piping
Appendix B provides parts lists and schematics for the hydraulic piping in the BMR-100 batch-
mixer trailer.
Table B.1—SAP 101342774-D: Installation, Piping, Hydraulic, Complete, Twin

Centrifugal Pumps, Batch Mixer Trailer, 2003 Model
Find
Part No. Ref. No. Qty. Description
No.
1 100025564 70.26549 1 HOSE, TEFLON, 100R14A, 8, 2000 PSI WP,

TEFLON TUBE, STAINLESS STEEL BRAID
COVER, 0.41 ID X 0.53 OD
E11074 PARKER HANNIFIN 919-8
2 100025652 70.26796 2 FITTING, HOSE, 250179-8-8, 100R14A, 1/2

NOM HOSE X 3/4-16 JIC SWIVEL FEMALE,
FIELD ATTACHABLE, BRASS NIPPLE &
FERRULE, STEEL NUT & SOCKET
E11074 PARKER HANNIFIN 20690-8-8
3 100025678 70.26858 1 ADAPTER, HOSE, 070202-8-12C, ELBOW, 3/

4-16 JIC MALE X 3/4-14 NPT MALE, STEEL
E10189 AEROQUIP 2024-12-8S
E11074 PARKER HANNIFIN 8-12 CTX-S
4 100034545 70.88713 1 DRYER, AIR, MODEL AD-9, INCLUDES

MOUNTING BRACKET KIT, 12V HEATER
E10008 BENDIX HEAVY VEHICLE SYS-
TEMS GROUP 65225
January 2008 Page B-1 of 14 App. B—Hydraulic Piping


Centrifugal Pumps, Batch Mixer Trailer, 2003 Model (Continued)
Find
No.
5 100025572 70.26563 1 HOSE, 1-WB, 100R5, 8, 2000 PSI WP,

NITRILE TUBE, NEOPRENE COVER, 0.41 ID
X 0.77 OD, J1942 H-2000/F-500, SPEC
700.71975
6 100031759 70.74728 2 DRAIN, VALVE, TANK, HEATED 12V, REEF

E12138 HORTON CLUTCH 995103
7 100034426 70.87979 8 FITTING, HOSE, 270146-8-8B, STRAIGHT,

100R5, 1/2 NOM HOSE X 3/4-16 JIC SWIVEL
FEMALE, FIELD ATTACHABLE, 3 PC,
BRASS
E11074 PARKER HANNIFIN 20622-8-8B
8 100024672 70.22473 1 FILTER, AIR, 3/8 NPT, 50 MICRON, MAN-

UAL DRAIN, TRANSPARENT BOWL, ELE-
MENT #70.22212
E10271 NORGREN F08-300-M3T
10 100002681 160.65 1 VALVE, SAFETY, 1/4, BRASS, 150 PSI PRES-

SURE RELIEF SETTING, SPEC
TEMS GROUP 205105
E10038 FWD 6C-AC-836
11 100020874 70.02955 2 ADAPTER, HOSE, 140137-4-2C, STRAIGHT,

1/4-18 NPT MALE X 1/8-27 NPT MALE,
STEEL
E10189 AEROQUIP AERO 2083-4-2S
E11074 PARKER HANNIFIN FF-4-2S
12 100034432 70.87985 1 ADAPTER, HOSE, 070202-4-4B, ELBOW, 7/

16-20 JIC MALE X 1/4-18 NPT MALE, BRASS
E10189 AEROQUIP 2024-4-4B
E11074 PARKER HANNIFIN 4-4 CTX-B
App. B—Hydraulic Piping Page B-2 of 14 January 2008


Find
No.
13 100032018 1 ADAPTER, HOSE, 2089-4-4S, 90 DEG, 1/4

MALE PIPE THREAD X 1/4FPT, AERO
E10189 AEROQUIP 2089-4-4S
E11074 PARKER HANNIFIN 1/4 CD-S
14 100048176 2 VALVE, CHECK, BUTT WELD, 800372, 1/2,

MALE, FEMALE, NEOPRENE SEAT
TEMS GROUP 800372
15 100034429 70.87982 2 ADAPTER, HOSE, 070202-8-8B, ELBOW, 3/4-

16 JIC MALE X 1/2-14 NPT MALE, BRASS

7/16-20 JIC MALE X 1/4-18 NPT MALE,
STEEL
E11074 PARKER HANNIFIN FTX-4-4S
17 100031298 70.72193 4 ADAPTER, HOSE, 2081-8-4S, 1/2-14 MALE

PIPE THREAD X 1/4-18 FPT, AERO
E10095 STRATOFLEX 1093-8-4S
E11074 PARKER HANNIFIN 1/2 X 1/4 PTR

3/4-16 JIC MALE X 3/4-14 NPT MALE, STEEL
E10189 AEROQUIP 2021-12-8S
E11074 PARKER HANNIFIN 8-12 FTX-S

STEEL


Find
No.

