Elite Cement Truck

The HCR Elite® Cementing Trailer
Part No. 101622692

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. 101622692
Printing History:
First Release (May, 2001)
Second Release (May, 2005)
Third Release (June, 2007)
Fourth Release (October, 2008)
Contents
Chapter 1—Introduction
Overview .................................................................................................. 1-1
Basic Equipment Report ................................................................... 1-1
Features of the HCR Elite® Cementing Trailer ....................................... 1-2
Safety Features ................................................................................. 1-5
Chapter 2—Major Components and Systems

Trailer Chassis ......................................................................................... 2-1
Deck Engines .......................................................................................... 2-2
4700 OFS Transmission .......................................................................... 2-5
Cummins QSB6.7 Auxiliary Engine ......................................................... 2-8
Hydraulic Circuits ..................................................................................... 2-9
6 × 5 and 4 × 4 Hydraulic Circuits ..................................................... 2-11
Start/Agitator Hydraulic Heat Exchanger Circuit ............................... 2-14
ADC® Mixing System Circuit ............................................................. 2-16
Micro Motion® F300 Mass Flowmeter ..................................................... 2-17
Control Stand ........................................................................................... 2-19
Deck Engine Controls ....................................................................... 2-22
Auxiliary Engine Controls and Light Switches ................................... 2-23
4 × 4 Mixing-Pump Controls .............................................................. 2-23
6 × 5 Recirculation-Pump Controls ................................................... 2-24
Remaining Hydraulic Instrumentation ............................................... 2-24
Lower Control Panel .......................................................................... 2-24
Heater Controls ................................................................................. 2-24
FLECS Controller .................................................................................... 2-26
Chapter 3—Prejob Inspection

Operator Checklist ................................................................................... 3-1
Lubrication ............................................................................................... 3-5
Air Cleaners and Filters ........................................................................... 3-5
iii
Hoses and Connections ........................................................................... 3-5
Fuel Lines ................................................................................................ 3-6
Coolant .................................................................................................... 3-6
Chapter 4—Operation
Introduction .............................................................................................. 4-1
General .................................................................................................... 4-1
Starting the Auxiliary Engine .................................................................... 4-1
Starting the Deck Engine ......................................................................... 4-2
Warm-Up Period ................................................................................ 4-3
Operation in Harsh Conditions .......................................................... 4-3
Engine Idling ...................................................................................... 4-4
Adjusting the Deck Engine Throttle ......................................................... 4-4
Setting High and Low Engine-Speed Limits ...................................... 4-4
Operating the ETC ............................................................................ 4-5
Engine Overspeed ................................................................................... 4-5
Deck Engine Overspeed ................................................................... 4-5
Auxiliary Engine Overspeed .............................................................. 4-6
Monitoring the Engines ............................................................................ 4-7
Monitoring Gauges ............................................................................ 4-7
Monitoring and Interpreting Engine Warning Lights .......................... 4-7
Engine Display and Diagnostic Readouts ......................................... 4-8
Operating the PowerView Module ..................................................... 4-9
Operating the Murphy PowerView Module ........................................ 4-10
Pump Operation ....................................................................................... 4-12
Priming the HT-400 Pumps and Centrifugal Pumps ......................... 4-12
Operating the 6 × 5 Recirculating Pump ........................................... 4-15
Operating the 4 × 4 Mixing Pump ...................................................... 4-17
Stopping the Engines ............................................................................... 4-19
Operating the Tub Agitators and Hydraulic Starters ................................ 4-19
Chapter 5—Mixing System Problems and FLECS

Controller Operation
FLECS Controller Operation .................................................................... 5-1
RCM® IIIr Mixer ....................................................................................... 5-1
Mixer Assembly Instructions .................................................................... 5-9
iv
Installing the Sleeve .......................................................................... 5-9
Installing the Metering Plug ............................................................... 5-9
Installing the Endplates and Indicator ............................................... 5-10
Mounting the Actuator Assembly ....................................................... 5-10
Completing the Mixer Assembly ........................................................ 5-11
Mixing Problems ...................................................................................... 5-12
Erratic Cement Delivery .................................................................... 5-12
Below-Normal Recirculation Rate on a 6 × 5 Pump .......................... 5-12
Aerated Slurry ................................................................................... 5-13
Heavyweight or Thixotropic Slurries .................................................. 5-13
Inability to Maintain Density Setpoint ................................................ 5-14
Dry Cement Entering the Mixing Tub ................................................ 5-15
RCM® Mixing System Troubleshooting Procedures ................................ 5-16
Cement Mixing Procedure ....................................................................... 5-22
Manual Mixing ................................................................................... 5-22
Shutdown/Restart Procedures ................................................................. 5-24
Cleanup Procedures ................................................................................ 5-25
Chapter 6—Test/Setup Procedures
Chapter 7—Pressure-Volume Curves

Introduction .............................................................................................. 7-1
How to Use Pressure-Volume Curves ..................................................... 7-1
Pump Curves for the HCR Elite® Trailer ................................................. 7-2
Appendix A—Low-Pressure Manifold Flow-Path Schematics

Introduction .............................................................................................. A-1
Appendix B—Schematics
Introduction .............................................................................................. B-1
Appendix C—Spare Parts Lists

Introduction .............................................................................................. C-1
Appendix D—Repair and Service Manuals

Manuals Reprinted in Appendix D ........................................................... D-1
Additional Repair and Service Manuals ................................................... D-2
v
vi
SECTION
Section
11
Preface
Introduction
Overview
This manual provides information on the major components and systems of the HCR Elite®
cementing 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.
Basic Equipment Report

Access to the Basic Equipment Report (BER) for this unit is essential for overall short-term and
long-term maintenance of this unit. The receiving location of this unit should receive the BER
shortly after the unit is delivered from manufacturing. The BER will contain the material number
to which the particular trailer was manufactured and all of the pertinent drawings used by
manufacturing for assembling the unit. Additionally, the BER includes critical information such
as pump fluid-end sizes, drawings that show how the unit was assembled, manufacture date, and
other options.
Important If the unit is transferred from one location to another, the BER should be sent
along with the unit. If the BER is not sent, the location that owns the trailer
should request it from the previous location or request another copy from the
Duncan Technology Center.
October 2008 Introduction 1-1

HCR Elite® Cementing Trailer Manual
Features of the HCR Elite® Cementing Trailer

Like the 75TC4 cementing trailer, the HCR Elite cementing trailer is designed for
high-performance cementing operations. Figures 1.1 and 1.2 (Page 1-3) show the trailer from
both the driver’s and passenger’s sides.
HCR Elite trailers are equipped with ADC® mixing equipment and the Flexible Electronic
Control System (FLECS) controller. The emission-certified engines on this trailer greatly
reduce pollution on location and help ensure that the trailer meets the long-term standards
established by the Environmental Protection Agency (EPA).
Although the HCR Elite trailer is similar to previous cementing trailers, the following features
are unique to this trailer:
• larger, more powerful, emission-certified, 420-bhp deck engine

• true 8-bbl capacity mixing system
– 5-bbl premix compartment and 3-bbl downhole compartment
– deeper mixing tub that reduces air entrainment in cement slurries
– high-energy RCM® IIIr mixing system with rotary-jet water valve
– variable speed control for both centrifugal pumps
– individual speed controls for each tub agitator
• control stand
– controls and instrumentation that are grouped together in a logical format
– FLECS controller
• displacement tank
– 4- and 6-in. external suction valves
– two 10-bbl compartments with simplified sump
• increased suction-hose carrying capacity with storage racks on both sides of the trailer
• storage boxes for miscellaneous components on the rear rather than the front of the trailer
• larger, more powerful, emission-certified Cummins QSB6.7 auxiliary engine
• easily accessible low-pressure manifold
1-2 Introduction October 2008

Figure 1.1—HCR Elite® trailer, passenger’s side
Figure 1.2—HCR Elite trailer, driver’s side

Figure 1.3—HCR Elite® unit, top view

Safety Features
The HCR Elite® cementing trailer has new safety features that help improve operational safety and
accessibility to routinely accessed areas. The trailer designers emphasized methods of accessing critical
areas of the trailer more safely. Designers incorporated the following safety features:
• 60° angled stairways with handrails for accessing the operator and observation platforms
• safety gates on the platform stairways
• removable panels over the premix and downhole compartments of the mixing tub, which helps
prevent cement dust from escaping and cement slurry from splashing workers or surrounding
equipment
• protection for helping prevent overpressure of high-pressure components
• handrails near the control stand for helping prevent the operator from falling from the side of the unit
• insulated exhaust manifold on the observation platform that helps prevent workers from touching hot
surfaces
• larger platform area around cement mixing tub for easier access to the release manifold, densometer,
ADC mixing system hydraulics, lube oil tanks, and mixing components
• removable control-stand panels for easier access to all internal and panel-mounted components
• overspeed air-shutoff protection and secondary manual emergency kill on both the deck and auxiliary
engines


SECTION
Section
12
Preface
Major Components and Systems

Section 2 lists the major components of the HCR Elite® trailer. The following items are also
discussed in this section:
• Basic operation for each of the trailer’s major components

• Parameters for each of the trailer’s major components
• Operational theory for the trailer’s hydraulic system
• Instrumentation, switches, and valves within the control stand that interface with the trailer’s
major components and hydraulic system
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
chassis is available in both standard and desert-service configurations.
The standard chassis includes:

• Hendrickson-Turner 44,000-lb air-ride suspension
• Spicer axle assemblies
• 11R × 22.5 tires, load-range G
• Antilock air brakes
The desert-service chassis includes:
• Hutch 50,000-lb leaf suspension
• Spicer axle assemblies
• 24R × 21 all-terrain tires, load-range H
• Standard air brakes
October 2008 Major Components and Systems 2-1

Deck Engines
HCR Elite® trailers built in 2000 were equipped with the Caterpillar 3176C engine (Spec. No.
106.00439, SAP No. 100046934). In 2001, the deck engine was changed to the Caterpillar
C-10 (Spec. No. D00018486, SAP No. 101239675). In 2005, the deck engine was changed to
the Caterpillar C-11 (Spec. No. D00165861, SAP No. 101381773). You will need these
numbers when ordering replacement engines from Customer Service. You will need the
engine serial number if a Caterpillar dealer requests information about specific engine
configurations provided by Caterpillar for Halliburton.
To order replacement deck engines, use the information for the HCR Elite trailer model listed
in Table 2.1.
Table 2.1—Part/Spec. Nos. for HCR Elite Trailer Deck Engines

HCR Elite
Caterpillar Specification bhp at
Trailer SAP No.
Engine No. 2,100 rev/min
Year/Model
2000 3176C 106.00439 100046934 425
2001 C-10 D00018486 101239675 425
2005 C-11 D00165861 101381773 420
The engine specification includes a description of the engine’s emission family as determined
by the Environmental Protection Agency (EPA). Pressure-volume curves (PVCs) for this
engine are provided in Section 8 of this manual. Information about different sizes of
HT-400™ pump fluid ends is provided in Sections 7 and 8. Figure 2.1 (Page 2-3) shows the
deck engine package mounted on the trailer.
2-2 Major Components and Systems October 2008

Air to air Air cleaner

aftercooler
dn000350
Webasto engine Hydraulic starter
coolant heater
Figure 2.1—Caterpillar deck engine package mounted on the trailer
The hydraulically started, straight six-cylinder, all-electronic engine includes a 1.75-turn pulse
width modulated (PWM) throttle. This throttle increases or decreases engine speed depending upon
which way the engine operator rotates the knob mounted on the sensor. Rotating the knob
counterclockwise increases engine speed, and rotating it clockwise decreases engine speed. The
engine is equipped with an alternator installed by Caterpillar. Each engine includes an air
compressor. To order replacement parts for the throttle, use the numbers in Table 2.2.
Table 2.2—PWM Throttle Part Nos.
Part SAP No.
Throttle 100046107
Throttle sensor 101273064

The engine includes a 6-in. diameter stainless-steel exhaust pipe and a Donaldson air cleaner with a
replaceable filter element (SAP No. 100002596). A butterfly valve is located after the turbocharger
that leads to the engine’s intake manifold. This butterfly valve stops the engine by closing when the
emergency kill switch is engaged or when an engine overspeed condition occurs.
The engine is equipped with a 101-qt capacity radiator with a suction-type cooling fan. In compliance
with EPA emissions standards, an air-to-air aftercooler is located in front of the radiator for cooling
the combustible air, thereby decreasing pollutant exhaust.
Three gauges are attached to the back of the muffler mount for the Caterpillar deck engine. These
gauges monitor engine water temperature, engine oil pressure, and transmission oil charge pressure.
Figure 2.2 shows these gauges. You can also use the PowerView display in the unit’s control stand to
monitor engine oil pressure and engine water temperature.
dn000351
Figure 2.2—Engine and transmission gauges

4700 OFS Transmission

Beginning with mid-year 2006 production, the HCR Elite® trailer is equipped with the Allison 4700 OFS
transmission (Halliburton specification D00176573; SAP No. 101336482). The transmission is equipped
with two hydraulic filters that include identical replacement elements. The SAP number for a
replacement element kit is 101363967. This kit contains two filter elements and necessary O-rings.
Transmission oil temperature and pressure can be viewed on the Power View display in the unit’s control
stand. Transmission pressure can also be viewed on the gauge panel at the rear of the deck engine
package, which also contains gauges for engine oil pressure and engine water temperature.
The oil used by the transmission is cooled by a shell-and-tube heat exchanger mounted on the engine.
Two 1-in. hydraulic hoses deliver oil to the heat exchanger where it is cooled. The oil is then returned to
the transmission. Figure 2.3 shows the transmission cooler.
dn000352
Figure 2.3—Transmission oil cooler

The 4700 OFS transmission is shifted electronically via a shift pad located in the unit’s control stand.
Figure 2.4 shows the transmission shift pad. The transmission oil level can be checked by
simultaneously pushing the Up and Down arrows on the shift pad. Simultaneously pushing these
arrows a second time causes the shift pad to display any fault codes in the transmission TCM. See the
shift selector operator’s manual (SAP 101511857) for a list of fault codes and further information.
The transmission is equipped with a remote fluid fill port. This port is located on the engine package
framework between the engine and the transmission. Figure 2.5 shows the remote fluid fill port.
Figure 2.4—Transmission shift pad

Figure 2.5—Transmission fluid fill port

Cummins QSB6.7 Auxiliary Engine

Beginning with 2007 production, the HCR Elite® trailer is equipped with a Cummins QSB6.7
auxiliary engine (Halliburton specification D00231475; SAP No. 101455443). The auxiliary engine
provides the hydraulic power necessary for starting the deck engine(s) and for powering all other
hydraulic circuits. It is rated at 173 bhp at 2,550 rev/min and is EPA Tier 3 non-road emission certified.
Figure 2.6 shows the auxiliary engine package.
Figure 2.6—Cummins QSB6.7 auxiliary engine package
A three-pad, 1:1 ratio Funk pump drive is directly coupled to the auxiliary engine. This pump drive
contains two SAE C pad-mounting flanges on the bottom portion of the pump drive and an SAE B
pad-mounting flange on the top portion. The hydraulic pumps required for each hydraulic circuit are
attached to the mounting pads.
Like the deck engines used on the HCR Elite trailer, the QSB6.7 engine is electronic and uses the same
type hand throttle as the deck engines. The engine is electrically started and includes a 12-V alternator
(SAP No. 100047094).

The stainless-steel exhaust pipe is routed from the top of the engine to the observation platform. An
exhaust bellows is located in the exhaust system to provide flexibility between the engine and the
observation platform. The entire length of the exhaust pipe is insulated with a temperature-resistant
insulation blanket.
Caution Do not remove the insulation blanket from the exhaust pipe. The blanket helps
prevent personnel from burning themselves on the pipe. It also helps prevent
excess heat from radiating into the surrounding hydraulic tank and Allison 4700
OFS transmission.
The engine includes a 5-inch outlet air cleaner with a replaceable filter element (SAP No. 100029673).
A valve is located ahead of the turbocharger air intake. When the emergency kill switch is engaged or
when an engine overspeed condition occurs, this valve closes, stopping the engine.
The engine includes a split-core radiator with a suction-type cooling fan. One core of the radiator is used
as a charge air cooler; the other core is used to cool the jacket water of the engine.
Hydraulic Circuits
The auxiliary engine powers all the hydraulic pumps on this unit. Both single- and twin-pump units
include four hydraulic pumps mounted to the pump drive on the auxiliary engine. All four hydraulic
pumps are designed and plumbed for left-handed rotation. Figure 2.7 (Page 2-10) shows the hydraulic
pumps and the pump drive attached to the Caterpillar 3126B engine. Descriptions of individual pump and
pump-circuit functions follow:
• 4 × 4 Hydraulic Circuit—This circuit is powered by an Eaton ACL054 hydrostatic pump. The

hydraulic pump is mounted on the lower left pad of the pump drive. This pump is located closer to
the trailer framerail than the other three pumps. It supplies oil to the hydraulic motor, which is
directly coupled to the 4 × 4 centrifugal pump.
• 6 × 5 Hydraulic Circuit—This circuit is powered by an Eaton ACL054 hydrostatic pump. The
hydraulic pump is mounted on the lower right pad of the pump drive. The part number, size, etc. for
this hydraulic pump is identical to that for the 4 × 4 hydraulic circuit. This pump supplies oil to the
hydraulic motor, which is directly coupled to the 6 × 5 hydraulic pump.
• Start/Agitator Circuit—This circuit is powered by a Barnes GT20W2W gear pump. The hydraulic
pump is mounted on the top pad of the pump drive. It supplies the hydraulic oil necessary for starting
the two deck engines and powering the hydraulic agitators in the cement mixing tub.
In addition to the hydraulic loads previously listed, this circuit includes a flow control valve and a
gear motor that powers a fan to cool hydraulic oil in a remote-mounted hydraulic cooler (Figure 2.8,
Page 2-11). A remote-mounted heat exchanger with a hydraulic-powered fan is required to cool the

hydraulic oil. This heat exchanger is mounted under the displacement tank on the driver’s side of
the trailer.
• ADC® Mixing System Circuit—This circuit is powered by a Parker PVP1630

pressure-compensated pump. The hydraulic pump is piggy-back mounted to the Barnes
GTW20W2W gear pump. It supplies hydraulic oil to the water rotary actuator, the cement rotary
actuator, and the master water valve, all of which are the hydraulic components of the ADC
mixing system circuit.
dn000356
Figure 2.7—Pump drive and hydraulic pumps

dn000356
Figure 2.8—Remote-mounted hydraulic cooler
6 × 5 and 4 × 4 Hydraulic Circuits

Both the 6 × 5 and 4 × 4 hydraulic circuits are closed-loop hydrostatic transmission circuits. These
circuits return only a portion of the hydraulic oil back to the hydraulic reservoir; the rest is recirculated.
Figure 2.9 (Page 2-13) is a process instrumentation diagram (PID) of these circuits. The design and
components of both circuits are also almost identical, except that the 6 × 5 centrifugal pump rotates more
slowly than the 4 × 4 centrifugal pump. Both circuits consist of a variable-displacement hydraulic pump
and a fixed-displacement hydraulic motor. The position of the RexRoth joystick controller handle
determines the speed of the fixed-displacement motor and, ultimately, the speed of the centrifugal pump.
When the RexRoth joystick controller is fully engaged and the variable-displacement hydraulic pump is
being fully stroked, the maximum speed for each centrifugal pump can be achieved. Centrifugal pumps
rotate clockwise when viewed from the shaft end. The nominal speed of the 6 × 5 centrifugal pump is
1,600 rev/min, and the nominal speed of the 4 × 4 centrifugal pump is 2,200 rev/min.
Because both the 6 × 5 and 4 × 4 hydraulic circuits are hydrostatic circuits, they are rated for a system
pressure of 5,000 psi. System pressure will fluctuate depending on the operating rate or speed of the

centrifugal pump and the load that is applied to the system. The nominal system pressures for pump
operation at full speed and with circulating water follow:
• 6 × 5 hydraulic circuit = approximately 1,600 to 2,200 psi

• 4 × 4 hydraulic circuit = approximately 2,600 to 3,200 psi
Because cement slurry is heavier than water, system pressure will increase when the cement slurry is
recirculated by the 6 × 5 centrifugal pump. System pressure also depends on rheological slurry
properties, such as viscosity and weight. Typically, when the cement slurry is brought up to weight,
the system pressure of the 6 × 5 hydraulic circuit will increase because of the slurry's increased
viscosity and density.
A filter in the charge circuit of each hydrostatic pump filters the oil as it leaves the charge pump for
both the 6 × 5 and 4 × 4 hydraulic circuits. (The SAP No. for the filter’s replacement element is
100021969.) The charge pump draws oil directly from the 30-gal hydraulic tank. Both the hydraulic
pump and the motor leak oil through their cases to cool the circuits. This oil is collected at the case
drain ports of both the hydraulic pump and the motor for each circuit. The return oil from the motor
case and the pump case is mixed together and plumbed to the heat exchanger that is in front of the
radiator. Oil is returned from the heat exchanger to the 30-gal hydraulic tank.

dn000356
Figure 2.9—6 × 5 and 4 × 4 process and instrumentation diagram (PID)

Start/Agitator Hydraulic Heat Exchanger Circuit

The start/agitator circuit is an open-loop, fixed-displacement hydraulic circuit. Hydraulic oil is drawn
from the reservoir and continuously moved through the circuit to power the motors for the tub agitators
or for starting the engines. Although the start/agitator circuit Figure 2.10 (Page 2-15) is designed to
withstand a maximum system pressure of 3,500 psi, a relief valve prevents system pressure from
exceeding 3,000 psi, thereby protecting the circuit from overpressure. This relief valve is part of the
aluminum cartridge valve assembly.
Both single- and twin-pump trailer units contain identical aluminum cartridge-valve assemblies. In
addition to the relief valve, the manifold assembly includes two normally closed (NC) cartridge valves
for starting the deck engine(s) and one normally open (NO) cartridge valve for operating the premix
agitators. Figure 2.11 (Page 2-16) shows the aluminum cartridge valve assembly.
Because the circuit is designed for fixed displacement, hydraulic oil begins flowing from the pump to
the entire circuit immediately after the auxiliary engine is started. Because the agitator circuit is
plumbed with an NO cartridge valve, oil flows to the agitator motors. If the needle valves on top of
the cement mixing tub are open, the oil will bypass the motors, flow to the hydraulic heat exchanger,
and then return to the reservoir. If the needle valves are partially or fully closed, some or all of the oil
will flow through the agitator motors, rotating the cement agitators within the tub. The setting of the
needle valves determines the volume of oil that flows to the agitator motors as well as the volume of
oil that is bypassed to the tank. These settings ultimately control the speed at which the agitators will
rotate.
After hydraulic oil flows through the agitator motors or is bypassed by the agitator motors, it is again
combined and enters into a flow-control valve. The flow-control valve directs a portion of the oil to
the hydraulic fan motor and a portion of the oil is bypassed eventually to the reservoir. The speed of
the hydrualic fan motor should be approximately 2,000 rev/min. The speed of the fan motor is directly
proportional to the controlled flow of oil supplied to the motor by the flow-control valve. To increase
the speed of the fan, the adjustment screw on the flow-control valve must be screwed out. After the oil
flows through the hydraulic fan motor, it is again combined with the excess flow or bypassed oil from
the flow-control valve and routed through the heat exchanger.
All hydraulic oil used by this circuit is plumbed through the air-to-oil heat exchanger and then returned
to the hydraulic reservoir. A temperature gauge is located inside the hydraulic tank for monitoring the
hydraulic oil temperature. The temperature of the oil in the reservoir should not exceed 180°F. If the
oil temperature exceeds 210°F, a red warning light will illuminate to indicate that a problem exists
with the hydraulic system.