16-20 JIC X 1/8-27 NPT MALE, BRASS
E11074 PARKER HANNIFIN 4 CTX-B
21 100034360 70.87521 2 ADAPTER, HOSE, 070102-4-2B, STRAIGHT,

BRASS
E11074 PARKER HANNIFIN 4 FTX-B

STEEL
23 100032632 70.79119 1 ADAPTER, HOSE, 140538-2-2C, TEE, CROSS,

1/8-27 FPT, STEEL
E11074 PARKER HANNIFIN 1/8 KMMOO-S
E13928 BRENNAN INDUSTRIES 5652-02-02-
02-02
24 100012854 70.26559 1 HOSE, 1-WB, 100R5, 4, 3000 PSI WP,

X 0.52 OD, J1942 H-3000/F-100, SPEC

BRASS


Find
No.
26 100033531 70.83329 38 CONNECTOR, PLASTIC TUBING, BRASS, 1/

4 TUBE X 1/4 MALE PIPE THREAD 90 DEG,
SWIVEL
E11508 PARKER PLASTIC W169PLP-4-4

STEEL
28 100029736 1 TUBING BUNDLE, TWO 1/4 IN NYLON

TUBES, WELD SPLATTER COVER, RED/
BLUE, BLACK COVER, 1/16 WALL, 1/8 WEB
29 100031753 70.74711 2 ADAPTER, HOSE, 140424-8-8-8C, TEE, 1/2-14

NPT MALE X 1/2-14 NPT FEMALE X 1/2-14
NPT FEMALE, STEEL
E11074 PARKER HANNIFIN 1/2 MRO-S
30 100025817 70.27230 1 ADAPTER, HOSE, 070433-4-4-4C, TEE, 7/16-

20 JIC MALE X 7/16-20 JIC MALE X 7/16-20
JIC SWIVEL FEMALE, STEEL
E10189 AEROQUIP 203101-4-4S
E11074 PARKER HANNIFIN 4 S6X-S
04
31 100016568 26.1 1 PLUG, PIPE, 1/8 IN, CAST IRON

E10047 DETROIT DIESEL 103877

BRASS
E11074 PARKER HANNIFIN 8-8 FTX-B


Find
No.
33 100031757 1 ADAPTER, HOSE, 140239-8-8C, 90 DEG, 1/2-

14 MALE PIPE THREAD X 1/2-14 FEMALE
PIPE THREAD, STEEL
E13928 BRENNAN INDUSTRIES 5502-08-08S
34 100025644 70.26774 1 ADAPTER, HOSE, 070202-8-8C, ELBOW, 3/4-

16 JIC MALE X 1/2-14 NPT MALE, STEEL
35 100033152 70.81714 1 ADAPTER, HOSE, 2080-8-8S, CROSS TEE, 1/

2-14 FPT, AERO, 15850-8-8S, STRATOFLEX

37 100031619 70.73769 1 ADAPTER, HOSE, 0701-6-8C, STRAIGHT, 9/

16-18 JIC FEMALE SWIVEL X 1/2-14 NPTFE-
MALE, STEEL
E11074 PARKER HANNIFIN 6-8 G6X
38 100016864 30.13018 1 NIPPLE, STANDARD, 1/2 X 2, BLACK

WALL, A120
39 101344663 1 PUMP, DIAPHRAGM, AIR-OPERATED, 1.0

INCH FPT INLET, 1.0 INCH FPT OUTLET
E15746 MASTER PUMPS YAMADA NDP-
25BAN
40 100033072 70.81357 2 ADAPTER, KAMLOC, 1 IN, MALE X MALE

PIPE THREAD -BRASS, 633-F, OPW/DOVER
E10505 DOVER 633-F 1 IN


Find
No.

E11074 PARKER HANNIFIN 8 CTX-S

4 TUBE X 1/4 TUBE, 1/4 MALE PIPE
THREAD BRASSANCH TEE, SWIVEL

STEEL


App. B—Hydraulic Piping
Page B-8 of 14
January 2008
D00100866 Rev. C—Installation, piping, hydraulic, complete, twin centrifugal pumps, batch mixer trailer, 2003 model (1 of 6)
January 2008
Page B-9 of 14

Page B-10 of 14
January 2008
January 2008
Page B-11 of 14

Page B-12 of 14
January 2008
January 2008
Page B-13 of 14


Appendix
C
Air Piping
Appendix C provides schematics and parts lists for the air piping in the BMR-100 batch-mixer
trailer.
Table C.1—SAP 101342775-C: INSTALLATION, PIPING, AIR, COMPLETE, TWIN

CENTRIFUGAL PUMPS, BATCH MIXER TRAILER, 2003 MODEL
Find
No.
1 100025564 70.26549 1 HOSE, TEFLON, 100R14A, 8, 2000 PSI WP,

TEFLON TUBE, STAINLESS STEEL BRAID
COVER, 0.41 ID X 0.53 OD
2 100025652 70.26796 2 FITTING, HOSE, 250179-8-8, 100R14A, 1/2

NOM HOSE X 3/4-16 JIC SWIVEL FEMALE,
FIELD ATTACHABLE, BRASS NIPPLE &
FERRULE, STEEL NUT & SOCKET
E11074 PARKER HANNIFIN 20690-8-8

E10189 AEROQUIP 2024-12-8S
4 100034545 70.88713 1 DRYER, AIR, MODEL AD-9, INCLUDES

MOUNTING BRACKET KIT, 12V HEATER
TEMS GROUP 65225
January 2008 Page C-1 of 12 App. C—Air Piping


CENTRIFUGAL PUMPS, BATCH MIXER TRAILER, 2003 MODEL (Continued)
Find
No.
5 100025572 70.26563 1 HOSE, 1-WB, 100R5, 8, 2000 PSI WP,

X 0.77 OD, J1942 H-2000/F-500, SPEC
700.71975
6 100031759 70.74728 2 DRAIN, VALVE, TANK, HEATED 12V, REEF

E12138 HORTON CLUTCH 995103

BRASS
8 100024672 70.22473 1 FILTER, AIR, 3/8 NPT, 50 MICRON, MAN-

UAL DRAIN, TRANSPARENT BOWL, ELE-
MENT #70.22212
E10271 NORGREN F08-300-M3T
10 100002681 160.65 1 VALVE, SAFETY, 1/4, BRASS, 150 PSI PRES-

SURE RELIEF SETTING, SPEC
TEMS GROUP 205105
E10038 FWD 6C-AC-836

STEEL
E10189 AEROQUIP AERO 2083-4-2S

16-20 JIC MALE X 1/4-18 NPT MALE, BRASS
App. C—Air Piping Page C-2 of 12 January 2008


Find
No.
13 100032018 1 ADAPTER, HOSE, 2089-4-4S, 90 DEG, 1/4

MALE PIPE THREAD X 1/4FPT, AERO
14 100048176 2 VALVE, CHECK, BUTT WELD, 800372, 1/2,

MALE, FEMALE, NEOPRENE SEAT
TEMS GROUP 800372
15 100034429 70.87982 2 ADAPTER, HOSE, 070202-8-8B, ELBOW, 3/4-

16 JIC MALE X 1/2-14 NPT MALE, BRASS

STEEL
17 100031298 70.72193 4 ADAPTER, HOSE, 2081-8-4S, 1/2-14 MALE

PIPE THREAD X 1/4-18 FPT, AERO
E11074 PARKER HANNIFIN 1/2 X 1/4 PTR

E10189 AEROQUIP 2021-12-8S
E11074 PARKER HANNIFIN 8-12 FTX-S

STEEL


Find
No.

16-20 JIC X 1/8-27 NPT MALE, BRASS
E11074 PARKER HANNIFIN 4 CTX-B

BRASS
E11074 PARKER HANNIFIN 4 FTX-B

STEEL
23 100032632 70.79119 1 ADAPTER, HOSE, 140538-2-2C, TEE, CROSS,

1/8-27 FPT, STEEL
E11074 PARKER HANNIFIN 1/8 KMMOO-S
02-02
24 100012854 70.26559 1 HOSE, 1-WB, 100R5, 4, 3000 PSI WP,

X 0.52 OD, J1942 H-3000/F-100, SPEC

BRASS


Find
No.