October 2008
T
2 #12 SWB
#16 78C
1
#6 SWB
C3 #12 SWB
2 1
Driver side
engine starter
#6 SWB
C2 #12 SWB
#20 SWB
2 1
Passenger side
engine starter
C1 #12 DWB IN
#16 #16 #16 #20

P1 EF 14.9 GPM
Premix agitators
CF
DN006540
7 GPM Fan
Hydraulic motor
reservoir #20 SWB
Figure 2.10—Start/agitator hydraulic PID

2-15
DS161CRTDO12HC
Parker
Ref. 70.99458
DS161NREDO12HC
Parker NC
Ref. 70.99457
NO
dn000113
RA10S30
Parker
Figure 2.11—Aluminum cartridge valve assembly
ADC® Mixing System Circuit

The ADC mixing system circuit is an open-loop, pressure-compensated circuit. Figure 2.12 (Page
2-18) is a schematic of this circuit. This circuit positions hydraulic actuators that are coupled to valves
that effectively meter water and cement into the cement mixer. The circuit is designed to withstand a
maximum pressure of 3,000 psi, but a pressure-relief valve in the circuit is designed to prevent
pressure from exceeding 2,500 psi. The compensator on the hydraulic pump is set to maintain a system
pressure of 2,100 psi.
The ADC mixing system circuit consists of a pressure-compensated pump, a manifold block with two
proportional valves and a directional valve, two rotary actuators with positioning control, and one
on-off actuator. One proportional valve controls the position of the rotary actuator mounted on the
cement valve; the other proportional valve controls the position of the rotary actuator mounted on the
water valve. The directional valve controls the master water valve actuator, which can be open or
closed. Figure 2.13 (Page 2-19) shows the ADC mixing system hydraulic manifold block.

The FLECS system controller determines the initial position of the actuators, which control the water
valve and the cement valve. Electrical feedback from the actuators to the proportional valve monitors the
position of the actuators. Ultimate feedback to the FLECS system controller from the mix-water
flowmeter and the recirculating densometer determine the position of the proportional valve and the
actuators. This feedback is constant when the ADC system circuit is being used, allowing the FLECS
mixing system controller to continually monitor the position of the rotary actuators and proportional
valves and incrementally change these positions as necessary.
If you must control the mixing process manually (by using handles to rotate the cement and water valve),
bypass the hydraulic oil from the manifold to the hydraulic reservoir by opening the 1/2-in. ball valve
located on the driver's side of the control stand. In addition, open the ball valve located on each hydraulic
actuator to bypass the hydraulic oil. Once the oil has been bypassed, the water and cement valves can be
moved manually. To restore automatic control by the FLECS system computer, close these ball valves.
Micro Motion® F300 Mass Flowmeter

Beginning with 2007 production, the HCR Elite® trailer is equipped with a Micro Motion F300 mass
flowmeter (SAP No. 101405359) instead of a radioactive densometer. This meter is used to measure
slurry density and works in conjunction with the mixing control system and the FLECS controller. The
RCM line is split into two lines at the F300 meter to reduce flow rate through the F300 for prolonged life.
A manual butterfly valve is located in the F300 meter bypass line. During wash-up, this valve should be
closed for a short period to force the maximum amount of rinse water through the meter.

dn000359
Figure 2.12—ADC mixing system hydraulic PID

dn000360
Figure 2.13—ADC mixing system hydraulic manifold block
Control Stand
The control stand is a single-console, one-piece enclosure that includes the controls, instrumentation, and
diagrams necessary for operating the major components of the trailer. It contains the FLECS controller,
engine and transmission controls and instrumentation, control valves for butterfly valve actuators,
hydraulic gauges, diesel-fired heater controls, centrifugal-pump speed controls, floodlight switches, and
ADC mixing system manual override controls. Figure 2.14 (Page 2-20) and Figure 2.15 (Page 2-21) show
the control panel.
Components are grouped on the panel for easy operation and maintenance. Instrumentation and switches
for each component or system are grouped together. Removable access panels for mounted components
are located on all four sides of the control stand. A bulkhead for termination of air and hydraulic lines
being routed into the control stand is located on the front side of the control stand, just below where the
operator stands. Wiring and terminal strips for the engines and the FLECS system controller are located

on a large panel inside the control stand, which can be accessed when the rear access panel is removed.
Additionally, the heart of the FLECS controller is contained within a separate enclosure on the driver’s side of the
HCR Elite® trailer.
Figure 2.14—Control panel, twin-pump unit, FLECS controller

Figure 2.15—Control panel, twin-pump unit

Deck Engine Controls

The operating switches and controls for the deck engines (Figure 2.16)
are on the extreme top right and left sides of the control panel. The
switches and controls include the following:
• Murphy PowerView module (Part No. 101339393)

• Morse hand throttle (Part No. 100046107; replacement sensor Part
No. 101273064)
• Circuit breakers for the engine control module (ECM) (mounted in
the interior of the control stand)
• Toggle switches
– 75% OVERSPEED VERIFY switch
– EMERGENCY KILL switch
– engine START/RUN/STOP switch
• Warning lights
– check engine (amber); stop engine (red)
– HT-400 pump high oil temperature; low oil pressure
• 4700 OFS transmission shift pad
The following deck engine controls are located elsewhere on the control
panel.
• air-pressure gauge
• on-off breaker switch for control-stand heater
• (optional) space reserved for on-off switches and circuit breakers
for the Webasto diesel-fired heaters used in cold-weather
environments
See Figure 2.15 (Page 2-21) for the locations of these controls.
Figure 2.16—Deck engine

controls

Auxiliary Engine Controls and Light Switches

The following operating switches and controls for the Cummins AUXILIARY
QSB6.7 engine are located on the lower middle portion of the front
ENGINE
panel (Figure 2.17).
• Murphy PowerView module (Part No. 101339393)

• check engine light (amber); stop engine light (red)
• START/RUN/STOP engine switch
• EMERGENCY stop switch STOP
ENGINE
CHECK
ENGINE
• 75% VERIFY OVERSPEED switch

• horn
• floodlights
75 VERIFY
E-KILL OVERSPEED
IGNITION POWER
– 20-bbl displacement tank lights STOP
RUN
ON
– 8-bbl mixing tub lights START OFF
– rear work-platform lights IDLE FULL

– side iron-rack lights
• control console viewing lights
• test lamp switch THROTTLE
Figure 2.17—Auxiliary
engine controls
4 × 4 Mixing-Pump Controls
The 4 × 4 mixing-pump controls (Figure 2.18) are
located in the lower right section of the control
panel. They include the following:
• case drain hydraulic oil-temperature gauge

• charge-pressure gauge
• system-pressure gauge
• pump-speed controller
• hydraulic oil-temperature warning light
Figure 2.18—4 × 4 Mixing-pump controls

6 × 5 Recirculation-Pump Controls
The 6 × 5 recirculation-pump controls (Figure 2.19) are
located in the lower left section of the control panel. These
controls are identical to the controls for the 4 × 4 mixing
pump. They include the following:
• case drain hydraulic oil-temperature gauge

• charge-pressure gauge
• system-pressure gauge
• pump-speed controller
• hydraulic oil-temperature warning light
Figure 2.19—6 × 5 Recirculation-pump controls
Remaining Hydraulic Instrumentation

The following hydraulic gauges (Figure 2.20) are located
at the far right of the control panel:
• high oil-temperature warning light for hydraulic

reservoir
• hydraulic reservoir oil-temperature gauge
• ADC mixing system-pressure gauge
• start/agitator system-pressure gauge
Lower Control Panel Figure 2.20—Remaining hydraulic instruments
The lower control panel of the control stand includes (1) two-position air valves for opening and closing the
butterfly valves and (2) the PID of the low-pressure manifold. Units are equipped with at least one spare, which
can allow additional control of butterfly valves added by operations personnel. See Figure 2.21 (Page 2-25).
Heater Controls
Circuit breakers and switches required for diesel-fired heaters are located in the center of the control panel. One
diesel-fired heater is used for each engine on the trailer. These heaters heat the coolant within each engine's
radiator and engine block. The control panel also includes a circuit breaker and switch for a control-stand heater.
This heater, which is mounted inside the control stand, warms air lines, preventing water vapor inside them from
freezing. The heater is normally included on all units.

October 2008
ADC
MASTER WATER
VALVE
OPEN OPEN
PASSENGER DRIVER
SIDE SIDE
20 BBL MEAS
TANK 5
DOWN
PRE-MIX
HOLE
SIDE
CLOSED CLOSED SIDE
7
6 8
1 3 5 7 9 11 13 15 17
1 10
6X5 6X5 6X5 6X5 HT400 PASS HT400 DRIVER HT400 HT400 CENTER
PRE-MIX MEASURING TUB BOOST AND SIDE MEAS SIDE MEAS PASS SIDE DRIVER SIDE DRAIN
TUB SUCTION TANK ACTION RECIRCULATION CLEANOUT TANK SUCT TANK SUCT REAR DRAIN REAR DRAIN
3 6X5
CONTROLS PUMP
ABOVE MEAS.
4X4 4X4 4X4 4X4 DOWN HT400 HT400 TANK
PASS SIDE MEAS DRIVER SIDE MANUAL

PASS SIDE DRIVER SIDE HOLE PASS SIDE DRIVER SIDE
4X4
REAR SUCT REAR SUCT TUB SUCT MEAS TUB SUCT TUB SUCT TUB SUCT TUB SUCT SPARE SPARE PUMP
2 4 6 8 10 12 14 16 18
MANUAL MANUAL
OPEN OPEN
2 4
9 11
CLOSED CLOSED
12 14 DRIVERS
PASS.SIDE SIDE
HT400 HT400
13 17 15
Figure 2.21—Lower control panel

2-25
FLECS Controller
The FLECS controller is located in the center portion of the main control panel. It controls the ADC
mixing system, provides overpressure pump protection, and acts as a readout device for
instrumentation. With the back access panel of the control stand removed, you can easily maintain the
terminal strips, and other wiring. Figure 2.22 shows the FLECS controller display. The only portion
of the FLECS controller mounted in the control stand is the display. The other hardware associated
with the FLECS controller is mounted in a stainless steel enclosure underneath the control stand
(Figure 2.23, Page 2-27).
DN006928
Figure 2.22—FLECS controller

DN006929
Figure 2.23—Stainless steel enclosure containing the FLECS controller

hardware


SECTION
Section
13
Preface
Prejob Inspection
Operator Checklist
Before using the HCR Elite® cementing trailer on a job, or on a daily basis, take the following
steps to help ensure that the HCR Elite trailer 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.
The following numbered items describe how to make each of these prejob checks. A summarized
list is included with a diagram of the trailer shown in Figure 3.1 (Page 3-2) so that each item can
be checked off as the operator completes the inspection.
Refer to Section 6 for periodic maintenance schedules.
1. Check and lubricate the carrier bearing if required.

2. Check and lubricate the U-joint and slip-joint for each of the main drive lines. Each
U-joint has one grease zerk fitting. The slip-joint is in the middle of the drivelines.
a. Turn the shaft and apply lubricant through a hole in the HT-400™ pump mount.
b. Check the pump seals for leakage.
3. Start the engine. Check the transmission fluid level at operating temperature (minimum
180°F) with the transmission in neutral. A sight glass is provided to check the transmis-
sion fluid level.
4. Check the transmission filters for leakage.
5. Check the operation of the engine gauges.
October 2008 Prejob Inspection 3-1

Figure 3.1—Operator checklist
3-2 Prejob Inspection October 2008

6. Check the engine water filters for signs of leakage before and after the engine is started.
The water filters are located at the rear of the engine, next to the bell housing.
7. Check the restriction indicator on theengine air filters. As restriction increases, an indicator
moves from green through yellow to red. Change the filter before the indicator reaches red.
Reset the indicator after each time you check it.
8. Check the crankcase oil level of both of the deck engines.
9. Remove or open the fan guard and check the fan belt for tension, wear, general condition,
and alignment. The fan belt is tensioned by adjusting the alternator.
10. Inspect the radiator hoses and connections for leaks. Check the coolant level in all three
radiators. The fluid level should be 1 1/2 to 2 in. (3.81 to 5.08 cm) below the filler neck in
the top tank.
Caution Do not remove the cap from a hot radiator. Major burns could result.
11. 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.
12. Check the auxiliary engine. Check the radiator coolant level, water pump, belts and guard,
engine oil, and air filter. Remove the cover of the air filter and check the element. Replace
it if it is dirty. Check the eight hose connections on the radiator and block.
13. Check the fuel level.
14. Check hydraulic hoses for leaks or for places where hoses might be rubbing against each
other or other surfaces. Fix any leaks and reroute hoses to prevent rubbing.
15. Check the gearbox behind the auxiliary engine for oil leaks. If oil leaks are found, check
the oil level in the gearbox. Lubricate the grease fittings if required.
16. Use the sight glass to check the oil level in the hydraulic tank. When the oil is cold, the level
should be 1 to 1 1/2 in. (2.54 to 3.81 cm) below the high-level mark. When the oil is warm,
the level should be at the high-level mark.
17. Check the 6 × 5 recirculation pump for leakage and bearing damage. Verify that flanges are
tight and not leaking. Check the lubricant line on the pump stuffing box.
18. Check the 4 × 4 mixing pump for leakage and bearing damage. Verify that flanges are tight
and not leaking. Check the lubricant line on the pump stuffing box.
19. Check hydraulic pumps and fittings for leaks.
20. Check the condition of pump packing. Remove the caps and check the valves, seats, and
springs.

21. Check the waste oil drain line and waste tank level. Drain if necessary.
22. Check the tire pressure and examine each tire carefully for wear, tread loss, bulges, and cracks.
23. Before every trip, drain moisture from the two airlock-brake tanks located below the HT-400
pumps. Open a petcock or quick-latch valve on each tank until all moisture is discharged.
24. Check the pressure lube system reservoirs. Turn the handle 90° to uncover the reservoir cap.
Check the dipstick for proper fluid level.
Caution Turning the handle releases air pressure on the system reservoirs. Be sure
reservoirs are not pressurized when you remove the cap. Have a supply of
lube oil if you anticipate continuous pumping. The reservoirs must be checked
every hour and must be refilled quickly unless the pumps are taken off the
line.
25. Check both 2-in. (5.08-cm) Lo Torc® plug valves in the release lines. Be sure they are easily
turned but not loose. If they are loose, tighten the plug with the bar used to open and close
these valves.
a. Grease the grease zerk fitting that is fitted to the 1-in. (2.54 cm) Lo Torc® plug valve in
the same line.
b. Grease the fittings on the release-line swivels behind the RCM® mixing system tank.
26. When the hydraulic system is warm and engaged, check the hydraulic oil filter condition indi-
cator.
27. Check the crankcase oil of the HT-400 pumps. The dipstick is attached to the filler cap.
28. Check the following mixing-system components:
a. Remove and check the cement head for cement buildup. Remove buildup by loosening
the 5-in. (12.7-cm) union and pivoting the head toward the front of the trailer. Be sure
the head rotates freely. Clean it well to ensure proper operation. Grease it if necessary.
b. Push the vacuum breaker to ensure that it operates and is free of cement buildup.
c. Check the mixing manifold water valve. Ensure that the valve rotates freely. Grease if
necessary.
Caution Do not overgrease the water valve. Valve will not operate if it is overgreased.
d. Check the master water valve and the washup valve to be sure they are operating and are
free of cement buildup.
e. Be sure the F300 mass flowmeter is clean and calibrated.

29. With engines running, make the following checks:

a. At the control stand, be sure all air-actuated valves are working properly. Although the con-
trols 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.
b. Check the engine throttles for each deck engine and for the auxiliary engine. The tachom-
eters are directly above the throttle levers of the control stand. Be sure each throttle operates
correctly.
c. Observe the engine oil-pressure and water-temperature gauges.
d. Check the transmission oil temperature. It should be below 275°F (135°C), but 300°F
(149°C) temperatures can be tolerated for short periods.
Note Typical operating temperature range is 200 to 250°F.
e. Oscillate the water and cement valves.

f. Run 6 × 5 and 4 × 4 centrifugal pumps. Verify that they are operating correctly.
g. Verify that tub agitators are operating properly.
30. With the auxiliary engine running, verify that all hydraulic pressure gauges are operating and
reading the correct pressure and temperature for the specific hydraulic circuit.
Lubrication
Oil and oil pressures are critical to an engine’s life. If part of the oil pressure is lost, watch the oil-pressure
gauge closely. If the pressure continues to drop, shut down the engine and notify your shop personnel.
Check with your shop foreman for the correct oil to use. Use the proper grade and viscosity of lubricant
in diesel engines (see Specification 278.90538 for further details).
Air Cleaners and Filters

Failure to clean or change the filters at regular intervals, which are determined by local dust conditions,
reduces filter efficiency. A clogged filter starves an engine for air. The air supply almost entirely controls
the amount of fuel that can be burned. On turbocharged engines, air restriction can cause the turbocharger
to overspeed and the exhaust temperatures to rise, often resulting in burned-out turbine bearings. When
servicing the intake air filters, also service the crankcase breathers. The replacement filter element for the
Cat 3176, C-10, and C-11 engines is SAP No. 100002596, and the replacement filter element for the
Cummins QSB6.7 engine is SAP No. 100029673.
Hoses and Connections

Check hoses and connections regularly. All intake air must pass through the air cleaner. Holes in piping
or connections can allow air to bypass the cleaner, contributing to the rapid wear of pistons, rings, liners,
and valves.

Large leaks in the intake system can be observed, but small leaks must be located by some other
method. The best way to find small leaks is to pressurize the system and measure the pressure drop
with a gauge.
Fuel Lines
When temperatures fall below freezing, fuel lines, filters, and other parts may freeze. Freeze-up can
be caused by moisture in the fuel supply or condensation in the fuel system.
To protect against fuel-system freeze-up, a cold-weather area generally should add to a full fuel tank
1 pt (0.47 L) pure anhydrous (waterless) alcohol or methanol (wood alcohol) per 50 gal (190 L) of fuel.
Check with shop personnel for local specific recommendations. Anhydrous alcohol and methanol
absorb moisture from the fuel system, helping prevent fuel-system freeze-up. Whenever possible, use
methanol, which is available in 1-gal containers or bulk lots at chemical supply houses in most sections
of the world.
Caution Methanol or anhydrous alcohol should be supplied in tightly closed drums. Be

sure the contents have not been exposed to the atmosphere. Exposed contents
may have absorbed near-capacity moisture. If the alcohol has absorbed
near-capacity moisture, it cannot be used as a drying agent. Never use
reclaimed methanol. Methanol absorbs all the moisture it can during
handling.
Coolant
Frequently check the coolant levels in all engines. Ask your shop foreman about coolant
recommendations for your local conditions (see Specification 70.85228).
Before adding antifreeze solution to a cooling system, check all water connections for leaks.
Note When refilling an engine cooling system, be sure all air is bled (purged) from the
system, including the radiator. Failure to do so may result in engine failure.
After the antifreeze mixture has been added and the system is free of all trapped air, run the engine
until the thermostats open and the solution is thoroughly mixed. Check the system for leaks. Antifreeze
solutions often leak when plain water will not. Ensure the coolant level is 1 1/2 to 2 in. (3.81 to 5.08
cm) below the filler neck.

SECTION
Section
14
Preface
Operation
Introduction
Section 4 discusses the following:
• operating procedures for the unit

• instructions for operating the engines, engine overspeed, and engine diagnostic
• instructions for priming the unit before the job
General
Before starting an engine, follow these steps:
1. Check the lubricating oil and coolant levels.

2. Shift the transmission to neutral.
3. Move the throttle control to the fast idle position.
Important Various instruments are installed on all diesel engines to help ensure proper
engine operation and normal life. Report abnormal instrument readings and
other unusual circumstances to shop personnel.
Starting the Auxiliary Engine

To start the auxiliary engine, perform the following:
1. Close all butterfly valves.

2. Turn the POWER switch on.
3. Turn the auxiliary STOP/RUN/START engine switch to the RUN position.
October 2008 Operation 4-1

4. Open the throttle slightly, pull the toggle switch down, and crank the engine. After start-
ing, release the toggle switch.
Warning Do not crank the engine for more than 30 seconds at a time. The electric
starter can overheat if the engine is cranked too long.
5. When the auxiliary engine has started, set the throttle at 800 to 1,000 rev/min, and allow
the engine to warm up until the engine water reaches a minimum of 170°F (77°C).
The operator should monitor the pressure gauges during auxiliary engine startup. When
the engine is started, the hydraulic system pressure should be between 1,200 to 2,000 psi.
A relief valve set at 2,500 psi protects the entire circuit. All system components are rated
at a maximum system pressure of 3,000 psi.
Starting the Deck Engine

To start the engine, the operator must engage the momentary STOP/RUN/START switch on the
control console, which energizes the engine’s cartridge valve. When this cartridge valve is
energized, it will shift from the normally closed (NC) to the open position, allowing oil to flow
to the hydraulic motor that starts the deck engine. At the same time, the normally open (NO)
cartridge valve for the premix agitators will be energized and shift from NO to a closed position,
forcing all hydraulic oil through the cartridge valve for the deck engine and to the line for the
engine’s starter motor. Once the engine has been started and the operator releases the momentary
STOP/RUN/START switch on the control stand, the cartridge valves on each engine will return to
their de-energized positions, and the oil will be redirected to the tub agitators.
Caution Never start both deck engines at the same time. Starting both engines
simultaneously will prevent adequate flow of hydraulic oil to each
hydraulic starter.
To start the deck engine, perform the following:
1. Put the transmission in neutral.

2. Turn the STOP/RUN/START switch to run.
3. Set the deck-engine throttle to fast idle (about 1,800 rev/min).
4. Open the auxiliary engine throttle until the tachometer indicates the engine has reached
maximum speed. The auxiliary engine provides power for the hydraulic start system.
5. Place the momentary STOP/RUN/START switch in the start position, and hold the switch
in this position until the engine starts. After the engine starts, return the switch to the run
position by releasing it. The hydraulic starter can be operated as long as hydraulic pres-
sure is available.
4-2 Operation October 2008

6. Immediately after starting the engine, check the oil-pressure gauge. If no pressure is indi-
cated after 10 to 15 seconds, stop the engine and check the lubricating system.
7. Check hydraulic fluids frequently.
8. Check the water-temperature gauges.
9. When the engine is running, set the throttle to 1,000 to 1,200 rev/min, and allow the engine
reach an operating temperature of 170° to 195°F (77° to 91°C).
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).
Note The nor mal o perating w ater t emperature fo r al l diesel eng ines us ed b y
Halliburton Energy Ser vices is 170 ° to 19 5°F ( 77° t o 91°C) . The maxi mum
water temperature is 210°F (99°C).
Important In col d ar eas w here te mperatures are oft en be low 32 °F (0 °C), the wa rm-up
period for tur bocharged engines is es pecially important. I n col d, ext ernal oil
lines that lead to the turbocharger, oil flows slowly until the engine warms up,
decreasing the oil supply to the bearings.
Operation in Harsh Conditions

If thermostats are heavily sludged or covered with scale, they can remain closed, causing the engine
to overheat. If they remain open, the coolant will not heat up enough to reach the normal operating
temperature. An engine that is too cool does not permit complete fuel combustion (burning),
causing varnish and gum deposits on rings and pistons and sludging of lubricating oil. Either
temperature condition is unhealthy for an engine and results in higher operating costs and more
frequent overhauls or repairs. Tell your shop foreman if an engine overheats or does not warm up
properly.