4 TUBE X 1/4 MALE PIPE THREAD 90 DEG,
SWIVEL

STEEL
28 100029736 1 TUBING BUNDLE, TWO 1/4 IN NYLON

TUBES, WELD SPLATTER COVER, RED/
BLUE, BLACK COVER, 1/16 WALL, 1/8 WEB
29 100031753 70.74711 2 ADAPTER, HOSE, 140424-8-8-8C, TEE, 1/2-14

NPT MALE X 1/2-14 NPT FEMALE X 1/2-14
NPT FEMALE, STEEL
E11074 PARKER HANNIFIN 1/2 MRO-S
30 100025817 70.27230 1 ADAPTER, HOSE, 070433-4-4-4C, TEE, 7/16-

20 JIC MALE X 7/16-20 JIC MALE X 7/16-20
JIC SWIVEL FEMALE, STEEL
E10189 AEROQUIP 203101-4-4S
E11074 PARKER HANNIFIN 4 S6X-S
04
31 100016568 26.1 1 PLUG, PIPE, 1/8 IN, CAST IRON

E10047 DETROIT DIESEL 103877

BRASS
E11074 PARKER HANNIFIN 8-8 FTX-B


Find
No.
33 100031757 1 ADAPTER, HOSE, 140239-8-8C, 90 DEG, 1/2-

14 MALE PIPE THREAD X 1/2-14 FEMALE
PIPE THREAD, STEEL
E13928 BRENNAN INDUSTRIES 5502-08-08S

35 100033152 70.81714 1 ADAPTER, HOSE, 2080-8-8S, CROSS TEE, 1/

2-14 FPT, AERO, 15850-8-8S, STRATOFLEX

37 100031619 70.73769 1 ADAPTER, HOSE, 0701-6-8C, STRAIGHT, 9/

16-18 JIC FEMALE SWIVEL X 1/2-14 NPTFE-
MALE, STEEL
E11074 PARKER HANNIFIN 6-8 G6X
38 100016864 30.13018 1 NIPPLE, STANDARD, 1/2 X 2, BLACK

WALL, A120
39 101344663 1 PUMP, DIAPHRAGM, AIR-OPERATED, 1.0

INCH FPT INLET, 1.0 INCH FPT OUTLET
E15746 MASTER PUMPS YAMADA NDP-
25BAN
40 100033072 70.81357 2 ADAPTER, KAMLOC, 1 IN, MALE X MALE

PIPE THREAD -BRASS, 633-F, OPW/DOVER
E10505 DOVER 633-F 1 IN


Find
No.

E11074 PARKER HANNIFIN 8 CTX-S

4 TUBE X 1/4 TUBE, 1/4 MALE PIPE
THREAD BRASSANCH TEE, SWIVEL

STEEL


App. C—Air Piping
Page C-8 of 12
January 2008
D00100864 Rev. C—Installation, piping, air, complete, twin centrifugal pumps, batch mixer trailer, 2003 model (1 of 5)
January 2008
Page C-9 of 12

App. C—Air Piping
App. C—Air Piping
Page C-10 of 12
January 2008
January 2008
Page C-11 of 12

App. C—Air Piping
App. C—Air Piping
Page C-12 of 12
January 2008
Appendix
D
Component Repair and
Service Manuals
Appendix D includes the following repair and service manuals for individual components:
• AAA Products International

• Dynalco Model MTH-103 Tachometer/Hourmeter/Trip Installation and Operation Manual
• Hendrickson HT Series Trailer Air Suspensions Operator’s Manual
• Funk Manufacturing Company Pump Drives Service Manual
• Mannesmann RexRoth Typ.-2 TH 6L, Series 1X, Service and Repair Manual
• Eaton Hydraulics Hydrostatic Fixed Motors Models 33 through 76 Parts Information
• Eaton Hydraulics Hydrostatic Transmissions Start-up Procedure
• Eaton Hydraulics Heavy Duty Hydrostatic Pumps Parts and Repair Information
• Eaton Hydraulics Heavy Duty Hydrostatic Transmissions Application Information
• Eaton Marketing Bulletin No. 990901: Heavy Duty Hydrostatic Pumps and Motors
• Precision Digital Model PD600 Loop-Powered Meter (Material No. 101288595)
• Yamada Air-Operated Diaphragm Pumps Maintenance Manual (Material No. 101344663)
• Bendix AD-9 Air Dryer Service Data (Material No. 100034545)
• Murphy PowerView Installation and Operations Manual (Material No. 101339393)
• Rexroth Spare Parts List for AA10VG45HD1D1/10L-NSC60F003D Pump (Material No.
101337076)
• Rexroth Spare Parts List for AA10VG45HD1D1/10L-NSC60F043D Pump (Material No.
101337070)
• Haldex 2990911 spare parts list for rotary gear type flow divider (Material No. 101335002)
• Parker Hydraulics, Torqlink™ Service Procedure for Model TG Low Speed, High Torque
Hydraulic Motors (Material No. 101334994)
January 2008 Page D-1 of 2 App. D—Repair/Service Manuals