Engine Idling
When deciding whether to idle an engine, consider fuel costs and the possibility of lubrication-oil
contamination. Not all fuel is burned when an engine idles.
Important Minimize idling time. Excessive idling causes unburned fuel to build up in the
cylinders a nd r un down t he c ylinder wa lls to the cr ankcase, di luting th e
lubricating oil.
If you anticipate a long idling period, stop the engine.
Adjusting the Deck Engine Throttle

The upper and lower engine rev/min limits have been set by manufacturing. However, if necessary,
the engine throttle control (ETC) will allow the operator to set the rev/min limits to help ensure
safety and efficiency. When the limits are correctly adjusted, the limit stops will provide a high and
low rev/min limit for engine speed, and the engine can be operated at any throttle setting necessary
for the job, as long as it is within the designated rev/min range (reference D00146642 in Matrix).
Setting High and Low Engine-Speed Limits

A tension nut maintains the high and low engine-speed limits. To adjust the limits, use a 1/16-in.
Allen hex wrench.
Low rev/min Limit

To set the low rev/min limit, perform the following:
1. With the control knob facing you, turn the knob clockwise until the low rev/min limit is
reached. If necessary, back out set screw “B” to obtain the required rev/min.
2. Tighten the tension nut to lock the control knob in place.
Low rev/min Limit Stop
To set the low rev/min limit stop, perform the following:
1. Turn set screw “B” inward (clockwise) until contact is made.

2. Release the tension nut.
3. Rotate the control knob counterclockwise, then clockwise, to check the adjustment.

High rev/min Limit

To set the high rev/min limit, perform the following:
1. With the control knob facing you, turn the knob counterclockwise until the high rev/min
limit is reached. If necessary, back out set screw “A” to obtain the required rev/min setting.
2. Tighten the tension nut to lock the control knob in place.
High rev/min Limit Stop
To set the high rev/min limit stop, perform the following:
1. Turn set screw “A” inward (clockwise) until contact is made.

2. Release the tension nut.
3. Rotate the control knob clockwise, then counterclockwise, to check the adjustment.
Operating the ETC

After adjusting the high and low speed limits, the operator can adjust the deck engine throttle by
turning or pushing the ETC control knob.
• To increase engine speed (rev/min), rotate the ETC control knob counterclockwise.
• To decrease engine speed, rotate the ETC knob clockwise.
• To instantly return the engine speed to idle, push the control knob inward.
Engine Overspeed
The engine overspeed is pre-set in the electronic control module (ECM).
Deck Engine Overspeed

The overspeed-protection system stops the engine during a potential runaway overspeed condition.
An overspeed condition could occur if a high concentration of flammable gases is present in the
atmosphere. In theory, normal engine control can be lost if these gases combust. The following
basic components are used for overspeed protection:
• ECM
• relay
• air-inlet solenoid
• air-intake flapper valve
A more detailed explanation of this system in available in the wiring diagram for a twin-pump unit.
(See Appendix B.)

The Cat C-10 and C-11 engines can operate at 2,100 rev/min fully loaded. The overspeed system
stops the engine if the speed reaches approximately 2,478 rev/min (18% above rated speed) or
higher. This speed is preset into the ECM.
If the engine reaches 2,450 rev/min, the ECM outputs a control voltage to close the normally open
relay and turns off the fuel injectors. The relay then sends a voltage that engages the air-inlet
solenoid. Once the solenoid is engaged, a spring will close the air-intake flapper valve, stopping the
engine.
The unit also includes an emergency kill switch in the control stand. When engaged, this switch
directly powers the relay and actuates the flapper valve, stopping the engine.
Warning Only use the emergency kill switch in emergency situations or when the
normal method of shutting off the engine fails. Using the emergency kill
switch to stop the engine closes the flapper valve, denying air to the intake
of the turbocharger. In certain situations, denying air to the turbocharger
can severely damage the engine.
Overspeed System Test

To test the overspeed system on the Cat C-10 and C-11 engines, engage the 75% verify overspeed
switch in the control stand. When the engine speed reaches 75% of the speed set in the ECM
(approximately 1,838 rev/min), the engine should stop. This test verifies that the overspeed is
working properly. Move the switch back to its normal position to return the engine to the normal
working mode.
Once the flapper valve for the air intake on the engine is engaged, it must be manually reset to the
open position before the engine can be restarted.
Auxiliary Engine Overspeed

The overspeed protection system on the auxiliary engine stops the engine during a potential
runaway overspeed condition. An overspeed condition can occur if a high concentration of
flammable gas is present in the atmosphere. Normal engine control can be lost if these gases
combust.
The Cummins QSB6.7 engine can operate at 2,500 rev/min fully loaded. The overspeed system
stops the engine if the speed reaches approximately 2,950 rev/min (18% above rated speed).
The air intake to the engine is equipped with an emergency shutdown valve that is closed in an
emergency kill situation by oil pressure. When an overspeed condition is detected or the
EMERGENCY KILL switch is activated, the ECM activates the versa valve (Part No. 101564662),
which opens and allows oil pressure to reach the emergency shutdown valve (Part No. 101302354).

This causes the emergency shutdown valve to shut off air to the engine and kills the engine. The
following bullets provide details for these parts.
• Part No. 101564662 versa valve, Deutsch 2-pin connector, diode transorb, 12v DC, for
Cummins e-kill.
• Part No. 101302354 shutdown valve, air, emergency kill, 4.0 in, with air cylinder, pressurize to
shut down
Warning Do not use the EMERGENCY KILL toggle switch except in an emergency
situation or in 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.
Important Once the emergency shutdown valve is activated, it must be manually

opened and reset before the engine can be restarted.
Monitoring the Engines
Monitoring Gauges
Important During engine operation, check all gauges frequently to ensure that the system
is working properly.
Monitoring and Interpreting Engine Warning Lights

Auxiliary Engine
The control panel for the auxiliary engine contains a single warning light (CHECK ENGINE). The
light is activated by one of the following conditions:
• Oil pressure is below 30 psi.

• Water temperature is above 210°F.
Warning If the engine warning light is activated, shut down the auxiliary engine
immediately and determine what the problem is.

Deck Engine
The control panel for the deck engine (Figure 2.15, Page 2-21) contains the following four warning
lights:
• The CHECK ENG. light (amber) illuminates when an engine problem is detected by the electronic
engine controls.
• The ENG. STOP light (red) indicates low oil pressure (<30 psi).
• The TRANSMISSION light (red) indicates high oil temperature (>220°F).
• The HT400 light (red) indicates low oil pressure (<40 psi) or high oil temperature (>220°F).
When a fault condition occurs, the CHECK ENG. light is usually the operator’s first indication of
a problem. The CHECK ENG. light will flash on and off according to the code displayed on the
“Caterpillar ADEM 3 Diagnostic Codes.” For instance, the flash code for a fault with cylinder
number 1 or 2 is 72. If this problem occurs, the CHECK ENG. light will flash seven times, pause,
and flash two more times, indicating a flash code of 72. If the problem is critical, the ENG. STOP
warning light will also illuminate, indicating a risk for engine failure.
When any of the four warning lights are activated, identify the fault code and use the diagnostic
code panel to assess the risk associated with the problem. Determine whether the engine must be
shut down.
If the fault code is noncritical, the operator can complete the job and perform maintenance
afterward.
The red warning lights for the HT-750 transmission and the HT-400 pump indicate that a critical
parameter in the component is not operating within the normal range. The engine will not shut down
or derate if either of these two warning lights illuminates. The operator must decide whether or not
to take the powertrain off line or to finish the pumping service and repair the component(s) later.
Engine Display and Diagnostic Readouts

HCR Elite® trailers are equipped with the Murphy PowerView module for monitoring engine
parameters and diagnostic codes.

Operating the PowerView Module

The PowerView module (Figure 4.1, Page 4-10) allows the operator to electronically monitor the
operation of the deck engines from the control stand. Each engine is equipped with its own Murphy
PowerView module, which contains the following basic parts:
• an engine data window

• buttons for selecting the information you want to view
• a parameter identification (PID) display key
See the Murphy PowerView Operation Manual in Appendix D of this manual.
When any of the warning lights are activated, identify the fault code and use the diagnostic code
panel to assess the risk associated with the problem. Determine whether the engine must be shut
down.
DN006930
Figure 4.1—Murphy PowerView module
Engine Data Window

The engine data window contains a three-digit PID number that categorizes the information
displayed in the window. The window also includes a second value that can represent a variety of
units (%, psig, temperature, voltage, rate, rev/min), depending on the vital sign being monitored.
For example, in Figure 4.1 the PID number 100 indicates engine oil pressure, and the number 65.3
indicates the engine oil pressure (psi).

PowerView Instructions
See Appendix D, Murphy, PowerView Installation and Operations Manual.
Identifying and Interpreting Fault Codes

A Caterpillar component identification (CID) number is similar to a PID number. The CID will
allow the operator to identify a fault. If an engine problem occurs, the engine data window will
display a fault code. A CID number will be preceded by the letter “F” and followed by a failure
mode indicator (FMI) number. The FMI number is more specific than the CID number and can help
an operator more accurately assess the cause of an engine problem. The decal on the side of the
control stand lists the CID number and the FMI for each type of fault that can occur on Caterpillar
3176 engines. If a fault is displayed on the Murphy PowerView module, note the fault code and
consult the Caterpillar Service Manual (Part No. 101279225) for instructions about correcting the
problem.
If the PowerView unit is set for autoscrolling when a fault occurs, a fault code will appear
immediately in the engine data window.
If the PowerView unit is set to display a discrete CID number when a fault occurs, the unit will
resume autoscrolling and display all active faults and the routine CID displays within 5 minutes.
Warning When a fault code is displayed, carefully monitor the control stand for the
activation of red warning lights. Illumination of warning lights could
indicate low oil pressure (engine or HT-400 pump), high oil temperature
(transmission), or high water temperature (engine), all of which require
immediate engine shutdown. See “Monitoring and Interpreting Engine
Warning Lights,” Page 4-9, for more information.
To interpret a fault code, identify the CID number listed in the fault code and locate the CID number
in the diagnostic code chart of the Caterpillar Service Manual (Part No. 101279225).
If the problem is critical (meaning that continued operation will likely result in damage to
equipment), shut down the engine.
If the problem is minor and will not threaten the job, reduce the engine speed, troubleshoot the
problem as needed, and continue operation.
Operating the Murphy PowerView Module

The Murphy display and diagnostic module (PowerView) is used for electronically controlling
engines with the SAE J1939 controller area network (CAN). HCR Elite® trailers built with the
Caterpillar C-10 and C11 deck engines will use the PowerView module. The PowerView module
includes a four-parameter backlit LCD display.

The PowerView module has four push buttons for scrolling through the parameter list and viewing
the menu list. Two LEDs (amber and red) are used to annunciate active fault messages received by
the PowerView module.
The following engine parameters are displayed by the PowerView module in English or metric units
(when applicable):
• engine hours
• engine rev/min
• system voltage
• % engine load at the current rev/min
• coolant temperature
• oil ressure
p
• fuel economy
• throttle position
• manifold air pressure
• current fuel consumption
• active service codes
• stored service codes from the engine
• set the units for display
• view the engine configuration parameters
The PowerView module is simple to use and allows quick and easy navigation through the menu
structure to find the information needed.
For specific information on viewing engine configuration data, viewing active engine service
codes, or viewing service codes in the ECM, refer to the PowerView Installation and Operation
Manual in Appendix D of this manual.

Pump Operation
Priming the HT-400 Pumps and Centrifugal Pumps

Before each cementing job, the centrifugal pumps, the HT-400 pumps, and all piping must be
primed with water. The following procedure explains how to prime each pump and the
accompanying piping for a single- or twin-pump unit. This procedure is general, and several other
priming methods are available. Over time, each operator will develop a slightly different method
for priming the unit depending on type of job being performed and the number of HT-400 pumps
being used (one or two). Some parts of the following procedure can be omitted depending on the
manner in which the truck is being used.
1. Attach a 4-in. (10.16-cm) ID suction hose (supplied with the cementing unit) between an
external water-holding tank or other water source and the outside suction for the mixing
pump.
Note The w ater-holding ta nk m ust be si tuated s o th at th e water le vel is above the

mixing pump’ s o utside s uction. I f the wat er le vel i s l ower t han th e mi xing
pump’s outside suction, the centrifugal pump must be primed initially.
Note Ensure that all ground manifolding is connected before you prime the pumps.
2. Engage the mixing and recirculating centrifugal pumps by moving the hydraulic joystick
controller forward.
3. Open the outside suction valve to the mixing pump, and increase the auxiliary engine speed
to the maximum speed. (The outside suction valve is hand-operated.)
4. Open the mixing-pump discharge valve located on top of the 20-bbl displacement tank, and
fill either side of the displacement tank. After one side is full, switch the fill manifold and
fill the other side of the displacement tank. Close the valve.
5. To fill the RCM® mixing system tub, open the master water valve and the water-metering
valve leading to the tub. Hydraulic actuators are mounted on both the master water valve
and the water-metering valve. The master water valve is wired to be open when electrical
power is not being supplied to the FLECS controller and ADC® mixing system. After the
FLECS controller is powered up, this valve will close. Either open the partition valve, or
allow water to spill over the weir of the tub so that it fills both the premix and downhole
portions of the cement tub.
6. After filling the RCM mixing system tub, idle the auxiliary engine, and close the master
water valve.

7. Begin recirculating the water in the RCM mixing system tub by opening the 6 × 5 tub recirc.
valve.
8. Close the 2-in. (5.08-cm) high-pressure discharge valves on the HT-400 pumps, and open
the three release-line valves. [The release-line valves are the two 2-in. (5.08-cm) and the
single 1-in. (2.54-cm) Lo Torc® plug valves.]
9. Open both HT-400 pump gravity-suction valves mounted directly on the displacement tank.
These valves are mounted with air actuators. The controls for these air actuators are located
on top of the displacement tank.
10. Prime the driver’s side HT-400 pump tank-suction lines for the twin-pump unit by perform-
ing the following steps:
a. Open the HT-400 pump drivers side meas. tank suction valve. Fluid will flow from the
displacement tank to the driver’s side of the HT-400 pump. Shift the transmission to
the 2-3 gear position for the driver’s side pump.
b. Open the driver’s side engine throttle to between 1,500 and 1,800 rev/min.
c. Circulate water until the lines are free of air. A smooth, even flow of water into the
tank indicates that the air has been removed and that the pump and lines are primed.
d. When the driver’s side system is primed, reduce the engine speed to 1,000 to 1,200
rev/min. Shift the transmission to neutral, and close the HT-400 pump DRIVERS SIDE
MEAS. TANK SUCTION valve.
11. To prime the tank suction lines on the passenger-side HT-400 pump, repeat Steps 10a
through 10d, opening the HT-400 pump PASS SIDE MEAS TANK SUCTION valve.
12. To prime the tank suction lines on the single-pump trailer, perform the following:
a. Repeat Steps 1 through 9.
b. Open the HT-400 pump MEAS. TANK SUCTION and HT-400 pump MASTER SUCTION
valves. Shift the transmission to the 2-3 gear position for the HT-400 pump.
c. Open the driver’s side engine throttle to between 1,500 and 1,800 rev/min.
d. Circulate water until the lines are free of air. A smooth, even flow of water into the
tank indicates that the air has been removed and that the pump and lines are primed.
e. When the driver’s side system is primed, reduce engine speed to 1,000 to 1,200
rev/min. Shift the transmission to neutral, and close the HT-400 pump MEAS. TANK
SUCTION and HT-400 pump MASTER SUCTION valves.
13. When the tank suction lines are primed, close the two valves leading from the measuring
tank to the HT-400 pump.
14. Follow these steps to prime the tub suction lines on the driver’s side HT-400 pump:
a. Open the DOWN HOLE TUB SUCTION and HT-400 pump DRIVERS SIDE TUB SUCTION
valves on the HT-400 pump.

b. Engage the driver-side transmission in the 2-3 gear position.

c. Open the throttle to 1,500 to 1,800 rev/min for the driver-side engine.
d. Operate the pump again until all air is removed from the lines. A smooth, even water
flow into the measuring tank indicates proper prime.
Note The RCM mixing system tub contains only 8 bbl of liquid. If necessary, open
the master water valve and the water throttling valve to add additional water to
the RCM mixing system tub for priming the tub suction. Refer to Steps 2–6.
e. After removing all air, idle the engine, disengage the transmission, and close the down
hole tub suction and HT-400 pump driver’s side tub suction valves.
15. To prime the passenger-side HT-400 pump tub suction lines, repeat Steps 14a through 14e,
but use the DOWN HOLE TUB SUCTION and HT-400 pump PASS SIDE TUB SUCTION valves.
16. To prime the tub suction lines on the single-pump trailer, repeat Steps 14a through 14e, but
use the DOWN HOLE TUB SUCTION, HT-400 pump TUB SUCTION, and HT-400 pump MASTER
SUCTION valves.
17. To recirculate water in the displacement tank with the HT-400 pump, perform the following
procedure. This procedure describes how to recirculate water from the displacement tank
with the 6 × 5 booster pump.
a. Close the PREMIX TUB SUCTION and 6 × 5 TUB RECIRC valves.
b. Open the 6 × 5 MEAS. TANK SUCTION and 6 × 5 BOOST & CLEANOUT valves. Both
valves are air-operated from levers on the control stand.
c. Open one of the discharge valves from the 20-bbl measuring tank. The controls for
these valves are located on top of the 20-bbl displacement tank.
d. Open both HT-400 pump tub suction valves. On a twin-pump unit, these are the
HT-400 PASS SIDE TUB SUCTION and HT-400 pump DRIVERS SIDE TUB SUCTION
valves. On a single-pump unit, these are the HT-400 pump TUB SUCTION and HT-400
pump MASTER SUCTION valves.
e. Engage the hydraulic control for the 6 × 5 pump, and open the throttle to the maximum
speed.
f. Open the HT-400 pump release-line valves so that water can flow from the 20-bbl
tank through the recirculating pump, the HT-400 pump suction-header, and the
release line back to the 20-bbl tank.
18. Prime the suction manifold from the 4 × 4 mixing pump to the measuring tank by perform-
ing the following steps:
a. Close all of the 4 × 4 mixing pump’s outside suction valves. The valves on either the
driver’s or passenger’s side are manually operated. The valves at the rear of the trailer
are air-actuated in the control stand.

b. Open the 4 × 4 MEAS. TANK SUCTION valve; then, open one of the discharge valves on
the 20-bbl measuring tank. The controls for these two valves are located on top of the
measuring tank.
c. Engage the hydraulic control for the 4 × 4 mixing pump, and open the throttle to
maximum speed.
d. Continue circulating water until all air is removed from the lines.
Operating the 6 × 5 Recirculating Pump

Figure 2.19 (Page 2-24) shows the controls for the 6 × 5 pump.
Figure 4.2 (Page 4-16) is a schematic of the 6 × 5 centrifugal hydraulic system.
When the lever of the joystick controller is centered, the hydraulic pump is not stroked and the
centrifugal pump will not rotate. When the lever is pushed forward (away from the operator’s body),
the hydraulic pump is stroked and the centrifugal pump will begin rotating. The further forward the
lever of the joystick controller is pushed, the further the hydraulic pump will be stroked, increasing
the speed of the centrifugal pump.
Operators should operate this pump fully stroked and carefully monitor the gauges to maintain the
following operating parameters:
• The charge pressure for this circuit should be 325 to 350 psi.
• The system pressure should not exceed 5,000 psi.
Important If either the gauge or the warning light indicates a hi gh hydraulic oil temper-
ature, investigate the cause.
• Approximate minimum speed of the 6 × 5 pump with auxiliary engine speed of 2,500 rev/min
is 1,700 rev/min.

4-16
#16 SWB
Outlet
#6 SWB
Heat
#20 SWB
Operation
exchanger
SWB #20
Inlet
SWB #20
2 1
Charge
pump
inlet Control stand
System press
gauge port
#6 SWB
Charge to
external System
filter pressure
Charge from guage
external
filter
Charge
pressure
guage T
2 1
#12 SWB
P
#12 SWB
#12 SWB 1 2
Upper case
drain 39 40 42 38
#6 SWB
#4 381
2 1
Control Control #6 SWB
port 1 port 2
Control To control port 1

#12 SWB Lower port 1
case drain 6 x 5 mixing pump
Pressure
#16 78C Port b

A
PORT
A
DN006548
PORT
B
Return
B
#16 78C Port a 2 1
Hydraulic control head
#8 SWB
Figure 4.2—6 × 5 Centrifugal hydraulic system
October 2008
Operating the 4 × 4 Mixing Pump

Figure 2.18 (Page 2-23) shows the controls for the 4 × 4 pump.
Figure 4.3 (Page 4-18) is a schematic of the 4 × 4 centrifugal hydraulic system.
Operating procedures for the 4 × 4 mixing pump are almost identical to operating procedures for
the 6 × 5 recirculating pump, except that the 4 × 4 mixing pump should not be fully stroked. The
hydraulic circuits of the 4 × 4 and 6 × 5 pumps are also virtually identical.
The operating speed of the 4 × 4 mixing pump varies according to the mixing rate required. To
operate the 4 × 4 mixing pump, perform the following:
1. Stroke the joystick controller forward to achieve 100 psi on the 4 × 4 mixing-pump dis-
charge manifold and to achieve the required pump rate.
2. Monitor the gauge on the discharge side of the centrifugal pump to maintain pressure.
Warning Do not operate the mixing pump at a pressure higher than 100 psi. This
decreases the life of the pump and the mixer jetting components.
3. Maintain the following operating parameters:

• The charge pressure for this circuit should be 325 to 350 psi.
• The hydraulic system pressure should not exceed 5,000 psi.
Important If e ither the gaug e or the w arning light i ndicates a hi gh hy draulic oi l

temperature, i nvestigate to de termine t he cause. Some common c auses of
hydraulic malfunctions are obstructions to air flow and dust buildup on the heat
exchanger.
• Approximate minimum speed of the 4 × 4 pump with auxiliary engine speed of 2,500
rev/min is 2,200 rev/min.

4-18
#16 SWB
Outlet
#6 SWB
Heat
#20 SWB
exchanger
Operation
SWB #20
Inlet
SWB #20
2 1
Charge
pump
inlet Control stand

System press
gauge port
#6 SWB
Charge to System
external
filter press
Charge from
guage
external
filter
Charge
press
guage T
2 1
#12 SWB
P
#12 SWB
#12 SWB 1 2
Upper case
drain 45 44 42 28
#6 SWB
#4 381
2 1
Control Control #6 SWB
Port 1 Port 2
Control To control port 1

#12 SWB Lower port 1
Case drain 4 x 4 mix pump
Pressure
#16 78C Port B

A
PORT
A
DN006549
PORT
B
Return
B
#16 78C Port A 2 1 Hydraulic control head
#8 SWB
Figure 4.3—4 × 4 Centrifugal hydraulic system
October 2008
Stopping the Engines

When you are ready to stop an engine, use the following procedures:
1. Release the load, and decrease engine speed.

2. Lower engine temperatures by allowing the engine to run at a fast idle (1,200 to 1,500
rev/min) for 15 to 20 minutes with the transmission in Neutral.
3. Once the engine has cooled properly, bring the throttle back to the idle position.
4. Before stopping the pump engines, shift the Allison HT-750 transmission range selector to
neutral.
5. Turn the ignition switch to the stop position, and hold it in this position until the engine
stops.
6. Turn off the ignition switch.
When an engine is operated under a load, heat builds up in the cylinder walls, on the pistons, rings,
valves, cylinder heads, bearings, and (if used) in the turbocharger. If an engine is stopped during or
immediately after loaded operations, the flow of all cooling water and oil will stop and heat will
migrate throughout the engine.
If you accidentally stop an engine during loaded operations, start it again as soon as possible, and
run it at approximately 1,200 rev/min for a few seconds before loading it. If the engine is stopped
immediately following a job, restart the engine, and run it for 15 to 20 minutes at 1,000 to 1,500
rev/min before shutting in down.
Important The cool-down period is particularly important for engines with turbochargers.
The turbocharger normally operates at temperatures of 1,200° to 1,300°F (649°
to 704°C). Oil flow provides the only protection the bearings and seals have
from t he high te mperatures. I f t he flow is su ddenly stopped dur ing or af ter
full-load o perations, the t urbocharger bearings c an melt, d estroying t he seals
and rendering the engine unusable.
Operating the Tub Agitators and Hydraulic Starters

Figure 4.4 (Page 4-20) is a schematic of the start/agitator hydraulic system. The hydraulic-system
operating tub agitators and the hydraulic starters are open systems powered by a fixed-displacement
gear pump. Needle valves are used for controlling the tub agitator speed, and on/off cartridge valves
are used for hydraulically starting the deck engines.
Separate needle valves control the speeds of the premix agitator and the downhole agitator. System
pressure in the tub agitator circuit should be between 1,500 and 2,500 psi, depending on the weight
of the cement being mixed and the speed at which the agitators are being operated.

4-20
Pressure gauge
Case drain line case
Outlet outlet on motor faces
37 down toward ground
Heat
exchanger
#12 SWB
Operation
SWB #20
Inlet
#4 381
SWB #20
#20 SWB
#12 SWB
Heat exchanger
#12 381
Pressure port
Driver’s side
engine
#12 381
#12 381
#20 SWB
Pressure port
Passenger’s side
engine
#20 SWB
Suction port #12 381
To case drain
ADC pump
Auxiliary engine
#12 381
DN006550
Pressure compensator Discharge port
Figure 4.4—Start/agitator hydraulic system
October 2008
SECTION
Section
15
Preface
Mixing System Problems and

FLECS Controller Operation
FLECS Controller Operation
FLECS stands for the Flexible Electronic Control System. The FLECS Manual (Part No.
101324382) provides specific information about this component as well as some
operational information. Much of the FLECS controller interface and operation is similar
to that of the Azonics 2500 controller. Additional information can be found at the FLECS
controller technical website:
http://halworld.halnet.com/HES/Hesps/hespspe/hespspe_fracacid/hespspe_fracacid_eqflecs/h
espspe_fracacid_eqflecs.asp
RCM® IIIr Mixer

The HCR Elite® trailer is equipped with an RCM® IIIr mixer with an 8-bbl mixing tub.
The volume capacity of the premix side of the tub (from the bottom to the top of the weir)
is 5 bbl. The volume of the downhole side of the tub is 3 bbl. Access holes are located
on both the premix and downhole sides of the tub. Both access holes include covers that
enclose the tub and prevent splashing during mixing.
Figures 5.2 and 5.5 (Pages 5-4 and 5-7) are simple breakdowns of the parts necessary for
assembling the RCM® IIIr mixer with rotary-jet water valve. Table 5.1 (Page 5-8), shows
the part numbers and descriptions for each numbered location on the diagrams.
The RCM® IIIr mixer with the rotary-jet water valve contains an inner sleeve with 27 jet
holes arranged in nine staggered vertical columns and three staggered horizontal rows.
The total length of holes is identical to the width of the drop-in insert, which is located
in the center of the mixer.
October 2008 Mixing System Problems and FLECS Operation 5-1

A plug that can be rotated on either end is mounted snugly inside the sleeve. This rotating
plug is hollow with two rectangular cutouts. In the closed position, the solid portion of
the plug covers the 27 jet holes. When the metering plug is rotated, the rectangular cutout
portion of the plug covers the jet holes and allows water to flow through the plug, the
sleeve, and the mixer in a velocity jetting pattern.
Figure 5.1—RCM® IIIr mixer with rotary-jet water valve
The metering plug and sleeve are contained within another sleeve that is permanently
welded to the mixer body. This outer sleeve contains a window opening that allows water
to flow to the center of the mixer. The metering plug slides within the sleeve, allowing
the solid portion of the plug to completely cover the jet holes.
The rotary actuator, which is prebolted onto the end plate, is normally fully turned to the
closed position. When the endplate containing the rotary actuator is installed with the
actuator in the closed position, it will align with the metering plug in the closed position,
holding the plug in place and thereby closing the entire rotary-jet valve.
5-2 Mixing System Problems and FLECS Operation October 2008

The rotary-jet valve uses two sizes of O-rings. Four small O-rings are mounted on the
metering plug, and four large O-rings are mounted on the sleeve. Grease holes and a grease
ring are machined into the sleeve, allowing grease to flow from the sleeve into the cavity
between the sleeve and the metering plug. Teflon® wear rings are included on each end of
the metering plug to better support the constant torque that the metering plug will
encounter, increasing the life of the O-rings.

5-4
7 10 3 10 7
dn000376
Note: Assemble after mounting

plate to acutator. (See Section E-E.)
14 5 14 4
13 6 13 5 9 2 9 13
E
Mixing System Problems and FLECS Operation

15
E
Top
15 4×
LOC 5 -1 has counterbored
holes for bolting actuator.
9° See Section E-E.
Section E-E
Front view
Figure 5.2—Parts breakdown of RCM® IIIr mixer with rotary-jet water valve (front and rear views)
October 2008
1 REF
(1/4 NC × 1)
(1/4 NC nut) Ring on mixer
with countersunk holes
(4 × 3/8 NC × 1 (.25)
with flat and
lock washer Flat washers for
10
spacers after
8
6
4
2
0
installation sheath
(1/4 NC × 1) (LOC 8) should
(1/4 NC nut) rotate in slot. 18
(1/4 NC jam nut) 8 REF

Section B-B
Detail A
11
See Detail A
8
dn000133
B
Side View
Figure 5.3—Side view of RCM® IIIr mixer with rotary-jet water valve

4 15 REF
5-6
See section B-B
13 14 REF
8 REF
dn000134
B
12
C C
12

D
Install these bolts 1 REF
after actuator (LOC 4) TOP
is bolted to flange. TOP
See Section E-E. 14 9 9
(4× 3/8NC × 1 1/2 with 10 10 3
9 5
lock and flat washer) 3
7 7
See Detail A
F/installation
of LOC 6
5 -1
5 -2
2
2 Make sure when LOC 2
is installed that water inlet Make sure when LOC 2
hole is facing this opening. is installed that jet holes
SECTION D-D are facing this opening.
SCALE 3/4
D SECTION C-C
SCALE 3/4
October 2008
Figure 5.4—Top and cutaway views of RCM® IIIr mixer with rotary-jet water valve
4 5
October 2008
15
11
Note: Assemble after

mounting plate to
Qty 4 actuator.
7 14
10
1
3
12
10 12
9
7
2
9
dn000377
5 8
6
Qty 4
13

Figure 5.5—Parts breakdown of RCM® IIIr mixer with rotary-jet water valve
5-7
Table 5.1—Parts Breakdown of RCM® IIIr Mixer with Rotary-Jet Water Valve
Find SAP No. Qty Material Description
1 101207816 1 Weldment - mixer - cement - low profile - with cylinder and flanges -
rotary-jet water valve
2 101207817 1 Sleeve - jet - rotary-jet water valve - 27-hole pattern - 5/16-in. holes
3 101207818 1 Plug - metering - rotary-jet water valve - for 27-hole jet - symmetrical
design
4 101470067 1 Actuator assembly - rotary - 90° - rotary-jet water valve
5 101207868 1 Kit - endplates - rotary-jet water valve - for manual and automatic
operation
6 101207888 1 Indicator - handle stop with position scale - mounted right of water
inlet - rotary-jet water valve
7 101208095 2 Ring - wear - Teflon - for metering plug - rotary-jet water valve
8 101208098 1 Sheath - splash - mixer - 72° opening - 9 5/16 in. long
9 100001962 4 O-ring, 90 duro, 2 7/8 × 2 1/2 × 3/16 568-333, spec. 599.33001 spec.
70.72000
10 100001957 4 O-ring, 90 duro, 2 3/8 × 2 × 3/16 568-329, spec. 599.33001 spec.

70.72000
11 101216037 1 Insert, mixer, low profile, 4.5 in. ID, Nylatron, RCM® IIIr mixer with
rotary-jet water valve
12 100024702 2 Fitting, grease, 1/8 MPT, straight, stainless steel E10001 alemite
1961-S
13 Fastener 4 Screw, hex cap, 3/8 NC × 1 with flat washer, lock washer, and nut
14 Fastener 4 Screw, hex cap, 3/8 NC × 1 1/2 with flat washer, lock washer, and nut
15 100028236 4 Screw, hex socket, 5/16-18 NC × 3/4, spec. 70.43270

Mixer Assembly Instructions

The following instructions describe the process of assembling the mixer. If these
instructions are not followed, the mixer could be damaged or may not work properly. Use
Figures 5.2 to 5.5 (Pages 5-4 to 5-7) as guides for assembly.
Installing the Sleeve

1. Push the sleeve (2) into the cylinder on the weldment.
2. Align the 27-hole jet pattern and the 2-in. main inlet with the appropriate openings on the
weldment.
3. Push the sleeve through the weldment approximately 4 in. and install two O-rings (9) on
the end of the sleeve.
4. Apply grease to the O-rings and the surface around the O-rings.
5. Carefully push the sleeve back through the weldment and repeat the procedure on the other
side.
6. Carefully return the sleeve to its original position with it aligned according to Step 2. While
returning the sleeve to its original position, place your other hand through the top of the
weldment and compress the O-rings with your fingers as they pass by the leading edge of
the window opening. This will prevent the O-rings from tearing.
Note To reduce the chances of tearing, install O-rings separately on each end of the
sleeve s o th at the y co ntact the wind ow open ing in t he w eldment a s l ittle a s
possible.
Installing the Metering Plug

1. Install two of the O-rings (10) on the metering plug (3).
2. Lightly grease the O-rings and area around the O-rings.
3. Carefully slide the metering plug (3) inside of the sleeve (2).
Important Be careful when installing the metering plug inside the sleeve. Although the
inside diameter of the sleeve has a fine finish, the two O-rings could be damaged
if the installation is not performed slowly and carefully.
4. Push the metering plug all the way through the sleeve so that the grooves for the O-rings
on the other side are just barely visible.
5. Install the other two O-rings (10) on the metering plug (3).

6. Apply grease to the O-rings and the surface around the O-rings.
7. Carefully slide the metering plug back inside the sleeve so as to minimize damage to the
O-rings.
8. Align the metering plug so that the solid portion of the center section covers the 27 holes.
The metering plug is symmetrical and can be correctly mounted in two of four possible 90°
rotations.
9. Lightly grease the Teflon® wear rings (7) both inside and out.
10. Install the wear rings (7) on either end of the metering plug.
11. Ensure the sleeve is aligned properly as in Step 2 of “Installing the Sleeve” (Page 5-9).
Installing the Endplates and Indicator

1. Locate the two endplates (5). The tabs on the sleeve are opposite and out of phase from each
other.
2. Facing the rotary-jet water valve from the 2-in. water inlet, properly mount the 1/4-in. thick
endplate (5) on the right side of the mixer. Rotate and flip the endplate as required so that
the tabs of the sleeve fit into the notches of the endplate.
3. Locate the indicator (6) and attach it to the ¼-in. thick endplate. Lock down the set collar
and the bolt to secure it in place.
4. Insert and finger-tighten the bolts through the weldment, endplates, and indicator. Lubricate
all bolts with Never-Seeze™ compound to prevent galling of the threads.
Mounting the Actuator Assembly

1. Secure the actuator assembly (4) in a vice with the mounting surface facing up.
2. Open the ¼-in. hydraulic bypass valve.
3. With Never-Seeze™ compound, lubricate the square bore of the actuator and the
socket-head screws.
4. With a square 5/8-in. piece of bar stock or similar tool, rotate the square bore of the actuator
counterclockwise, or left-hand rotation, until it stops.
5. Close the 1/4-in. bypass valve.
6. Mount the actuator assembly (4) to the 3/4-in. endplate. The endplate has two sets of mount-
ing holes for the actuator assembly. With the actuator assembly turned at a 9° angle as
shown in Section E-E of Figure 5.2 (Page 5-4), screw the actuator assembly to the endplate
with lubricated socket-head screws (15).

Completing the Mixer Assembly

1. Carefully slide the assembled actuator assembly and endplate onto the weldment and
metering plug. The notches in the endplate should align with the tabs on the sleeve and the
side of the endplate labeled “top” should be facing upward.
2. Lubricate all bolts with Never-Seez® compound to help prevent galling.
3. Insert bolts through the weldment and endplate and finger-tighten them.
4. Ensure that the sleeve alignment is oriented as in Step 2 of “Installing the Sleeve” (Page
5-9).
5. Ensure that the metering plug alignment is oriented as in Step 8 of “Installing the Metering
Plug” (Page 5-10).
6. Tighten the bolts on either end of the rotary-jet water valve.
7. Secure the mixer assembly and open the ¼-in. hydraulic bypass valve.
8. Install the pointer that comes with the indicator (6), as in Detail A of Figure 5.3 (Page 5-5).
9. With a suitable wrench, rotate the metering plug clockwise or right-hand rotation 64° to
verify correct assembly.
10. Look through the 2-in. inlet to verify that water jets are opening from the top down as the
metering plug is rotated. If this does not occur as described, stop and investigate what step
was done incorrectly.
11. Return the rotary-jet water valve to the zero mark and close the ¼-in. bypass valve.
12. After installing the sheath (8), verify that it will open and relatch as designed.

Mixing Problems
Erratic Cement Delivery

Poor bulk delivery to the mixer is the most common problem that can affect a uniform
slurry blend. Any RCM® mixer, whether ADC® mixing system-controlled or not, requires
a constant supply of cement to help ensure consistent slurry density. Eventually, the slurry
weight will be affected if the bulk delivery is substandard. Common causes of poor bulk
delivery include the following:
• The bulk tank has a faulty or worn compressor. Repair the compressor when it shows signs
of wear to prevent below-normal air pressure.
• The aeration pads in the bulk tank are dirty. Clean these pads periodically so cement will
be sufficiently aerated to avoid packing problems.
• The cement delivery lines are too long. Keep delivery lines to the unit as short as possible and
ensure that they have a minimal number of bends. If the cement must enter the unit from a long
line, equip the line with purges that can be used to open it in the event of a blockage.
• The cement blend has been stored in the bulk tank too long. If the cement is a weighted
blend or has been in the unit for some time, aerate the cement in the tank thoroughly to “fluff it
up” before the job begins.
• The venting system contains cement residue or is not fully operational. On offshore units
and land units equipped with a steady-flow bin, ensure that the venting system is clean and in
good operating condition before starting a job.
Below-Normal Recirculation Rate on a 6 × 5 Pump

For consistent mixing of the slurry blend, the energy inside the mixer must be sufficient.
Most of this mixing energy is created by the Halliburton 6 × 5 recirculation pump, and a
rate of 13 to 16 bbl/min of recirculation flow should be maintained. The following
problems can affect the recirculation flow rate:
• The engine speed is too slow. The engine driving the 6 × 5 centrifugal pump should operate at
1,400 to 2,000 rev/min to help ensure good recirculation flow.
• The centrifugal pump is worn. Check the condition of this pump periodically. Maintain
proper impeller clearances, and replace the impeller if it is worn. Verify that the seals in the
pump are in good condition.
• The 6 × 5 pump suction line is restricted. If the system seems to recirculate water efficiently
but tends to slow down with heavier, more viscous fluids like slurry, the suction line may be
restricted. Check the sump area in the mixing tub and the suction line to the 6 × 5 centrifugal
pump, and verify that neither contains cement buildup.

Aerated Slurry
Many slurries containing salts and other chemicals become aerated when they are
recirculated or stirred vigorously. The aeration may be caused by slurry properties or
mechanical failure such as leaking seals in the centrifugal pump. This slurry aeration can
cause the centrifugal pump to lose partial prime or stop pumping completely, allowing dry
powder to accumulate in the mixing tub. Take the following steps to recognize and help
prevent slurry aeration:
• Ensure that the unit’s 6 × 5 recirculation pressure gauge functions correctly. When the
centrifugal pump is properly primed, the discharge pressure should be 25 psi or greater. A drop
to 10 psi indicates that the slurry is aerated.
• Verify that the water level in the mixing tub is at least in the center of the agitator blades before
you add dry cement to bring it up to weight.
• Do not allow the mixing water to circulate at a high rate for a prolonged period of time before
you begin cement delivery.
• Rotate the agitators at a speed that achieves good blending but does not churn air into the slurry.
Rotate agitators at a high rate only when dry cement or lumps are present in the tub; the
accelerated rotation helps break up the dry material. As soon as the tub has “leveled out,” slow
the agitator to approximately half-speed.
• Verify that cement delivery is constant and pressure on the tank is 15 to 20 psi (9 to 10 psi on
steady-flow separators). Excessive air sometimes enters the tub from the bulk unit because of
erratic cement delivery or an excessively high compressor setting.
• When the cement blend is brought up to weight, deliver it quickly from 8.33 lb/gal (water) to
12 lb/gal, the critical range on these blends. Some cement slurries tend to create air. Add a
defoaming agent to the slurry to control the aeration level when appropriate. Do not circulate
“air-prone” slurries at a high rate for a prolonged period.
Heavyweight or Thixotropic Slurries

Heavyweight or thixotropic slurries have minimal water content and approach the upper
limits of mixing capabilities. The minimal water-to-cement ratio can cause improper
wetting of the cement entering the mixer, resulting in a poor-quality blend in the mixer. If
necessary, begin mixing at a low rate and increase the mix rate in small increments until the
required rate is attained. Improper wetting of the cement occurs most often if bulk material
is added too quickly, especially at the start of continuous mixing or if density fluctuations
are extreme.
Note Engineers d esign s lurries i n la bs t ests wit h War ing® B lenders. T here is lit tle
correspondence between the kinds of materials that can be mixed in a lab blender
and those that can be blended by an RCM® mixer.

At the start of continuous mixing, the operator cannot easily determine exactly where to set the
throttling valve. If the throttling valve is opened too far, the system can become overwhelmed
with excessive cement and air.
Begin mixing at a lower rate. When the proper valve position is determined for the low mixing
rate, increase the mixing rate and the corresponding valve position from the benchmark that
has been established. When using this technique, you may find that the slurry cannot be mixed
at the required rate. When the prescribed rate is approached slowly in increments of
approximately 0.5 bbl/min, small clumps will begin to appear in the mixing tank. These clumps
indicate that the upper limit on the mixing rate has been reached.
Significant density fluctuations, especially on the lower end, result in an overreaction on the
throttling valve position as the valve attempts to recover. This situation can easily lead to too
much cement and air in relation to the volume of water being pumped into the mixer. Make
small adjustments in the throttling-valve position to help ensure that the density does not drift
too far from the setpoint for continuous mixing. Density fluctuations generally occur either at
the start of the job or when poor bulk delivery causes the density level to drop well below the
setpoint.
Inability to Maintain Density Setpoint

If the density setpoint cannot be maintained and remains just under the required level, you
should recognize the problem and take appropriate steps to bring the density level under
control. The following factors may be responsible for this situation:
• Outrunning the Bulk Supply. The maximum normal delivery rate from a bulk system will average
35 to 40 sacks/min. If the delivery is below this level but the density cannot be maintained, lower
the mixing rate to match the delivery from the bulk supply. Achieving the proper density on slurry
going downhole is more vital than maintaining the high mix rate.
• Blocked Cement-Throttling Valve. A rock or other obstruction may be lodged in the 5-in. master
cement valve or in the opening to the mixer.
• Blocked Throat in the Mixer. Cement that has accumulated between the cement-throttling valve
and the water jet in the mixer can cause the mixer cement inlet to become blocked. This problem is
more prevalent when thixotropic slurries and blends with high-gel concentrations are mixed. Clean
the area thoroughly after each job to help prevent buildup. However, if the bulk delivery is higher
than normal or if the slurry level in the tub is allowed to become too high, splashback will
continuously wet the area above the water and recirculation jets.
This splashback can eventually cause buildup in the inlet to the mixer. To avoid splashback, do
not allow the vacuum breakers to become clogged with cement. If the vacuum breakers are
clogged, the resulting vacuum will pull water backward into the cement-throttling valve and

can create the buildup. If the vacuum breakers are not kept clean and in good operating
condition, the water can eventually migrate down the bulk line.
Warning Do not plug a vacuum breaker to prevent dry cement from being deposited
onto the tub.
Dry Cement Entering the Mixing Tub

Occasionally, dry cement material may float on top of the slurry in the tub, eventually
causing the mixer to become clogged. If this condition occurs, the recirculation pump will
lose prime and cause the mixing operation to shut down. You must constantly monitor the
density readout on the Unipro II™ controller and the tub condition. The factors in the
following section can contribute to dry cement entering the mixing tub.
• Erratic Bulk Delivery. If the bulk unit cannot deliver cement to the mixer efficiently because
of poor aeration or low air pressure, you may have difficulty controlling the cement-metering
valve to bring the correct proportion of cement into the tub. When the tub density drops rapidly,
do not open the throttling valve too much. If the throttling valve is opened too much, it is
difficult to lower the setting quickly enough to prevent a large slug of cement from entering the
mixer when good bulk delivery is re-established.
• Inadequate Recirculation Pump Flow. Increase the recirculation pump speed, or add a
defoaming agent to the slurry if it is aerated and is causing the recirculation pump to lose prime.
• Agitators Rotating Too Slowly. Increase the agitator speed if the slurry contains lumps or
small amounts of dry materials.
• Improperly Designed Cement Slurry. Some cement blends do not have the water-to-cement
ratio necessary to achieve their required densities. This improper ratio results in dry cement in
the tub when the bulk flow is not consistent or is increased too rapidly. Check cement blends
thoroughly to help ensure that they can be mixed with good results.
• Air in the Recirculation Pump. In some cases, adding defoamer to the slurry in the premix
side provides a “kick-start” that clears air from the recirculation pump and allows the mixing
process to be resumed.

RCM® Mixing System Troubleshooting Procedures

Table 5.2 lists troubleshooting procedures for the RCM® mixing system.
Table 5.2—RCM® Mixing System Troubleshooting Chart
Problem Causes Remedies
Slow mixing rates Restricted mix-water manifold Clean the unit immediately.
Restricted throttling valve Clean the unit immediately.
Low bulk-cement delivery rate Check the bulk unit thoroughly.
Partially plugged cement delivery Check bulk-unit delivery hose thor-

oughly.
Dirty bulk unit or manifold Check the bulk unit thoroughly.
Low bulk air pressure Check pressure (see the bulk system
manual).
Low mixing pressure 100- to 120-psi normal closed-in pres-

sure. Check centrifugal pump trouble-
shooting procedures. Check for proper
rpm and impeller adjustment.
Low recirculation pump pressure 25- to 35-psi normal closed-in pres-

sure with water. Check centrifugal
pump troubleshooting procedures.
Check for proper rpm, partially
clogged suction, or impeller adjust-
ment.
Dusting Improper bulk delivery pressure Check the bulk pressure (see the
bulk-equipment operator’s manual).
Bulk system being purged by air Check bulk operation (see the
bulk-equipment operator’s manual).
Low or no recirculation pump Check centrifugal-pump troubleshoot-

flow ing procedures. Check pump speed
and pressure. Check for blocked suc-
tion from RCM® mixing system tub.
Low or no mixing pump flow Check centrifugal-pump troubleshoot-

ing procedures. Check pump speed
and pressure.