App. D—Repair/Service Manuals Page D-2 of 2 January 2008

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BMR-100 Batch-Mixer Trailer

Operation and Maintenance Manual

Part No. 101605800

Part No. 101605800

Printed January 2008

Overview .................................................................................................. 1-1

Section 2—Major Components and Systems

Trailer Chassis ......................................................................................... 2-1

Section 3—Pre-Trip Inspection

Introduction .............................................................................................. 4-1

Section 5—Test and Setup Procedures

Introduction .............................................................................................. 5-1

Appendix A—Unit Wiring Schematic

Appendix B—Hydraulic Piping

Appendix C—Air Piping

Appendix D—Component Repair and Service Manuals

January 2008 Page 1-1 of 4 Sec. 1—Introduction

Features of the BMR-100 Batch-Mixer Trailer

Sec. 1—Introduction Page 1-2 of 4 January 2008

January 2008 Page 1-3 of 4 Sec. 1—Introduction

Sec. 1—Introduction Page 1-4 of 4 January 2008

• Hendrickson-Turner 44,000-lb air-ride suspension

Deck Engine Module

January 2008 Page 2-1 of 12 Sec. 2—Major Components and Systems

• Two RexRoth AA10VG45 or Sauer-Danfoss Series 90 Closed-Loop Pumps—These pumps

Sec. 2—Major Components and Systems Page 2-2 of 12 January 2008

Centrifugal Pump Module

Material No. Description

Figure 2.1 shows the 6 × 5 recirculating pump.

January 2008 Page 2-3 of 12 Sec. 2—Major Components and Systems

Figure 2.1—6 × 5 recirculation/booster pump

Sec. 2—Major Components and Systems Page 2-4 of 12 January 2008

Table 2.2—Subcomponents of Each 50-bbl Batch-Tank Module

Figure 2.2—Front 50-barrel batch tank

January 2008 Page 2-5 of 12 Sec. 2—Major Components and Systems

Figure 2.3—Batch-tank agitator rotation diagram

Sec. 2—Major Components and Systems Page 2-6 of 12 January 2008

January 2008 Page 2-7 of 12 Sec. 2—Major Components and Systems

Figure 2.4—Inside view of 50-barrel batch tank with tank-washing nozzle

Sec. 2—Major Components and Systems Page 2-8 of 12 January 2008

Figure 2.5—DL-200 mass flowmeter

Figure 2.6—The 4- to 20-mA readout for the DL200 mass flow-

January 2008 Page 2-9 of 12 Sec. 2—Major Components and Systems

Operator Control Stand

Figure 2.7—Batch-mixer trailer twin centrifugal pump

Sec. 2—Major Components and Systems Page 2-10 of 12 January 2008

January 2008 Page 2-11 of 12 Sec. 2—Major Components and Systems

Sec. 2—Major Components and Systems Page 2-12 of 12 January 2008

3. Check the crankcase oil level on the engine.

January 2008 Page 3-1 of 2 Sec. 3—Pre-Trip Inspection

12. Check the hydraulic pumps for leaks.

Sec. 3—Pre-Trip Inspection Page 3-2 of 2 January 2008

January 2008 Page 4-1 of 4 Sec. 4—Operation

Sec. 4—Operation Page 4-2 of 4 January 2008

Figure 4.1—Pit connection for washup water

January 2008 Page 4-3 of 4 Sec. 4—Operation

Sec. 4—Operation Page 4-4 of 4 January 2008

Important Always use the latest version of all specifications.

This section contains the following specifications:

• Specification D00120521: Test for BMR-100 Batch Mixer Trailer

January 2008 Page 5-1 of 2 Sec. 5—Test and Setup Procedures

Sec. 5—Test and Setup Procedures Page 5-2 of 2 January 2008

Description Min Typ Max

Max Fuel Supply Line Restriction (In. Hg) 4.1