Table 5.2—RCM® Mixing System Troubleshooting Chart (Continued)
Moisture in bulk Vacuum breaker not operating Check for cement buildup around vac-
equipment or hose properly uum breaker.
Splashback Check mixing jets for restrictions or

wear. Check for excessively high tub
level.
Restriction of cement Check mixer bowl, and remove all

cement buildup.
Throttling valve washup valve Close valve immediately.

open
Excess cement Vacuum breaker not operating Check for cement buildup around vac-
buildup in the throt- properly uum breaker.
tling valve
Throttling-valve washup valve If the valve is open, close it. If the
open or leaking valve is leaking, replace it.
Splashback Check the mixing jet for restrictions or

wear. Tub level may be too high during
mixing.
Restriction of cement buildup in Check the mixer throat, and remove all
mixer throat cement buildup.
Unable to maintain Erratic delivery of bulk cement Check bulk-equipment operator’s and
constant density maintenance manuals.
Erratic mixing pressure Check mixing pump for 100- to 120-psi

normal closed-in pressure.
Losing prime of Slurry bridging off in suction or Check the manifold for obstructions.
recirculation pump discharge of recirculation pump
Closed valve from tub to recircu- Open the valve. See RCM® IIIr system
lation pump operating procedures.
Centrifugal pump stopped turn- Check centrifugal-pump drive system.

ing
Air entrained in volute of recircu- Add slurry-defoaming agent.

lation pump

Losing prime of Recirculation pump defective Check rpm of recirculation pump

recirculation pump (1,500 rpm normal) 25 to 35 psi
(continued) closed-in pressure. Check impeller
adjustment or seal leaking allowing air
to be pulled in during operation.
Low recirculation- Centrifugal pump not turning at Check the centrifugal-pump drive sys-
pump pressure proper speed tem (1,500 rpm normal).
Partial plug of cement in suction Check the manifold for obstructions.
Air entrained in slurry Add defoaming agent to slurry.
Gauge or gauge protector not Check, repair, and/or replace as nec-

operating properly essary.
Centrifugal pump seals leaking Check the seals and replace them as
pressure or vacuum necessary.
Low mixing pump Centrifugal pump not turning at Check the centrifugal-pump drive sys-
pressure proper speed tem (2,100 rpm normal).
Restriction in suction side of cen- Check the manifold for obstructions.

trifugal pump
Centrifugal pump seals leaking Check seals and replace them as nec-
essary.
Gauge not operating Replace gauge.
Losing prime on Centrifugal pump stopped Check the centrifugal-pump drive sys-
mixing pump tem. Check for foreign object in volute
of pump. If pump is hydraulically
driven, the system pressure will be at
maximum.
Source of water shutoff or run- Check the water supply.

ning out of water
Insufficient head from the water Check the water supply and elevation
source of in relation to volute of mixing pump.
Suction leaks Check suction manifold and/or centrif-

ugal-pump packing for leaks.
Cement buildup between plug Clean out cement buildup.

valve and throttling valve housing

Cement-throttling Inadequate lubrication of plug Lubricate the plug valve.

valve difficult to valve
operate
Lumps in slurry Erratic delivery of bulk cement Check bulk-equipment operator’s

maintenance manuals.
Plugged or eroded mixing jet Clean or replace mixing jet.
Improper agitation Check that agitators are turning and

operating properly.
Inadequate air supply to bulk Check air supply and proper

system bulk-equipment operation.
Bulk cement stops Plugged bulk delivery line or Check the cement-delivery line or
hose hose for restrictions or buildup.
Out of cement Check cement level in bulk tanks.
Plugged discharge valve in bulk Clean or replace.

tank
Inadequate air supply to bulk Check air supply and proper

system bulk-equipment operation.
Dry cement in mix- Cement-throttling valve open too Reduce or close cement-slurry throt-
ing tub wide tling valve. Add water and mix dry
cement.
Losing prime of mixing pump Check the centrifugal-pump system.
No mixing water being added to Check the centrifugal-pump system.

slurry
Low pressure of recirculation Check the recirculation pump for

pump proper rpm and pressure. Check for
cement buildup or blockage on the
recirculation pump tub suction. Speci-
fications are 1,500 rpm minimum and
20- to 35-psi normal closed-in pres-
sure with water.

Cavitation of Trying to pump too fast for den- Reduce pumping rate.
HT-400 pump sity of slurry being mixed
Blockage in suction line from Check the tub-suction manifold.

RCM® system to tub-displace-
ment pump(s)
Restriction at tub’s suction valve Check the tub-suction valve. Check

RCM® IIIr system cleanup procedures.
Improper HT-400 pump operation Check the HT-400 pump manual.
Agitators not turn- Control valve in “off” position Turn the control valve to the “on” posi-
ing tion.
Improper function of hydraulic Check hydraulic-system troubleshoot-

system ing and maintenance manuals.
Erratic delivery Improperly maintained bulk Check bulk-equipment maintenance

equipment manual.
Improperly operated bulk equip- Check bulk-equipment operation.

ment
Non-gross aerated bulk equip- Add gross-aeration cartridges to bulk

ment being used tanks, or repair existing cartridges.
Dirty throttling valve Clean the throttling valve (see RCM®

IIIr system maintenance procedures).
Dry cement dis- Erratic delivery of dry cement Check bulk equipment operation.
charging out of
vacuum breaker Vacuum breaker poppet not seat- Check/clean/repair vacuum breaker as
ing properly required.
Air in slurry Improper slurry level in downhole Maintain proper tub level.
side of tub
Improper type of cement used Add defoaming agent.
Air purging of cement Check bulk-equipment operation.
Vacuum leak at circulating pump Replace or regrease seals.

seals

Butterfly valves dif- Cement buildup in valves Clean valves thoroughly.

ficult to operate
Improperly lubricated valves Lubricate valves properly.
Faulty valve Repair or replace valve.
Cement buildup in Improper cleanup Check and observe mixer cleanup pro-
mixer cedures.
Partially plugged jet Clean jet thoroughly.
Eroded mixing jet Replace mixing jet immediately.
Improper RCM® system opera- Check RCM® system operating proce-

tion dures.
Low or no mixing or circulating Check centrifugal-pump systems.

pressure
Wild fluctuation in Excessive air entrainment See “Air in slurry” problem above. Cir-
recirculation den- culating pump seals leaking on vac-
sity (± 0.3 lb/gal) uum. Replace or regrease seals.
Faulty densometer Check densometer cable or repair

densometer.
Densometer reads Signal from densometer lost Check cables for good connections.
210 to 220 lb/gal
Power card faulty or other prob- Have densometer repaired.
lems in densometer

Cement Mixing Procedure

Manual Mixing
When the unit has been primed, review the prejob checklist in Section 3, and follow the
procedures outlined in this section. These procedures explain how to mix cement manually.
The operator can independently control the speed of each agitator with the separate needle
valves for each agitator. The premix agitator should be operated at a high speed to impart
full mixing energy into the cement slurry directly after it leaves the mixer. The agitator on
the downhole side of the tub is typically operated at a slower speed to reduce splash that
could occur with varying downhole tub levels.
The RCM® IIIr mixer with rotary-jet water valve combines the following materials:
• Water from the water manifold
• Recirculated slurry from the premix side of the RCM® mixer tub
• Dry cement from the cement-throttling valve
To mix cement manually, perform the following steps:
1. Ensure that the Micro Motion® F300 mass flowmeter is clean and calibrated.
2. Ensure that the master cement valve and master water valve are closed.
3. Set the cement-throttling valve to the 2 or 3 position (20 or 30%).
4. Open the water-metering valve to the one-third position.
5. Set the approximate mixing rate desired.
6. With the tub partition valve in the closed position, open the master water valve, and fill the
premix side of the tub to a level approximately 6 in. above the agitator blades. Then, close
the master water valve.
7. Engage the recirculating pump, and open both the recirculating pump discharge valve and
the tub suction valve. Water will circulate from the premix side of the tub, through the
mixer, and back into the tub.
Important Do not proceed with mixing until the discharge from the recirculating pump is
uniform and not surging. If all air is not out of the system, pumping may not be
efficient.
8. Before continuing the mixing procedure, empty all water from the downhole side of the
tub. The water from this compartment can be pumped back into the displacement tanks.
9. Ensure that the F300 flowmeter is set for the specific gravity of water (8.33).

10. Turn on the agitators.
Important During m ixing, kee p the cover in pl ace over the premix compartment of the t ub
because t his side cr eates the most spl ashing and dus t. Addi tionally, ke ep th e
downhole side of the tub open, which will allow you to monitor the tub level while
the cement is being mixed.
11. Coordinate with the bulk equipment operator to ensure a steady delivery of dry material. Open
the master cement valve, and begin adding cement. The cement will be blended with the water
in the premix side of the tub. The slurry components are circulated through the densometer and
the mixing manifold and sent back into the premix side of the tub.
12. Note the weight buildup indicated on the visual gauge. As the weight builds, the volume builds
in the premix side of the tub. Generally, the slurry reaches the desired weight when it begins to
pour over the partition into the downhole compartment.
13. When the slurry weight is within 0.5 lbm/gal of the desired weight, open the master water valve
and begin adding water.
14. Open the cement-throttling valve past the 2 or 3 position to compensate for the additional water
being added through the water-metering valves.
Important Fresh wat er an d dr y c ement a re now b eing a dded to t he r ecirculated s lurry.

Continually monitor the slurry density. To change the slurry density, slowly open or
close either the cement-throttling valve or the water-metering valve openings.
15. After the slurry has reached the proper density, and the downhole section of the slurry is above
the agitator paddle, begin flowing the slurry to the HT-400 pumps. In the downhole compart-
ment, maintain a slurry level approximately 2 in. below the top of the weir.
Important If the slurry begins to pour over the partition before reaching the correct density, open
the ce nter par tition valve. This val ve al lows slurry in bot h si des of the tub t o be
circulated through the system. When the tub is full of slurry at the correct density,
close the tub partition valve, open the tub suction valve, and start pumping slurry
downhole.
16. Slowly open or close the water-metering valve and the cement-throttling valve openings to
achieve the desired mixing rate. Maintain the correct slurry density.
Important Follow these guidelines during the mixing process:

• Maintain a full downhole compartment.
• Continually monitor slurry density and make corrections to slurry as required.
• For densified slurries, control density with water-metering valves. For slurries
with high water ratios, control density with cement-throttling valve.
• Run the tub agitators continually; they perform most of the slurry blending.

Caution Never use the master water valve or the master cement valve to control the
rate of material being added.
17. After all the cement has been mixed, open the tub partition valve, and pump the remaining
cement from the tub.
18. Close the downhole tub suction valve, and begin adding fresh water to the mixing tub. Con-
tinue circulating fresh water during the entire displacement pumping process.
19. When the displacement fluid has been pumped downhole, begin cleaning the RCM® IIIr
system thoroughly.
Shutdown/Restart Procedures
To stop the pumping operation for manual or FLECS controller mixing, perform the following
steps:
1. Close the master cement valve.
2. Close the master water valve.
3. Open the tub partition valve, and continue recirculating the slurry.
To resume pumping for manual or FLECS controller mixing, perform the following steps:
1. Close the tub partition valve.
2. Open the master water valve.
3. Open the master cement valve.
Important When you restart the pumping procedure, the slurry density and mixing rate should
be approximately the same as they were before pumping stopped. Therefore, you
should o nly mak e mi nor a djustments t o the c ement-throttling va lve o r the
water-metering valve.

Cleanup Procedures
After you have completed the mixing job either manually or with the FLECS controller, perform
the following cleanup procedure:
1. Flood the mixing tub with water, and continue circulating it during displacement. If water is not
immediately available, circulate and agitate the slurry during displacement. In either case, open
the valve between the two compartments.
2. Circulate clean water through the mixing pump, the manifolding, all manifolding valves, and the
tub’s suction valve.
3. Close the master cement valve. Wash the cement-throttling valve through the washup connec-
tion, rotating the cement-throttling valve during the washing process.
4. Remove the cement-throttling valve and remove all remaining cement buildup.
5. With the recirculating pump turned off, open the master water valve.
6. Open the water-metering valve.
7. Remove the slurry jet, and check for foreign material or wear. Rotate and/or replace the jet if nec-
essary.
8. Close the master water valve, turn on the recirculating pump, and recirculate clean water through
the pump.
Note If discharge into the premix side of the tub appears normal while you are testing the
mixing manifold, but recirculating discharge is below normal, remove the discharge
line from the recirculating pump to the recirculating slurry jet and check for cement
buildup.
9.Ensure that each air-operated valve on the unit is functioning properly.

10. Open and close each manually operated valve to check for cement buildup.


SECTION
Section
16
Preface
Test/Setup Procedures
Section 6 includes procedures for testing the HCR Elite® trailer after assembly. Minimum
performance specifications for different individual components are included, as well as setup
procedures for the major systems. If a major repair or maintenance schedule has been completed,
review these test procedures for setup and testing of the unit.
Section 6 includes reprints of the following two test procedures:
• D00268736—Test Procedure, HCR Elite Trailer

• D00171055—HCR Elite FLECS Setup, Calibration, and Test
• 278.02740—Installation, Test, Webasto, Diesel, Fired Engine Preheater
• D00268738—Setup/Test Procedure, MicroMotion F300 Flowmeter
October 2008 Test/Setup Procedures 6-1

Halliburton Energy Services Specification D00268736 Revision E
Tested Unit: Elite Trailer, C11, 4700 OFS, FLECS,
Duncan, OK QSB6.7, F300
Date: 05/02/2008
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
Elite Trailer, FLECS Controlled, Twin HT-400, 344 Inch Wheelbase, Hydraulic Start
Cat C11 & Battery Start Cummins QSB6.7 Engines, 6x5 and 4x4 Centrifugal Pumps,
F300 Micro Motion Mass Flow Meter, RCM Mixing System, Allison 4700 OFS
Transmission .
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.
iv. Review specification D00135679 for any changes to this test and/or information
pertaining to the testing of equipment and testing standards.
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 PART NO.
Lubrication Standard 278.90538
Elite Trailer Operation Manual 101237455
FLECS Service / Operators Manual 101324382
Caterpillar C-11 Service Manual 101397644
Caterpillar C-11 Parts Manual 101397641
Service Manual, Cummins 101458278
Parts Manual, Cummins 101458284
Operation and Maintenance Manual, Cummins QSB Engines 101458286
Troubleshooting and Repair Manual, Cummins Elec. Control Sys 101458290
Allison 4700 Series, Service Manual 101489258
Allison 4700 Series, Parts Manual 101489259
Allison 4700 Series, Operators Manual 101489205
Allison 4700 Series, Trouble shooting Gen IV Controls Manual 101489261
Funk Pump Drive Service Manual 100032617
Halliburton Centrifugal Manual 100003124
Halliburton Ht-400 Pump Manual 100002809
Alternator Service Manual 100047095
Alternator Parts Manual 100047096
Murphy PowerView Installation and Operations Manuel D00118626
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b. General operating parameters for this unit.

Pump Engines - Caterpillar C11, ACERT, ATAAC, TIER III, 420 BHP, 2100 RPM
Min Typ Max
Low Idle Speed (Rpm) 700
Rated Engine Speed (Rpm) 2100
Top No Load Speed (Rpm) 2250
Overspeed Setting (Rpm) 2450
Coolant Temperature (F) 180 210 220
NOM Oil Pressure At Rated Speed (Psi) 36 47 87
Min Oil Pressure At Low Idle (Psi) 5.7 16 87
Fuel Return Restriction (In. Hg) 15.1
Fuel Supply Line Restriction (In. Hg) 8.9
Air Cleaner Restriction (In. H2O) 15 25
Exhaust Restriction (In. H2O) 27
System Voltage (V) 12
Start Requirements (RPM) 100
Allison 4700 Deck Transmission Min Typ Max
Oil Temperature, Sump(F) 19 160-200 250
Oil Temperature, Fluid to Cooler(F) 300
Oil Temperature, Retarder out Fluid(F) 330
Engine – Cummins QSB 6.7, 173 Hp @ 2500 Rpm
Min Typ Max
Low Idle Speed (Rpm) 690 700 710
Rated Engine Speed (Rpm) - 2500 -
Top No Load Speed (Rpm) - 2530 2560
Overspeed Setting (Rpm) - 2950 -
Coolant Temperature (F) 160 - 225
Oil Pressure At Rated Speed (Psi) - - 55
Oil Pressure At Low Idle (Psi) 10 - -
Fuel Filter Restriction (In. Hg) - - 4.1
Fuel Return Restriction (In. Hg) - - 20.4
Air Cleaner Restriction (In. H20) - 15 25
Exhaust Restriction (In. HG) - - 3.0
System Voltage (V) 12
Battery Rec For Starter (Cca) 1250
Hydraulic System Min Typ Max
Hydraulic Tank Capacity (gal) 30
Hydraulic Oil Temp (F) 160 180
Hydraulic Cooler Fan Speed (rpm) 2950 3000
6x5 Centrifugal Loop (psi) 1500 4900
6x5 Centrifugal Charge (psi) Stroked 325 350
6x5 Centrifugal Charge (psi) Neutral 350 375
6x5 Pump Speed (rpm) 1600 1900 Max on curve
6x5 Pump Closed In Pressure (psi) 40 65
4x4 Centrifugal Loop (psi) 2450 4900
4x4 Centrifugal Charge (psi) Stroked 325 350
4x4 Centrifugal Charge (psi) Neutral 350 375
4x4 Pump Speed (rpm) 2100 2200 2600 Max on curve
4x4 Pump Closed In Pressure (psi) 105 110
Start/Agitate Relief Setting (psi) 3000
Start/Agitate Circuit (psi) 1500 2600
Agitator Speed (rpm) 150
ADC Relief Setting (psi) 2400-2500
ADC Compensator Setting (psi) 2100
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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. Transmission Fluid (4700)
i. Fill transmission(s) to appropriate fill level. Top off after engine is started, as fill level
has fluid level visible in sight glass with engine running and transmission in neutral in
operating temperature range.
1. Before starting the engine, fill transmission per best practice.
ii. Automatic Transmission Fluid Halliburton Part No. 100001835 per lubrication standard,
Part No. 100053807
d. Fuel tanks
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, Halliburton Part No. 100001739 per lubrication standard, Part No.
100053807
e. 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).
f. 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
g. Hydraulics
i. Fill hydraulic reservoir to full level.
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.
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xi. Prime all hydraulic pumps driven by the pump drive.

xii. Automatic Transmission Fluid Halliburton Part No. 100001835 per lubrication standard,
Part No. 100053807
h. Halliburton centrifugal pumps ( 4x4, 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.
i. Halliburton positive displacement pumps ( HT400)
i. Power end lubricant
1. SHC634 gear lubricant, part no. 100026257. See HT-400 manual, 316.11294 p.2-3/5, for a full list
2. Fill power end to full level on sight glass or dipstick.
3. Fill suction line of power end lube pump.
4. Check all valves, hoses, etc... for correct installation and direction of flow.
5. Fill inlet hoses and both coolers.
6. Supply pumps with fluid
7. Purge air from main drive pump suction line.
8. Prime lube pump.
ii. Fluid end lubricant
1. Rock drill oil (see HT-400 manual, 316.11294 p.2-7/8, for a full list).
2. Fill suction line from the packing lube tank to the packing lube pump.
3. Fill packing lube tank to top of sight glass.
j. Axle hubs
i. Fill to site glass level if low.
ii. Lubricant per lubrication standard (Part No. 100053807).
k. 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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vii. Wiring and hoses are shielded when going over sharp corners, contacting other rub
surfaces, near hot surfaces, and near rotating shafts.
b. 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 any 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.
c. Pump primer on the fuel filter and prime fuel system.
d. Check torque of driveline bolts.
e. Connect pump suction hose(s) to water supply (1 suction hose per 10 bpm) and provide
water with a centrifugal pump at the maximum rate of pump test and at minimum
pressure of 30 psi.
f. Connect pump discharges to a choke of adequate capacity.
i. Discharge manifold and choke must have a pressure rating greater than the maximum
pressure listed in the pump schedule for the fluid end size being tested.
g. Check all fluid levels.
h. Verify that the battery cables are labeled with a Pos and Neg nameplate or color coded
cables and connected correctly.
i. Verify that all suction valves on hydraulic lines/tank, fuel lines/tank, water lines/tank
are open.
j. Verify that all quick-disconnects are properly tightened and secured.
k. Open all hydraulic valves to purge air from system.
l. With unit air system fully charged, adjust pressure regulators to maintain 10-12 psi in
the HT-400 lube tanks (tank regulator may be located in control stand).
m. Open both of the HT-400 packing lube valves.
i. Ensure discharge line is open.
n. With unit air system fully charged, adjust pressure regulators to maintain 5-7 psi in
the Centrifugal pump lube tanks, if present, (tank regulator may be located in control
stand).
o. Open both of the centrifugal packing lube valves if present.
i. Ensure discharge line is open.
p. Test Webasto engine coolant heaters in accordance with specification 278.02740, if
installed on units.
q. 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).
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5. FLECS CONTROLLER
a. Set up and test FLECS controller per specification D00171055.
b. FLECS COOLER
i. Caution: Vortex cooler creates very hot exhaust air and very cold cooling air; do not
place any body parts into air streams.
ii. Build unit air pressure to greater than 100 psi
iii. Check to make sure that there is no air going into the cooler
iv. Turn the FLECS test on (energize the solenoid) and make sure there is about 40% of the
air coming out the hot air side (bottom exhaust) and about 60% coming out the vent
(cold side) on the top of the display.
v. Ensure there are no leaks and that the air is passing through the filters in the proper
direction (view alignment arrows)
6. MICRO MOTION F300 MASS FLOW METER
a. Set up and test mass flow meter per Test Procedure D00268738.
7. AUXILIARY ENGINE STARTUP
a. Safety
i. Verify that all unessential personnel are cleared from the unit and out of the direct line
of sight of the unit.
ii. Verify that all personnel are clear of any pressurized lines and/or parts.
iii. Verify that personnel and equipment are clear of unit and potentially moving or rotating
components and that all guards and shielding are properly installed.
iv. Verify that all lubrication has been completed and that supply valves from tanks and
reservoirs (fuel, hydraulic fluid, pump lube, etc) are open.
v. Verify that discharge piping is properly connected to hydraulic choke and that hydraulic
choke is fully open.
vi. Verify that muffler is properly positioned with exhaust ventilation system, and that
exhaust ventilation system is running.
b. Setup and Adjustment
i. Turn the main power on and correct all engine faults
ii. Cummins QSB6.7 does not have settable customer parameters. View parameters for
appropriate values as given by Heavy Equipment Components & Standards Team.
iii. Set over speed verify to off or disable.
c. Starting Procedure
i. Ensure that the air tank is charged.
ii. Ensure the centrifugal pumps and agitators are in the off or neutral position.
iii. Turn the main power switch on at the control stand.
iv. Flip Control Panel Warning Lamp Test Switch to on position and check all lamps for
proper function, then switch off.
v. Place the power on/off switch in the off position.
vi. Engage the starter with the stop/run/start switch until engine oil pressure gauge indicates
10 psi.
vii. Once oil pressure is established, engage the starter with the stop/run/start switch with
the power in the on position.
viii. Start the engine.
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ix. Observe Unit for Major leaks and shut down immediately if necessary.
x. Observe the engine oil pressure gauge. If the oil pressure does not rise to above 6 psi
within 15 seconds after the engine starts, shut the engine down and determine the cause.
xi. 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 700 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 sucking air through radiator.
9. All engine faults have been corrected.
10. Main throttle controls are operational.
11. Test over speed verify switch.
12. Main Emergency shutdown controls are operational.
13. Murphy PowerView is initialized per D00118626 (PowerView operating instructions) and correct
any faults displayed.
e. Verify operation of the engine gauges and controls.
i. Engine water temperature gauge.
ii. Engine oil pressure gauge.
iii. System voltage gauge
iv. System air pressure
v. Hydraulic oil temperature gauge.
f. 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
g. Over speed System Test--To test the over speed system on the Cat 3126B, engage the
75% VERIFY OVERSPEED switch in the control stand. When the engine speed
reaches 75% of the speed set in the ECM (approximately 1,800 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.
h. An emergency kill toggle switch is included on the control stand for the 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.
i. 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
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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.
j. Turn on water supply line.
k. With the water supply hose connected and flowing, fill tanks 1/2 full
l. Bleed air from suction manifold and discharge manifold by manipulating valves in
plumbing while supplying water.
i. Close all external valves.
8. HYDRAULIC SYSTEM STARTUP
a. Check oil level in hydraulic reservoir often and refill as needed.
b. At control panel, ensure all hydraulic systems are in the off position.
c. With the centrifugal pumps and agitators in the off or neutral position, allow
hydraulic system to warm up.
d. Observe charge pressure gauges for indication of charge pressure. Charge pressure
should start showing on the gauges within 30 seconds after starting engine. 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 (if present) is outputting the correct voltage.
h. Increase the throttle to full speed (2500 RPM).
i. Check for proper rotation of the ASA Hydraulic Cooler Fan, air flow should be to the
outside of trailer. If pump rotation is incorrect, verify hydraulic plumbing per
applicable engineering drawings.
j. The charge pressure for the centrifugal pump circuits should be within the following
ranges:
i. charge pressure in neutral (minimum) = 350 to 375 psi
ii. charge pressure in stroked position (minimum) = 325 to 350 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.
k. Stroke the mix (DS) pump slightly and check for proper rotation of the pump. If
pump rotation is incorrect, verify hydraulic plumbing per applicable engineering
drawings.
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.
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iv. If the centrifugal pump rotation is incorrect, determine the cause as per the engineering
drawing and correct the problem accordingly.
l. Stroke the recirculation (PS) pump slightly and check for proper rotation of the
pump. If pump rotation is incorrect, verify hydraulic plumbing per applicable
engineering drawings.
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.
m. 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.
n. Set agitator-start pressure relief in the following manner:
i. Back out agitator relief valve a few turns.
ii. Physically lock the agitator paddle with a pipe wrench with handle firmly against tub
wall.
iii. Slowly close agitator bypass needle valve until paddle is firmly locked. Close bypass
valve fully.
iv. Raise aux. engine throttle to 2500 rpm.
v. Set relief cartridge to 3000 psi.
vi. Idle engine, open agitator bypass needle valve and remove pipe wrench.
vii. Fill the mixing tub with water and raise the engine speed to full throttle.
viii. Close the needle valve.
ix. Check agitator rpm at full throttle. (150 rpm minimum)
x. After deck engines are prepared for service, check starter RPM.
o. Record the speed of the agitators and the hydraulic pressure reading on the Test Data
Sheet
p. Check for proper rotation of the agitators, should be counter clockwise as seen from
above.
q. Check oil level in hydraulic reservoir and refill as needed.
r. ADC system pressure adjustment
i. The ADC system is controlled by a pressure compensator with a maximum pressure
relief for a safety.
ii. Back out ADC system relief several turns. (located on the ADC valve manifold block).
iii. Adjust pressure compensator fully clockwise on ADC pump.
iv. Close ADC system bypass valve under control stand and actuator bypass valves on
actuators.
v. Adjust ADC system relief clockwise to achieve 2400 to 2500 psi.
vi. Secure locknut.
vii. Slowly back out compensator adjustment until pressure drops to 2100 psi.
viii. Tighten locknut on relief valve and record final relief setting on Test Data Sheet.
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ix. Complete ADC control system unit test procedure (FLECS )

x. Refer to ADC test procedure, for setup of water valve, cement valve, and FLECS
Controller. Record parameters on FLECS Test Data Sheet
s. Centrifugal Checks
i. Priming the 6 x 5 Recirculation Pump and 4x4 Mixing Pump To Set Max Speed.
1. Open the 4x4 mixing pump suction valve (the tank fill valve should be closed).
2. Open the master water valve by placing the HAND/AUTO switch in the HAND position.
3. Engage the 4x4 mixing pump.
4. Open the water metering valve and fill the mix tub to approximately two-thirds full. Disengage the
4x4 mixing pump.
5. Open the 6x5 tub suction valve and 6x5 recirculating valve.
6. Engage the 6x5 pump and increase the throttle on the chassis engine until the 6x5 pump is primed.
Disengage the 6x5 recirculating pump.
ii. Mix pump (4x4) maximum speed adjustment
1. With 4x4 pump in the on position, open flow control on the motor while observing rpm with hand
tachometer and aux. engine speed set @ 2500 rpm.
2. Adjust flow control on 4x4 motor to achieve 2200 rpm pump speed
3. Lock adjustment knob.
iii. Recirculation pump (6x5) maximum speed adjustment
1. With recirc pump (6x5) toggle switch in the on position open flow control valve on the motor while
observing the 6x5 pump rpm with a hand tachometer and the aux. engine speed set @ 2500 rpm
2. Adjust flow control on the 6x5 motor to achieve 1600 rpm
3. Lock adjustment knob.
9. FUNCTION TEST
a. Ensure hydraulic power pack engine speed is set to 2450-2500 rev/min.
b. Open the Packing Lube valves before operating the pumps.
c. Engage the recirculation 6x5 centrifugal pump, circulate water at maximum speed.
i. Record centrifugal pump system pressure on test sheet.
d. 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 (max allowable 220 °F).
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,
and system voltage.
e. 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
iii. The minimum acceptable performance at “closed-in” conditions is:
1. 6 X 5 PUMP – 40-65 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.
f. Disengage the recirculation 6x5 centrifugal pump
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g. Engage the 4x4 centrifugal pump, circulate water at maximum speed and finish filling
the tanks.
i. Record centrifugal pump system pressure on test sheet.
h. Record the discharge pressure of the centrifugal pump while circulating water.
i. The minimum acceptable performance at “open” conditions is:
1. 4x4 PUMP – 50-65 PSI.
ii. Measure bearing/seal temperature(s) on pump with infrared thermometer on 5-minute
intervals. Record measured values on test data sheet (max allowable 220 °F). .
iii. After bearing/seal temperature(s) have stabilized for three measurements (10 minutes),
and system voltage.
i. 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
iii. The minimum acceptable performance at “closed-in” conditions is:
1. 4x4 PUMP – 105 -110 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.
j. With the engine speed at 2500 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 4x4 and 6x5 pump with infrared thermometer
on 5 minute intervals. Record measured values on test data sheet. (max allowable 220
°F)
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),
and system voltage.
viii. Record agitator speed of each of the agitators in all tanks. 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.
k. 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.
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Date: 05/02/2008
1. Keep the hydraulic reservoir filled to the full mark, and continually observe the system connections
for leaks.
2. 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.
l. Record speed of agitators on test sheet. (min 150 rpm)
m. After operating the system for 30 minutes and while still fully loaded, record the
hydraulic oil pressures, engine speed, and air pressure.
n. Record the hydraulic oil temperature in the reservoir.
o. Unload the engine and record speed on test sheet.
p. Follow proper system shutdown procedures.
q. Check all fluid levels.
r. Grease all zerks with lithium grease, Part No. 100026247.
10. DECK ENGINES AND PUMPS START UP
a. Safety
i. Verify that all unessential personnel are cleared from the unit and out of the direct line
of sight of the unit.
ii. Verify that all personnel are clear of any pressurized lines and/or parts.
iii. Verify that personnel and equipment are clear of unit and potentially moving or rotating
components and that all guards and shielding are properly installed.
iv. Verify that all lubrication has been completed and that supply valves from tanks and
reservoirs (fuel, hydraulic fluid, pump lube, etc) are open.
v. Verify that discharge piping is properly connected to hydraulic choke and that hydraulic
choke is fully open.
vi. Verify that muffler is properly positioned with exhaust ventilation system, and that
exhaust ventilation system is running.
b. Verify that all suction valves on hydraulic lines/tank, fuel lines/tank, water lines/tank
are open.
c. Starting Procedure
i. Setup and Adjustment Deck Engine DS & PS
1. Connect CAT Engine Technician (ET) diagnostic software to Engine.
2. Turn the main power on and correct all engine faults
3. Set all customer parameters to the appropriate values as given by Heavy Equipment Components &
Standards Team.
4. Confirm that run/stop control switch, engine throttle controls, and emergency kill switches are
working correctly.
5. Test over speed verify switch (if included on equipment).
6. Set over speed verify to off or disable.
ii. Setup and Adjustment Deck Transmission DS & PS
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1. Connect Allison DOC diagnostic software to transmissions.

2. Turn the main power on and correct all transmission faults
3. Verify all customer parameters to the appropriate values as given by Heavy Equipment Components
& Standards Team.
4. Check shift selector pad for any error codes
iii. Starting Procedure Deck Engine DS & PS
1. Place range selector for transmission in the neutral position.
2. Ensure hydraulic system is operating before attempting to start deck engine.
3. Place the on/off switch on the engine control panel to “off”.
4. Crank engine with the stop/run/start on the engine control panel until engine oil pressure gauge
indicates 3 to 5 psi.
5. Place the on/off switch on the engine control panel to “on”.
6. Push the stop/run/start on the engine control panel to “Start” and start the engine.
7. Note the system hydraulic pressure and cranking RPM while cranking and record in the table below.
The engine should crank at a minimum of 100 RPM. Record the actual pressure and RPM on the test
data sheet.
8. Observe Unit for major leaks and shut down immediately if necessary.
9. Observe the engine oil pressure gauge. If the oil pressure does not rise to above 23.2 psi within 15
seconds after the engine starts, shut the engine down and determine the cause.
10. Allow engine to warm up at 1000-1100 rpm in neutral.
11. Check shift selector pad for any error codes
12. Verify the following items while engine is warming up:
a. Engine oil pressure is acceptable.
b. System voltage is correct.
c. Low Idle speed is correct.
d. Rated speed is correct.
e. Top No Load Speed is correct.
f. All leaks have been corrected.
g. The charging system is operating correctly.
h. The radiator fan is blowing air through radiator.
i. The speed of the radiator fan
j. All engine faults have been corrected (for electronic engines).
13. Verify throttle controls are operational.
14. Verify Emergency Shutdown controls are operational.
15. Verify engine overspeed protection is operational.
16. Verify reverse blockout. Shifter on operator platform should not be able to shift 4700 OFS
transmission into reverse. If transmission shifts into reverse, stop engine and troubleshoot. If
problem persist, contact appropriate DME.
d. 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
e. Over speed System Test--To test the over speed system on the Cat C11, engage the
75% VERIFY OVERSPEED switch in the control stand. When the engine speed
reaches 75% of the speed set in the ECM (approximately 1,575 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.
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Date: 05/02/2008
f. An emergency kill toggle switch is included on the control stand for the 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.
g. Check oil level in hydraulic reservoir and refill as needed.
h. Prime the HT-400 Pumps
i. Ensure suction valves on both pumps are open.
ii. Make certain the discharge to the choke or the HT-400 high-pressure valves are open to
the release line back to the tank.
iii. Engage the DS HT-400 shift lever to fifth gear. Increase the engine rev/min and run the
pump until the pump is primed.
iv. Move shift lever back to neutral.
v. After making certain the HT-400 discharge valve is open, engage the PS HT-400 shift
lever to fifth gear. Increase the engine rev/min and run the pump until the pump is
primed.
vi. Move shift lever back to neutral.
i. HT-400 Pump Warm-up And Lubrication Adjustment
i. Open plunger lubrication return lube valves.
ii. Ensure pump’s power end lube valve circuit pressure is operating at a minimum of 80
psi during warm-up.
iii. With choke full open and boost pressure at a minimum of 30 psi, run for 3 minutes in
each gear at rates listed in table below.
iv. Ensure that plunger lube relief valve shows minimum 10 psi pressure.
v. While performing warm-up, verify shifting operation. If transmission will not achieve
all gears, stop running and troubleshoot. If problem persists, contact engineering.
vi. With transmission is in 5th gear and engine set to 2100 RPM, set plunger lube relief
valve to 10-12 psi and after the pump’s power end lube temperature reaches operating
temperature (150°F), ensure power end lube circuit pressure is 80-100 psi.
vii. Record pressure setting.
viii. Check driveshaft speed against table below during warm-up to verify correct
transmission lockup converter operation.
ENGINE TRANS DRVSHFT RUN
SPEED RANGE SPEED TIME
1800 RPM 1ST - 7.63 236 3 MIN

1800 RPM 2ND - 3.51 513 3 MIN
1800 RPM 3RD – 1.91 942 3 MIN
2100 RPM 4TH – 1.43 1469 3 MIN
2100 RPM 5TH - 1.0 2100 3 MIN
j. HT-400 Neutral Tests
i. Shift transmission to neutral after warm-up is completed.
ii. Transmission should not roll over when shifted to neutral after reaching operating
temperature of at least 180 deg. F.
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Date: 05/02/2008
iii. If the driveshaft continues to turn when neutral is selected, gradually close choke until
driveshaft stops.
iv. Record pressure at discharge of HT-400 pump. If more than 500 psi, stop engine and
troubleshoot. Contact engineering if problem persists.
k. HT-400 Over-Pressure Kick out Test
i. Set trip point of pressure sensor at 1000 psi.
ii. Open manifold choke to the fully open position.
iii. Place the transmission in 2nd gear and increase engine speed to 1500 rpm.
iv. Slowly close the manifold choke to obtain the 1000 psi set point.
v. Record the pressure at which the transmission shifts to neutral and the engine speed
returns to neutral.
vi. After the pressure kick out is verified, reset the pressure sensor for operation according
to the following chart for the various sizes of fluid ends.
FE SIZE KICKOUT SETTING
3.38” F/E 20,000 PSI (137895 KPA)
4.0” F/E 14,000 PSI (96526 KPA)
4.5” F/E 11,200 PSI (77221 KPA)
5.0” F/E 9,000 PSI (62052 KPA)
6.0” F/E 6,250 PSI (43092 KPA)
CAUTION: These are the maximum pressures for the pumps; it does not take into consideration the discharge
piping being utilized on the pump.
l. Perform normal stop procedures (required for engine shut down)
i. Run engines at high idle (approximately 1000 rpm) for 10 minutes.
ii. Engine temperature should be at or below 180 f.
iii. Depress stop valve for engine currently in operation on operator control panel.
iv. Verify fan belts (if present) are properly tensioned.
v. Check and fill all fluid to required levels.
m. Check the all fluid levels.
n. Grease all zerks with lithium grease, Part No. 100026247.
o. Verify pressure transducers and calibration to FLECS. Also verify proper operation
of Martin Decker gauges.
p. Repeat 9f-9o for second HT-400.
11. PERFORMANCE TEST HYDRAULICS AND CENTRIFUGALS
a. Ensure hydraulic power pack engine speed is set to 2450-2500 rev/min.
b. Open the Packing Lube valves before operating the pumps.
c. With the engine speed at 2500 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.
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Date: 05/02/2008
v. Measure bearing/seal temperature(s) on 4x4 and 6x5 pump with infrared thermometer
on 5 minute intervals. Record measured values on test data sheet. (max allowable 220
°F)
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),
and system voltage.
viii. Record agitator speed of each of the agitators in all tanks. 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.
d. 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. 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.
e. Record speed of agitators on test sheet. (min 150 rpm)
f. After operating the system for 30 minutes and while still fully loaded, record the
hydraulic oil pressures, engine speed, and air pressure.
g. Record the hydraulic oil temperature in the reservoir.
h. Unload the engine and record speed on test sheet.
i. Follow proper system shutdown procedures.
j. Check all fluid levels.
k. Grease all zerks with lithium grease, Part No. 100026247.
12. PERFORMANCE TEST DECK ENGINES AND PUMPS
a. Ensure that all discharge and suction line connections to the unit are still established.
b. Verify reverse block out.
c. Begin the warm-up by pumping in successive gears as outlined in 9.i.
d. Verify neutral operation by shifting the transmission to neutral after the warm-up is
complete.
e. Check lube oil circuit relief valves.
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Date: 05/02/2008
f. Keep hydraulic reservoir (if equipped) at full mark and continually observe system
connections for leaks.
i. Continually watch and listen for cavitation noises at hydraulic pumps.
ii. Tighten all hoses that appear to leak any amount of hydraulic fluid.
iii. Hydraulic temperature should not exceed 180°F. Verify that this does not occur.
iv. With system warm, check hoses at heat exchanger to make certain that oil is not
bypassing the heat exchanger.
v. Verify that direction arrow on cooler check valve is in proper orientation. Arrow should
point from the inlet to the outlet line.
vi. Observe filter bypass indicators for bypass condition and change elements if bypass is
indicated or major failure occurs on system.
g. HT400 Pump performance test
i. Complete the performance testing in accordance with pump schedule in this section for
the appropriate fluid end size, and record the results in the tables provided for each
pump in the test data sheet.
ii. Start deck engine.
iii. Allow engine to reach operating temperature and pressure.
iv. Raise engine speed to 2100 rpm.
v. Ensure engine coolant is at least 180 F and running at rated speed
vi. Do not exceed pressure rating of discharge manifold.
vii. Record engine, transmission, and pump temperatures and pressures during runs. (This
data may also be completed with Data Acquisition System)
viii. Look for leaks at manifold, pump fluid ends and all fittings. Packing lubricant leaks
at or below 3 drops per minute from each plunger are considered acceptable. Repair
unacceptable leaks.
ix. At least two of high HP runs (Runs 6-9) shall be completed with no delay between runs.
x. After completion of the pumping schedule and prior to stopping engine, follow cool
down procedures.
xi. If a disruption of this test procedure requires shutdown for more than 30 minutes, repeat
run 1 prior to completing test procedure.
xii. Both pumps may be run at the same time for this testing provided adequate testing
apparatuses are available. Run time provided is minimum testing requirement.
Additional run time may be required to accept unit as field ready.
xiii. Complete runs "6-9" as follows:
1. Fully open discharge choke.
2. Run engine at full throttle in gear listed.
3. Slowly close choke until engine rpm drops below 2100 rpm.
4. Record actual psi at 2100 rpm, choked setting.
5. If actual pressure exceeds the "MAX" or “MIN” pressure, contact the Duncan Technology Center.
xiv. Record system voltage at 700 rpms after test runs.
xv. Verify that system voltage is in normal range.
h. Perform normal stop procedures (required for engine shut down)
i. Run engine at high idle (approximately 1000 rpm) for 10 minutes.
ii. Engine temperature should be at or below 180 f.
iii. Depress stop button for engine currently in operation on operator control panel.
iv. Verify fan belts are properly tensioned.
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Date: 05/02/2008
v. Check and fill all fluid to required levels.

13. COMPLETE ELECTRICAL SYSTEM VERIFICATION.
a. Verify that instrument battery voltage does not drop when the aux engine is started
(while cranking)
b. Verify that once the aux engine has started, the aux alternator indication lamp is on
and the instrument battery voltage is above 12 Vdc (at alternator output voltage)
c. Let each engine run by itself under full electrical load (lights and all) to verify that:
i. Only the respective alternator lamp is on
ii. Alternator voltage is sensed at the instrument voltmeter - and - the aux. Batteries
iii. This will verify that each alternator can independently drive the entire electrical load
14. COMPLETE ROAD TEST PROCEDURE (Specification D00113295)
15. COMPLETE FINAL INSPECTION TEST PROCEDURE (Spec D00113918).
16. 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: 05/02/2008
Pump schedule
Pumping Unit, Elite Trailer, Standard, with CAT C11 Deck Engines, Allison 4700 OFS
Transmission, HT400 Pumps
Find Appropriate Pump Schedule For Equipment Being Tested.
For all runs

1. Complete Run #1 until the unit reaches operating temperature.
1. Observe engine, transmission, and pump temperatures and pressures during runs.
2. If a disruption of this test procedure requires shutdown for more than 30 minutes, repeat run "1"
prior to completing test procedure.
3. After completion of the pumping schedule or prior to stopping engine follow shutdown
procedure before stopping engine
For runs 6 - 9
1. At least two of the high hp runs shall be completed with no delay between runs.
2. Fully open discharge choke,
3. Run engine at full throttle in gear listed,
4. Slowly close choke until engine rpm drops to listed speed.
5. Record actual psi at listed speed, choked setting,
6. If actual pressure exceeds the "max" pressure, horsepower is too high. Contact the Duncan
Technology Center.
7. If the actual pressure is below the "min" pressure, horsepower is too low. Take "corrective
action".
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Date: 05/02/2008
Pumping Unit, Elite Trailer, CAT C11 Deck Engine, 4700 OFS Transmission, HT400 Pumps
3 3/8 ” Plungers
RUN RPM RPM GEAR BPM PSI PSI HHP MINUTES

ENGINE DRIVELINE (MIN) (MAX) (MIN)
1 2100 2100 5 5.40 561 - 74 10
WARM UP
Or until operating temperature is reached
2 2100 1470 4 3.78 1573 - 146 10
BREAK IN
3 2100 1102 3 2.83 3204 - 223 10
4 2100 598 2 1.54 5886 - 222 10
MANIFOLD
5 2100 275 1 0.71 14500 15000 252 2
6 2100 2100 5 5.40 2237 2375 296 10
7 2100 1470 4 3.78 3137 3331 291 10

HIGH HP
8 2100 1102 3 2.83 4260 4524 296 10
9 2100 598 2 1.54 7827 8311 295 10
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Date: 05/02/2008
4” Plungers

1 2100 2100 5 7.59 399 - 74 10
WARM UP
2 2100 1470 4 5.31 1120 - 146 10
BREAK IN
3 2100 1102 3 3.98 2281 - 222 10
4 2100 598 2 2.16 4190 - 222 10
MANIFOLD
5 2100 275 1 0.99 11810 12540 288 2
6 2100 2100 5 7.59 1592 1691 296 10
7 2100 1470 4 5.31 2233 2371 291 10

HIGH HP
8 2100 1102 3 3.98 3033 3221 296 10
9 2100 598 2 2.16 5572 5917 295 10
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Date: 05/02/2008
4 ½ ” Plungers

1 2100 2100 5 9.60 315 - 74 10
WARM UP
2 2100 1470 4 6.72 885 - 146 10
BREAK IN
3 2100 1102 3 5.04 1802 - 222 10
4 2100 598 2 2.74 3311 - 222 10
MANIFOLD
5 2100 275 1 1.26 9331 9908 288 2
6 2100 2100 5 9.60 1258 1336 296 10
7 2100 1470 4 6.72 1765 1874 291 10

HIGH HP
8 2100 1102 3 5.04 2396 2545 296 10
9 2100 598 2 2.74 4403 4675 295 10
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Date: 05/02/2008
5” Plungers

1 2100 2100 5 11.85 256 - 74 10
WARM UP
2 2100 1470 4 8.30 717 - 146 10
BREAK IN
3 2100 1102 3 6.22 1460 - 222 10
4 2100 598 2 3.38 2682 - 222 10
MANIFOLD
5 2100 275 1 1.55 7558 8026 288 2
6 2100 2100 5 11.85 1019 1082 296 10
7 2100 1470 4 8.30 1429 1518 291 10

HIGH HP
8 2100 1102 3 6.22 1941 2061 296 10
9 2100 598 2 3.38 3566 3787 295 10
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Date: 05/02/2008
6” Plungers

1 2100 2100 5 17.07 177 - 74 10
WARM UP
2 2100 1470 4 11.95 498 - 146 10
BREAK IN
3 2100 1102 3 8.96 1014 - 222 10
4 2100 598 2 4.86 1862 - 222 10
MANIFOLD
5 2100 275 1 2.24 5249 5574 288 2
6 2100 2100 5 17.07 708 752 296 10
7 2100 1470 4 11.95 993 1054 291 10

HIGH HP
8 2100 1102 3 8.96 1348 1431 296 10
9 2100 598 2 4.86 2476 2630 295 10
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Date: 05/02/2008
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 FLUID LEVELS DRIVER SIDE DECK ENGINE AND PUMP

Engine Oil
Transmission Fluid
Engine Fuel
Engine Coolant
HT-400 Pump Lubed (Power and Fluid Ends)
LUBRICATION OF GREASE ZERKS
Driveshaft slip joints
Universal joints
Manifold supports.
Pump supports
Lo-Torq valves
FLUID LEVELS PASSENGER SIDE DECK ENGINE AND PUMP
Engine Oil
Transmission Fluid
Engine Fuel
Engine Coolant
HT-400 Pump Lubed(Power and Fluid Ends)
LUBRICATION OF GREASE ZERKS
Driveshaft slip joints
Universal joints
Manifold supports.
Pump supports
Lo-Torq valves
FLUID LEVELS AUXILIARY ENGINE, HYDRAULICS, CENTRIFUGALS
Engine Oil
Engine Coolant
Hydraulics Fluid (Reservoirs, lines, fittings, motors, pumps) Filled And Checked
Funk pump drive
Hydraulic reservoir
Hydraulic pumps, motor cases, lines, coolers, filter housings
Centrifugal Pumps Lubed (Power and Fluid Ends)
Grease zerks
Axle hubs
4 PRE-START INSPECTION
CABLES & HOSES ROUTED AND TIED DOWN TO CLEAR SHARP EDGES AND MOVING
PARTS IN FOLLOWING AREAS:
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Date: 05/02/2008
Wiring secured at 2 ft max intervals

Hoses secured at 4 ft max intervals
Wiring and hose 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
All Drive Line Bolts Torqued
INSPECT UNIT FOR GENERAL HAZARDS
Leaking Fluids Loose Wires, Cables, or Hoses
Missing Welds Deformed or Cracked Components
Loose Nuts or Bolts Covers, Lids, or Guards Improperly installed
Misaligned Connectors or Shafts Loose Chains, Belts, or Idlers
All fluids at appropriate level
Battery cables labeled POS and NEG
Hydraulic components are properly installed, routed, and not reversed.
Pneumatic components are properly installed, routed, and not reversed.
Check woods couplings for proper alignment.
TEST INSTRUMENTS
TI # Description (DAS, Gauge, Unipro) Serial No. Last Cal Cal Due
1
2
3
4
SETUP AND ADJUST PUMPS

Water Supply
Flow Meter
Choke
Data Recording Devices
Discharge and Suction Valves
Webasto engine coolant heaters tested in accordance with spec. 278.02740, if required
Air to Lube tanks (psi) HT-400s
Air to Lube tanks (psi) Centrifugals
5 FLECS CONTROLLER SETUP

FLECS controller setup and tested per specification D00171055
6 AUXILIARY ENGINE/CONTROL STAND 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 700 RPM check and record the following after warm-up is completed
Engine Oil Pressure psi
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Date: 05/02/2008
Engine Water Temp °F

Charging System Volts
System air gauge
Murphy Power View
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
Hand operated valves operate correctly
1 2 3 4 5 6
Lights operate correctly
20BBL 80BBL Rear Side Control Stand C.S. Warning
Operators Lamps
Heaters operate correctly
Pass Side Engine Drivers Side Engine Auxiliary Engine Control Stand
7 SETUP AND ADJUST HYDRAULICS/AGITATORS/CENTRIFUGALS

Air Bled Off
6x5 Pump charge pressure set (psi)
4x4 Pump charge pressure set (psi)
Pumps Primed
6x5 Pump system pressure (psi)
4x4 Pump system pressure (psi)
Agitators are correctly configured in each tank.
Agitators are rotating in a counterclockwise direction as seen from above looking down
Agitator relief pressure (psi)
Agitator system pressure (psi)
Maximum tub agitator speed (rpm) #1
ADC relief pressure (psi)
ADC compensator setting (psi)
6x5 Pump Speed Set (rpm)
4x4 Pump Speed Set (rpm)
ASA Hydraulic Cooler Blows to outside of trailer
8 FUNCTION TEST HYDRAULICS/AGITATORS/CENTRIFUGALS

PUMP TEST RESULTS 6x5
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)
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Date: 05/02/2008
System Voltage (V)

Flow Condition Full Flow Closed In
Engine Speed (rpm)
System Voltage (V)
8 Function Test
Start of 30 Minute Test Run
Engine speed unloaded (rpm)
Engine speed loaded (rpm)
6x5 Centrifugal stroked charge pressure loaded (psi)
6x5 Centrifugal system pressure loaded (psi)
Agitator system pressure loaded (psi)
6x5 Centrifugal pump speed loaded (rpm)
Tub agitator motor Temperature (F) #1
Full Flow Flow Condition
Engine Speed (rpm)
System Voltage (V)
8 Function Test
End of 30 Minute Test Run
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Date: 05/02/2008

Engine Speed Unloaded (rpm)
System Voltage (V)
9 STARTUP, INSPECT, ADJUST DECK ENGINES AND PUMPS

INSPECTION AND ADJUSTMENT DECK
Inspect engine gauges, control stand gauges and controls for proper operation
Power View DS
Power View PS
Air Pressure
DS PS
System voltage
Auxiliary engine controls
All engine faults corrected
All customer parameters set
Run/Stop control switch functions
Engine throttle controls function
Emergency Kill Functions
At 700 RPM check and record the following
DS PS
Hyd Oil Temp (psi)
Hydraulic Start Pressure (psi)
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Date: 05/02/2008
Starter RPM
Engine Oil Pressure psi
Engine Water Temp °F
Trans Oil Pressure psi
Trans Temperature °F
Charging System Volts
Engine idle speed rpm
PUMP TEST RESULTS HT-400

Pressure to stop rotation of HT400 Pump #1 while in neutral. (psi)
Pressure to stop rotation of HT400 Pump #2 while in neutral. (psi)
HT-400 DS power end relief valve pressure setting (psi)
HT-400 DS lube relief valve pressure setting (psi)
HT-400 DS pressure kick out set (psi)
HT-400 PS power end relief valve pressure setting (psi)
HT-400 PS lube relief valve pressure setting (psi)
HT-400PS pressure kick out set (psi)
After Warmup and Adjustment DS PS
Engine Speed (rpm) DS
Engine Temperature (°F) DS
Engine Oil Pressure (psi) DS
System Voltage (V) DS
Trans Oil Pressure (psi) DS
Trans Temperature (°F) DS
Pump Oil Pressure (psi)
Pump Oil Temperature (°F)
10 Performance Test Hydraulics and Centrifugals

Start of 30 Minute Test Run
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Date: 05/02/2008

Engine Speed (rpm)
System Voltage (V)
10 Performance Test Hydraulics and Centrifugals

End of 30 Minute Test Run
Engine Speed Unloaded (rpm)
System Voltage (V)
11 AFTER PERFORMANCE TEST DS PS

Engine Speed (rpm)
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Date: 05/02/2008

System Voltage (V)
Hydraulic Oil Temp (°F)
Pump Oil Pressure (psi)
Pump Oil Temperature (°F)
Trans Oil Pressure (psi)
Trans Temperature (°F)
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Date: 05/02/2008
PUMP TEST RESULTS FOR HT400 PUMP DS (Record Average Values For Each Run)
(given values assume a 4.0” plunger )
RUN 1 2 3 4 5 6 7 8 9
GEAR 5 4 3 2 1 2 3 4 5
ENG1 2100 2100 2100 2100 2100 2100 2100 2100 2100
RPM
PUMP1 2100 1470 1102 598 275 598 1102 1470 2100
RPM
MIN. 74 146 222 222 288 295 296 291 296
HHP
HHP
BPM
ENG
RPM
PSI
DSCH
ENG
TEMP
ENG
OIL PSI
TRNS
TEMP
TRNS
OIL PSI
F.E.
PSI
P.E.
PSI
PUMP
TEMP
ENG
VOLT
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Date: 05/02/2008
PUMP TEST RESULTS FOR HT400 PUMP PS (Record Average Values For Each Run)
(given values assume a 4.0” plunger )
RUN 1 2 3 4 5 6 7 8 9
GEAR 5 4 3 2 1 2 3 4 5
ENG1 2100 2100 2100 2100 2100 2100 2100 2100 2100
RPM
PUMP1 2100 1470 1102 598 275 598 1102 1470 2100
RPM
MIN. 74 146 222 222 288 295 296 291 296
HHP
HHP
BPM
ENG
RPM
PSI
DSCH
ENG
TEMP
ENG
OIL PSI
TRNS
TEMP
TRNS
OIL PSI
F.E.
PSI
P.E.
PSI
PUMP
TEMP
ENG
VOLT
13 ELECTRICAL SYSTEM VERIFICATION

Electrical Charging System Has Been Verified.
14 ROAD TEST
Road Test (D00113295) completed and acceptable.
15 FINAL INSPECTION
Final Inspection (D00113918) completed and acceptable.
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Date: 05/02/2008
ACCEPTANCE CERTIFICATION
I certify by signature below:
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.
Exceptions: Reason Accepted:
Printed Name Signature Date

Test Tech 1
Test Tech 2
Test Tech 3
Test Tech 4
35 of 35
Halliburton Energy Services Specification D00171055 Revision B
Tested Unit: FLECS Setup, Calibration, and Test, Dual
Duncan, OK Pumps
Date: 07/09/2007
1. TEST INFORMATION
i. This test procedure is intended to identify the minimum requirements for the setup,
calibration and testing of a FLECS Controller on a Dual Pump Cementing Unit.
data entry.
2. UNIT INFORMATION
a. Operating and service standards for this unit.
MANUAL DESCRIPTION PART NO.
FLECS Service / Operators Manual 101324382
b. General operating parameters for this unit.
3. SOFTWARE VERIFICATION
a. Any unit that utilizes FLECS software will have the software checked to ensure the
current version of the software is installed.
b. The current version of the software may be found at the following link:
i. FLECS Software
c. If the current version of the software is not loaded, load the current version as defined
in the upgrade road map for the type of unit as posted.
4. ELECTRONICS PRE-POWERUP INSPECTION
a. Disconnect ALL Powered Instruments and Electro-hydraulic Valves.
i. Disconnect all the instruments that receive power. Devices such as densometers,
pressure transmitters and electro hydraulic valves. Disconnect at the connection on the
sensor/valve. If no Glenair type connection exists disconnect power to the device at the
junction box. Only passive devices like Magnetic Pickups can remain connected. Refer
to master wiring diagram contained in FLECS Elite Operator’s manual or FLECS
Controller Technical manual.
b. Check terminations in junction box.
i. Make sure all wires are snugly secured in their respective terminals. Tighten or re-
terminate as needed.
c. Make sure instrument battery is charged and well above 10.5 volt minimum.
1 of 9
Duncan, OK Pumps
Date: 07/09/2007
d. Make sure Instrument Battery is connected and that Polarity is correct.

5. ELECTRONICS FIRST POWER UP
a. Turn the power on to the FLECS system at the Control Stand.
i. Check that display comes on shortly after turning on switch.
1. If display does not power up shortly after turning on switch, turn switch off and double check the
power connection to the display.
ii. Check that display begins receiving data after a 45 second delay. (Check for flashing
green light on lower right hand side of FLECS Display).
1. If unit does not receive data after approximately 45 seconds. Double check display serial wiring. You
may also want to open up the junction box and connect a VGA monitor to the FLECS controller and
verify the power up and boot process visually.
b. Set feedback voltages for the Water and Cement Valves.
i. Make sure that in the closed position the feed back voltages for both valves is
approximately 1.0 volts. This voltage should rise steadily as the valve is slowly opened.
c. Connect powered Instruments and Valves.
i. Connect pressure transmitters one at a time. Verify that an approximate 0 psi reading is
observed at the FLECS display.
ii. Connect the R/A Densometers.
1. You may want to double check the power connections and be sure +12 volts is on Pin A and GND is
on Pin D before re-connecting the cable connector to the sensor.
2. After connecting the densometer’s you should see some kind of density reading on the FLECS
display. (This may not be 0.0 lbs because we have not entered cal data yet this will be done in
following procedures).
iii. Connect the electo-hydraulic valves for cement and water control.
iv. Connect any other remaining instruments or devices.
6. UNIT CALIBRATION
a. Calibration procedures are subject to frequent change and alteration dependent on
the version of software installed. Refer to current Operator’s Manual “Unit
Calibration” section for the version of software installed on this machine. Follow the
procedures there and fill in check list at end of this document as you proceed.
7. UNIT TEST
a. PRESSURES
i. After calibration a standard 15000 psi WECO union transmitter, the FLECS display
should show -3750 psi when the unit is disconnected with no current coming in. 0 psi
when connected with 4 mA coming in with no applied pressure. (Optional: inject 20mA
with a current source either at the Junction box or at the Glenair cable and you should
read 15000 psi.)
b. DENSOMETERS
i. If the densometers were calibrated correctly and are currently empty of fluid you should
read Air or 0 ppg in the Recirc Density and Downhole Density boxes. A heavy reading
of 100.00+ lbs or more indicates that no frequency at all is being read and that the
Densometer is probably not functioning. Check wiring on densometer.
c. MIXWATER FLOWMETER
i. After calibrating the 3” mixwater valve, run some fresh water through the mixwater
flowmeter. You should see a flow rate and a stage total appear in the FLECS Display in
the Mix Water Rate box.
2 of 9
Duncan, OK Pumps
Date: 07/09/2007
d. DISPLACEMENT PUMPS
i. After calibrating the displacement pumps, roll the passenger side displacement pump a
little bit. You should get a flowrate in the Combined Rate box. Repeat for the driverside
pump. You should also see the slurry volume increment in the Combined Stage Total
box.
e. WATER AND CEMENT VALVES
i. Manual Check: Flip the Auto-Manual switches over to Manual control for the water and
cement valves and turn the manual control pots to verify that the Parker valves are
operating properly. Make sure each valve can be moved through its full range of
operation using the control pots.
ii. Auto Check: Flip the Auto-Manual switches to auto. On the FLECS Display go to
Manual Control. Now using the FLECS display open the valves from 0 to 100% open.
Verify that valves move throught their entire range. Oscillate both valves and verify
that system oscillates both valves between 25% and 75% open. Exit the manual mode.
iii. Start Water Check: Issue a “Start Water” command and verify that cement valve opens
to 50% open. Run water through the 3” flowmeter. When proper total is reached the
water valve should automatically shut off. (If unit is equipped with a master water valve
make sure the valve is opening with the start mix and closing when the mix water valve
is closed).
iv. Start Cement Check: Issue a “Start Cement” command and verify that cement valve
opens to the 20% open position and holds there waiting for cement. Issue a “Stop Mix”
command and the cement valve should shut to closed position.
f. OTHER MISC SENSORS
i. Contact technology if a new device related to the mixing system appears for which no
test procedure is included in this specification.
g. OVERPRESSURE KICKOUT
i. Prepare the unit to pump against a closed valve or a constriction so that the pressure will
steadily increase.
ii. Set the Driver Side and Passenger Side Kickout Pressures to a safe value for unit test.
Verify that your new kickout settings are in place by checking the Passenger and Driver
Side pressure indicators on the FLECS display. The kickout setting should be clearly
indicated. (Refer to operator’s manual if you need more details).
iii. You can now pump against the closed valve or constriction in order to raise the pump
pressure. Carefully monitor the pressure rise on the pressure gauge and go slowly and
with caution.
iv. When the pump pressure exceeds the Kickout Value indicated in red the transmission
should automatically kick to neutral. The gauge background in will flash RED to
indicate that the pumps have kicked out to neutral. After a pump is kicked out you will
have to relieve the pressure then go and reset the kickout value again to clear the red
display and repeat the test.
h. SERIAL COMMUNICATIONS TEST
i. Connect a standard rs232 serial cable (not a null modem) to the serial output port on the
Elite Trailer communications box. Connect the other end of the serial cable to your PC’s
serial port. (If you connect directly to COM4 on the FLECS controller from inside the
Junction box you will need a null modem serial cable.)
3 of 9
Duncan, OK Pumps
Date: 07/09/2007
ii. Make sure the FLECS Display is up and running and receiving display updates. Look
for flashing green light on lower right hand corner.
iii. Open a HyperTerm serial communications session or other suitable serial com
application on your laptop. Select the COM number you are connected to your PC
(Usually COM1 or COM2). Set your serial communications settings to 9600 bits per
second, 8 data bits, No parity and 1 Stop bit. (9600,8,N,1). You may have to also issue
a connect command to open the COM port and start receiving data.
iv. The ADC Serial Output should be sending a stream of data to your display in
HyperTerm once every second. You should a stream of comma delimited numbers and
units.
i. ETHERNET COMMUNICATIONS TEST
i. Connect a standard wired (not a crossover) CAT5 ethernet cable to the Elite
Communications Box Ethernet port and your PC. (If you connect directly to the
Ethernet port on the FLECS controller contained inside the Junction Box you will need
a Crossover wired Ethernet cable).
ii. Make sure the TCPIP settings for the Laptop Computer are as follows
IP Address = : 10.0.0.21
NetMask = : 255.255.252.0
Default Gateway =: Blank
Most COE laptops from Halliburton are configured to get their IP address from a DHCP server. You
will need to change your network adapter to the above specific settings in order for the test to work.
To check or change these settings perform the following steps(Steps may vary slightly between
versions of Windows).
1) Click on Start Button
2) Click on Settings
3) Click on Control Panel
4) Click on the Network or Network Connections Icon
5) Double Click the network adapter you are using
6) Click on the Properties Button
7) Click on the IP Address Tab or Scroll down to “Internet Protocol (TCP/IP)”
8) Click on Properties
9) The “Specify an IP Address” radio button should be selected. If not then select it.
10) Enter 10.0.0.21 for the IP Address
11) Enter 255.255.252.0 for the NetMask
12) Leave the Default Gateway field blank.
13) Click on the Apply Button
14) Click on the OK Button.
If you are requested to reboot then please do so.
iii. Open a command prompt (also known as DOS box) on the laptop computer.
iv. Type “ping 10.0.0.1” in the command prompt box and hit return. You should make at
least 3 attempts.
v. If Ethernet communication is connected and working you should see a “Reply from
10.0.0.1:” message. Otherwise you will see a “Request timed out” reply indicating that
you were unsuccessful.
4 of 9
Duncan, OK Pumps
Date: 07/09/2007


Model Number Date
FLECS Control System Master Check List

UNIT #: __________________________ DATE:_____________________
TESTED BY:___________________________________________________
ELECTRONICS PRE-POWERUP INSPECTION

¾ ______ Disconnect All Powered Instruments and Electro-hydraulic valves
¾ ______ Check Terminations in Junction Box.
¾ ______ Instrument battery has good charge and polarity properly attached.
ELECTRONICS FIRST POWER UP
¾ _____ Turn power on to the FLECS at the control stand.
¾ _____ FLECS Display came on and showed job screen.
¾ _____ FLECS Display receiving data.
¾ _____ Feedback voltages set at 1.0 volts closed for water and cement valves.
¾ _____ ALL Powered instruments and valves connected successfully
DENSOMETER CALIBRATION (Refer to Operator’s Manual)
¾ _____ Frequency Calibration for Recirculating Densometer entered.
Point 1: Weight__________________ Frequency ______________
¾ _____ 4-20mA Recirc Densometer calibration entered
Point 1: Weight__________________ milliAmps ______________
Point 2: Weight__________________ milliAmps______________
5 of 9
Duncan, OK Pumps
Date: 07/09/2007
¾
_____ Frequency Calibration for Downhole Densometer entered.
¾ _____ 4-20mA Downhole Densometer calibration entered
Point 1: Weight__________________ milliAmps ______________
Point 2: Weight__________________ milliAmps______________
PRESSURE SENSORS CALIBRATION (Refer to Operator’s Manual)
¾ _____ Passenger Side Pressure Device
Pressure Device Type = ________________________________(example: 15000 psi weco)
Point 1 Current = ____________________ mA
Point 1 Pressure = ____________________ psi
Point 2 Current = ____________________ mA
¾ _____ Driver Side Pressure Device
Pressure Device Type = ________________________________(example: 15000 psi weco)
Point 1 Current = ____________________ mA
Point 2 Current = ____________________ mA
DISPLACEMENT PUMP CALIBRATION (Refer to Operator’s Manual)
¾ _____ Passenger Side Displacement Pump
Fluid End _________________________________________
Point 1 Frequency __________________________________
Point 1 Volume ____________________________________
Point 2 Frequency __________________________________
Point 2 Volume ____________________________________
¾ _____ Driver Side Displacement Pump
Fluid End _________________________________________
Point 1 Frequency __________________________________
Point 1 Volume ____________________________________
Point 2 Frequency __________________________________
Point 2 Volume ____________________________________
MIXWATER CALIBRATION (Refer to Operator’s Manual)
¾ Flowmeter Size ____________________________________
¾ Point 1 Frequency __________________________________
¾ Point 1 Volume ____________________________________
¾ Point 2 Frequency __________________________________
¾ Point 2 Volume ____________________________________
6 of 9
Duncan, OK Pumps
Date: 07/09/2007
CEMENT AND WATER VALVE CALIBRATION (Refer to Operator’s Manual)

¾ ______ Cement Valve
Cement Open Percent ___________________%
Cement Closed Percent __________________%
Anticipation(secs.)______________________
Start Fill Percent _______________________%
Delivery ______________________________Dry Gallons/Minute/Degree
Tub Volume ___________________________Gallons
______ Cement Valve Oscillated, Opened and Closed.
¾ ______ Water Valve
Water Open Percent ___________________%
Water Closed Percent __________________%
Anticipation(secs.)______________________
Start Fill Percent _______________________%
Delivery ______________________________ Gallons/Minute/Degree
Tub Volume ___________________________Gallons
______ Water Valve Oscillated, Opened and Closed.
PRESSURE DEVICE CHECK
¾ Driver Side Pressure
Pressure Reading with cable disconnected _________________.
Pressure Reading with cable connected and no applied pressure ______________.
Pressure Reading with 20mA current ____________________.
¾ Passenger Side Pressure
Pressure Reading with cable disconnected _________________.
Pressure Reading with cable connected and no applied pressure ______________.
Pressure Reading with 20mA current ____________________.
DENSITY DEVICE CHECK
¾ Recirculating Densometer
Density Reading with cable disconnected_________________.
Density Reading with cable connected and Air_____________.
Density Reading with cable connected and Water___________.
___________Autocal to Water(freq mode) successful.
___________Set Density to Water(4-20mA mode) successful.
¾ Downhole Densometer
Density Reading with cable disconnected_________________.
Density Reading with cable connected and Air_____________.
Density Reading with cable connected and Water___________.
___________Autocal to Water(freq mode) successful.
___________Set Density to Water(4-20mA mode) successful.
MIXWATER FLOWMETER CHECK
¾ ______Flow Rate Increments.
¾ ______Stage Total Increments.
DISPLACEMENT PUMPS
¾ ______Combined Rate Increments.
¾ ______Combined Total Increments.
¾ ______DS Rate displayed on correct gauge.
¾ ______PS Rate displayed on correct gauge.
WATER AND CEMENT VALVE CHECK
¾ ______ Manual Check: Manual Mode. Manual Control Knob Works and moves valves.
¾ ______ Auto Check: Auto Mode. Manual Control from FLECS software works.
¾ ______ Start Water Check: Auto Mode. Valve opens to 50 percent. Fills and shuts off.
¾ ______ Start Cement Check: Valve opens to 20 percent and waits for density to rise.
7 of 9
Duncan, OK Pumps
Date: 07/09/2007
OVERPRESSURE KICKOUT
¾ _____ Passenger Side Kickout Test Successful at _________________psi
¾ _____Driver Side Kickout Test Successful at _________________psi
DATA OUTPUT
¾ _____ Serial Output Tested Successfully
¾ _____ Ethernet Output Tested Successfully
NOTES:
8 of 9
Duncan, OK Pumps
Date: 07/09/2007
below.

Test Tech 1
Test Tech 2
Test Tech 3
Test Tech 4
9 of 9
278[1].02740NW.txt
NOTES:
TEST PROCEDURE
THIS PROCEDURE IS INTENDED FOR INITIAL SET-UP AND TESTING OF
WEBASTO DIESEL-FIRED ENGINE PREHEATERS. APPLIES TO BOTH 12VDC AND
24VDC UNITS, REGARDLESS OF HEATER SIZE.
I. PRE-START UP:
A. REMOVE SHEET METAL COVER FROM HEATER.
B. FILL FUEL FILTER WITH DIESEL.
C. PRIME DIESEL SUPPLY LINE AND OPEN SUPPLY VALVE, LOCATED
JUST UPSTREAM OF THE FILTER.
D. INSPECT COOLANT LINES RUNNING TO/FROM ENGINE AND ENSURE
THERE ARE NO RESTRICTIONS AND THEY ARE PLUMBED CORRECTLY.
E. LOCATE TERMINAL STRIP ON TOP OF ELECTRIC MOTOR ON THE
LEFT HAND SIDE OF THE PREHEATER UNIT. IF NOT ALREADY
DISCONNECTED, UNPLUG THE FARTHEST LEFT HAND (THERMOSTAT)
CONNECTOR. A TAG SUPPLIED BY WEBASTO SHOULD BE PRESENT
ON THIS CONNECTOR, WHICH ALSO CONTAINS GENERAL OPERATING
AND START UP PROCEDURES.
II. START UP:
A. TURN PREHEATER SWITCH TO "ON" POSITION. THE SWITCH COULD
BE REMOTELY MOUNTED, OR ON THE HEATER ITSELF DEPENDING ON
THE UNIT ITS INSTALLED ON.
B. COOLANT PUMP SHOULD NOW BE RUNNING, BUT NOT THE HEATING
ELEMENT. UNPLUGGING THE THERMOSTAT CONNECTOR IN I.E
ABOVE, DISENABLES THE HEATER PORTION OF THE WEBASTO.
C. RUN COOLANT PUMP LONG ENOUGH TO CONFIRM CORRECT OPERATION
AND ALL AIR IS PURGED FROM SYSTEM. LOOSEN HOSES TO BLEED
AIR IF REQUIRED.
D. SWITCH HEATER OFF.
E. PLUG IN THERMOSTAT CONNECTOR AND SWITCH HEATER BACK ON.
F. UNIT SHOULD NOW BE HEATING AS WELL AS CIRCULATING
COOLANT. RUN LONG ENOUGH TO ENSURE PROPER OPERATION BY
CHECKING THAT "COOLANT BACK TO ENGINE" LINE IS GETTING
WARM AND COMBUSTION EXHAUST IS PRESENT.
G. TURN PREHEATER OFF AND REPLACE SHEET METAL COVER.
Page 1
Halliburton Energy Services Specification D00268738 Revision A
Tested Unit: MicroMotion F300E Mass Flow Meter
Duncan, OK Date: 01/03/2007
1. TEST INFORMATION
i. This test procedure is intended to identify the minimum requirements for the set up and
testing of a MicroMotion F300 Mass Flow Meter.
data entry.
2. UNIT INFORMATION
Introduction
The Micromotion F300E is a resonant-vibrating-tube device which measures mass flow
rate, fluid density, and temperature. For the cementing recirculation line application
Halliburton is using the F300E primarily as a density measurement device. This
document provides information which may be helpful when considering the installation of
a Micromotion F300E Mass flowmeter / densometer in a Halliburton cementing
recirculation line. This document is intended as an overview only. Detailed installation
information is available in manuals from Micromotion (available freely from
MicroMotion.com). Detailed installation instructions specific to a Halliburton application
will be available in unit design drawings.
F300E Specifications
Overall dimensions: 36.8" x 14.50" x 7.00"
Weight: 160 lb
End connections: 3" Victaulic
Internal construction: Flow is split into two tubes, each 1.5 inch ID.
Orientation: "Flag" orientation, axis vertical within 15 degrees, flow upwards
Material for case, end connections, and wetted parts: 316L stainless steel
Maximum mass flow rate: 5000 lbm/minute
Maximum recommended pressure: 150 psi
Minimum pressure while circulating water: 30 psi at F300E entrance
Flow rate while circulating water with centrifugal pump at full rpm: 200-320 gpm
1 of 15
Power requirements
Without transmitter: clean 15 vdc 150 ma nominal, 500 ma peak
With Micromotion 2500 transmitter: 19-29 vdc 200 ma nominal, 1.0 amp peak
With Micromotion 2700 transmitter: 18-30 vdc 208 ma nominal, 1.5 amp peak
Cost and SAP Numbers

MicroMotion F300E densometer: SAP 101405359 ~$12,400
Kit with densometer, 2700 transmitter, cables: SAP 101417408 ~$17,000
Options
BlackBox IC1521A-F RS-485 to RS-232 converter: $93 SAP 101343263
Power supply 12 vdc in, 15 or 24 vdc out $100
MicroMotion 2500 transmitter $1700
MicroMotion 2700 transmitter with display $1900
MicroMotion 2700 transmitter without display $1800
2 of 15
3" Victaulic (3.50" OD)
Overall length
36.81 +/- .12
3 of 15
View

mixing
Typical F300 Installation head
plate valves on each branch
Rotate core
processor housing F300
to point gland
downwards rather
than upwards as
shown here
F300 with outer shell

removed. Note the 6x5
twin parallel bowed centrifugal
tubes pump
discharge
4 of 15
Installation 1. FLECS with serial communication to F300E
IC1521A-F RS-232
SAP 101343263 port
4 conductor FLECS
15v dc
power
supply
Installation 2.
2700 Transmitter (with display) with analog output to Unipro/Azonix/FLECS
2700
Transmitter
with Display Density*
active Unipro,
4-20 ma Azonix,
4 conductor
FLECS,
PC, or
24v dc
power
supply
The density output of the F300 can be communicated to the cementing control system
processor (Unipro II, Azonix, FLECS, or PC) using serial communication or analog
signals. No transmitter is required for serial communication. For analog output of density,
a MicroMotion 2500 or 2700 transmitter is required. The MicroMotion 1500, 1700, or 9739
transmitters will not work.
* In addition to density, the F300 flow rate and temperature can be output.
5 of 15
F300 Installation Tips for Cementing Recirc Systems

1. Install butterfly valves with multi-position locking plates in both the F300 branch and
the bypass branch. The F300 line valve should be placed on the downstream side of
the density sensor.
2. Mininize pressure drop between the 6x5 pump outlet and the F300 entrance.
3. Provide the operator with a way to read the flow rate measured by the F300 (2700
transmitter, FLECS display, alternate display).
4. If the MicroMotion 2700 transmitter is used, mount it so the operator can read it. Use
MicroMotion ProLink’s Display Config tab to disable the “Display Offline Menu” option.
5. The housing which surrounds the F300 core processor swivels. Point the gland
downwards before connecting to the 4 leads on the core processor. After wiring up the
core processor, wire-tie the cable coming out of the sensor to prevent puck housing
swivel.
6. After recirc system plumbing is complete, measure the F300 pressure and rate while
circulating clean water with the 6x5 recirc pump at full rpm. Pressure at the F300
entrance must be at least 20 psi (30 psi recommended). Flow rate through the F300
should be in the range 200-320 gpm.
F300 Operator Tips

1. Keep the 6x5 recirc pump at full rpm while mixing.
2. Check the 6x5 pump outlet pressure gage while mixing. If pressure falls below 10 psi,
partially close the valve downstream of the F300 until flow rate is 60 gpm.
3. While mixing, check the cement flow rate through the F300. If less than 40 gpm,
partially close the valve on the bypass line. If above 300 gpm, fully open the valve on
the bypass line and partially close the valve downstream of the F300.
4. F300 calibration at startup: while circulating clean water at full rate, do an “autocal” to
make the FLECS (or Unipro or Azonix) display 8.33 ppg. Leave the F300 calibration
alone for the remainder of the job.
5. While mixing, measure slurry density using a pressurized mud cup. “Cal” the
downhole density to bring it into agreement with the mud cup. Leave the downhole
densometer calibration alone for the remainder of the job (unless another pressurized
mud cup reading is taken).
6. While mixing, vary the controller’s density setpoint to make downhole density match
the target density. The controller’s density setpoint value may often be 0.1 to 0.3 ppg
less than the target downhole density.
7. Clean up the F300 as soon as possible after mixing by circulating clean water through
it with the bypass line valve closed.
6 of 15
MicroMotion F300E with 2700 Transmitter

Setup Using ProLink
This section covers setting up a MicroMotion F300E flowmeter/densometer installed with

a MicroMotion 2700 transmitter. This document recommends settings for the F300E but
does not cover F300 installation, ProLink communication, etc. For help with these other
matters see:
• Manuals at www.MicroMotion.com. The ProLink manual is probably the most

pertinent to the setup matters discussed here.
• Halliburton’s internal collection of MicroMotion related material at
http://halworld.halnet.com/HES/Hesps/hespspe/hespspe_fracacid/hespspe_fracaci
d_eqsensors/content/hespspe_fracacid_micromotion.asp
• Halliburton specific notes on F300 installation and establishing Prolink
communication – contact Dick Headrick.
With the F300 and 2700 wired up and powered up, connect to the 2700 service port and
run ProLink II version 2.2 or later on your laptop. After establishing communication
between ProLink and the 2700, select menu ProLink option Configure. A multi-tabbed
window should appear. The tabs of interest are shown on the following pages along with
comments on settings.
7 of 15
Flow tab:
Check the following settings and change if necessary. After changing a setting, click the
“Apply” button.
• Set the “FlowDamp” value to 5 seconds. Enter 5 in the box, hit the Apply button.
The actual value may be slightly different (5.2 seconds rather than 5.0 seconds for
example).
• The “Flow Cal” value should match the value on your F300’s tag.
• “Vol Flow Units” setting should be “US gal/min”
• Mass, Dens, and Vol Factors should all be 1.00000
• The “Enable Entrained Air Handling” box should be on.
• The flow damping, mass flow cutoff, and volume flow cutoff should be close to the
values shown above but are not critical to F300 operation.
8 of 15
Density tab:
• Set Dens Units to lbs/USgal.

• The K1, K2, FD, D1, D2, DT values should match the values on your F300’s tag.
The temperature coefficient may be shown as TC on your tag.
• The dens damping, slug high limit, slug low limit, slug duration, and low density
cutoff should be close to the values shown above but are not critical to F300
operation.
9 of 15
Events tab:
I suggest setting the events to a temperature or density which will never be triggered.
10 of 15
Analog Output tab:
• Set Primary Variable to “Density”.

• Set Lower Range Value to 0.0000 (this will corresond to 4 ma output)
• Set the “Upper Range Value” to 20, 25, or 26 lb/gal. (this density will corresond to
20 ma output). Remember the value used here and use the same value when
setting up the Unipro, Azonix, or FLECS.
• Set “AO added damp” to 0.0 sec.
• Set “AO fault action” to “None”.
• Set Last Measured Value Timeout to 0 sec.
11 of 15
Frequency/Discrete Output tab:
In some cases the volume flow rate from the F300 is sent to the Unipro, Azonics, or
FLECS controller. If you are using this signal, set the values as shown above. Note that
the maximum frequency output for the 2700 transmitter is 1000 hz. By setting the pulses-
per-US-gal to 60.0, the output frequency in hertz is the same as the volume flow rate in
gallons per minute.
12 of 15
RS-485 tab:
Set as shown above.
13 of 15
Display Config tab:
• Uncheck all boxes in the “Display Options” panel.

• Set Var 1 to “Density”.
• Set Var 2 to “Volume Flow Rate”.
• Set remaining display Var boxes to “None”
Select OK to complete the configuraton and close the tabbed window.
14 of 15


Model Number Date
below.

Test Tech 1
Test Tech 2
Test Tech 3
Test Tech 4
15 of 15
SECTION
Section
17
Preface
Pressure-Volume Curves
Introduction
The pressure-volume curve (PVC) sheets (Figures 7.1 to 7.5, Pages 7-3 through 7-7) that
have been included in this manual can help you accomplish the following:
• achieve maximum equipment efficiency
• detect a unit that is not operating at its rated peak capacity
Information for each curve was drawn from actual tests, in which clear water was used
as the pumping fluid. Only the data covering full-power operation is plotted on the curve
sheets. Torque-converter curves are plotted down to the 80% efficiency point.
To achieve the most efficient operation of the equipment, use the gear indicated on the
curve. If a unit does not perform as the curve indicates it should, verify the reason and
correct the problem.
How to Use Pressure-Volume Curves

Two variables must be considered for all pumping jobs: pressure and rate. Pressure is the
amount of resistance that must be overcome to pump fluid down the hole. Rate is the
amount of fluid pumped within a given time.
Usually, both pressure and rate are known in advance for each pumping job, but identical
circumstances are rarely encountered on different wells.
Although pressure is not always constant within a given well, it usually does not
fluctuate greatly. You adjust the pump rate through equipment selection.
October 2008 Pressure-Volume Curves 7-1

The equipment you have at your disposal normally has an efficient operation standard,
using the engine/transmission/pump combination. All these items must be considered
when using a PVC.
First, determine your engine/transmission/pump combination. Then refer to the upper

right corner of the appropriate performance curve for the information. For instance,
Figure 7.3 (Page 7-5) is plotted for an HT-400™ pump with a 4.5-in. bore and an 8.6:1
worm ratio.
The pump is driven by a Caterpillar C-11 engine through an Allison 4700 OFS
transmission. The 4.5-in. pump is capable of pumping up to 11,200 psi maximum
pressure. Table 7.1 summarizes the charts included in this section.
Table 7.1—Pressure-Volume Performance Curves
Figure HT-400 Pump Maximum

No. Bore Size Operating Pressure
(in.) (psi)
7.1 3.38 20,000
7.2 4.0 14,000
7.3 4.5 11,200
7.4 5.0 9,000
7.5 6.0 6,250
All engines used by Halliburton are designed to operate most economically and
efficiently between 1,700 and 2,100 rev/min. Instruments on the control panel indicate
engine speed. Instruments should also be included that monitor accurate pressure and
rate conditions as the job progresses.
Pump Curves for the HCR Elite® Trailer

Figures 7.1 to 7.5 (Pages 7-3 through 7-7) are pump curves for the HCR Elite trailer. All
the pump curves are valid for the CAT C-11 engine and Allison 4700 OFS transmission.
Pump curves are supplied for 3.38-, 4.0-, 4.5-, 5.0-, and 6.0-in. fluid ends.
7-2 Pressure-Volume Curves October 2008

Figure 7.1—Pressure-volume curve for 3.38-in. fluid ends

Figure 7.2—Pressure-volume curve for 4-in. fluid ends





SECTION
Appendix
1
A
Preface
Low-Pressure Manifold
Flow-Path Schematics
Introduction
Figures A.1 to A.4 illustrate low-pressure manifold flow-path schematics. The schematics show
that the low-pressure piping connections for the 20-bbl displacement tank, the 8-bbl mixing tub,
and both centrifugal pumps. The PID diagram detailing the flow path for the low-pressure
manifold is a useful tool for determining which valves need to be open or closed for a particular
type of pumping requirement.
October 2008 Low-Pressure Manifold Flow-Path Schematics A-1

Figure A.1—Normal mixing procedure
A-2 Low-Pressure Manifold Flow-Path Schematics October 2008

Valves linked together to allow switching
ADC system master
from one compartment to another water valve
ide
ers Pass Driver
e ng side side
October 2008
ss Down-
Pa Premix
20-bbl measuring hole
ide tank side
rs side
ive r
Dr ixe
M
6×5
4 × 4 Pump Pump
Controls above
measuring tank
Manual
Manual Manual
Pass side HT-400 pump Driver side HT-400 pump
Displacement tank fill line

(used when displacement
tank is filled by rig Alternate connection Valve Actuator Diagram
centrifugal pump)
dn00386

(used when 4 × 4 pump
fills displacement tank)
Alternate
Displacement fluid path from 20-bbl tank to HT-400 pumps connections
Displacement fluid path to fill 20-bbl tank with 4 x 4 pump

Displacement fluid path to fill 20-bbl tank with rig centrifugal pump
Low-Pressure Manifold Flow-Path Schematics

Figure A.2—Displacing procedure, gravity feed
A-3
ADC system master
A-4
water valve
Valves linked together to allow switching
from one compartment to another Pass Driver
e side side
sid Down-
er 20-bbl measuring Premix
eng hole
ss tank side
Pa side
ide
rs
ive r
Dr ixe
M
6×5
4 × 4 Pump Pump
Controls above
measuring tank
Manual
Manual Manual

Displacement tank fill line Alternate connection Valve Actuator Diagram

(used when displacement
tank is filled by rig
centrifugal pump)
dn00388

(used when 4 × 4 pump
fills displacement tank)
Alternate
connections
Displacement fluid path from 20-bbl tank to HT-400 pump
Displacement fluid path to fill 20-bbl tank with 4 x 4 pump
Displacement fluid path to fill 20-bbl tank with rig centrifugal pump
Figure A.3—Displacing procedure, boosted with 6 x 5
October 2008
ADC system master
water valve
ide
rs Pass Driver
October 2008
e
eng side side
ss
Pa Down-
20-bbl measuring Premix
hole
ide tank side
rs side
ive r
Dr ixe
M
6×5
Pump
Controls above 4 × 4 Pump
measuring tank
6 × 5 Outside suction Manual
(for connection Manual Manual
to batch mixer)
Valve Actuator Diagram

dn00390
4-in. Weco Union outside connection to 6 × 5 pump.

Ideal place for connection to batch mixer or acid tank.

Figure A.4—Pumping services only
A-5
A-6 Low-Pressure Manifold Flow-Path Schematics October 2008

SECTION
Appendix
1
B
Preface
Schematics
Introduction
Appendix B includes the wiring diagrams and drawings for control stand installations listed as
follows:
• D00243783—Master wiring, FLECS, C-11 deck engine and Cummins QSB6.7 auxiliary,
HCR Elite® trailer
• D00169064—Installation, HCR Elite, final wiring
October 2008 Schematics B-1

Master
wiring, FLECS, C-11 deck engine and Cummins QSB6.7 auxiliary, HCR Elite® trailer (Drawing D00243783, Sheet 1 of 6)

Master wiring, FLECS, C-11 deck engine and Cummins QSB6.7 auxiliary, HCR Elite® trailer (Drawing D00243783, Sheet 2 of 6)




ELITE™ Cementing Trailer Manual
June 2007 Schematics B-7

This page
Blank to Make
Next Page
Right-hand
B-8 Schematics October 2008

8
RJ45
19 18 14 13
RS232
17 16
1-ORANGE
2-GREEN
3-ORANGE/WHITE
4-BLUE/WHITE
NULL MODEM
5-BLUE
6-GREEN/WHITE
7-BROWN/WHITE
12
8-BROWN
9-NOT USED
19
2X 11 10 9 18
20
ETHERNET & RS232 ENCLOSURE
Figure B.5—Installation, HCR Elite®, final wiring

B-10 Schematics October 2008

SECTION
Appendix
1
C
Preface
Spare Parts Lists

Introduction
Appendix C includes a recommended two-year spare parts list for the HCR Elite® trailer.
Tables C.1 through C.11 include spare part information for the following items:
Table No. Spare Parts for: Page No.

C.1 Automatic density control system C-2
C.2 Control stand C-3
C.3 4700 OFS transmission C-4
C.4 Caterpillar 3176/C-10/C-11 engine C-4
C.5 Cummins QSB6.7 engine C-5
C.6 RCM® IIIr cement mixer C-5
C.7 Hydraulics C-5
C.8 Centrifugal pumps/low-pressure manifold C-6
C.9 High-pressure manifold C-8
C.10 Electronics C-9
C.11 HT-400™ pumps C-9
October 2008 Spare Parts Lists C-1

Table C.1—Spare Parts for Automatic Density Control System

IMS No. SAP No. Qty. Description
70.87230 100013192 1 Pump - hydraulic - pressure-compensated piston - SAE "A "
mount - SAE spline shaft - .96 in.3/rev displacement - adjustable
from 500 to 3,000 psi - left-hand rotation - model
#PVP1630BL/312 - with spec. 70.77566 protective coating
70.99384 100002616 1 Valve - hydraulic - proportional directional control - D1FH - 12V -
equal metering - bi-directional - external closed loop - potted
70.81458 100009520 6 Element - filter - hyd - 3 micron - for 15P pressure filters - Parker
925578
70.87295 100034314 1 Kit - seal - HTR 1.8 actuator
70.87296 100034315 1 Kit - seal - HTR 7.5 actuator
70.52033 100002219 2 Potentiometer - 10k for HTR/STR 7.5J and 1.8J Parker rotary
actuator with feedback - 6538S-1-103
— 101446251 1 Actuator - rotary - rack and pinion - 1,800 in.-lbs torque at 3,000
psi hyd - 90° rotation - direct mounted to square stem 2 thru 6 in
butterfly valve - with 5/8 in. male aux shaft
psi hyd - 90° rotation - direct-mounted to square stem 2 thru 6 in
butterfly valve with feedback 10k potentiometer - spec
psi hyd - 90° rotation - standard 1.25 in shaft with 5/16 key
C-2 Spare Parts Lists October 2008

Table C.2—Spare Parts for Control Stand

IMS No. SAP No. Qty Description
N/A 101339393 1 Display - LCD - PowerView - engine rev/min - coolant temp - oil
press - fault codes - uses J1587 ATA data - mating connector
70.39175 (100014462) - terminal 70.11065 (100022192) qty. 4
70.28772 100025936 4 Lamp - auto - #1893 - T3 1/4 - min bay - 14V
70.79659 100002390 2 Switch - toggle - DPDT - 3 pos - on - off - momentary on - 125
VAC - 3A - 0.4687 dia bushing - screw terminals
70.77658 100002368 5 Switch - toggle - DPST - sealed - 8501K9 - CH
70.77940 100002372 2 Switch - toggle - SPDT - on/none/on - environmentally sealed -
15/32 dia bushing - screw terminal connections - min rating: 25
microamps/5 millivolts - max rating: 25 amps/VDC 20
amps/115VAC
70.87542 100009824 1 Switch - toggle - DPDT - sealed
70.78185 100032425 2 Controller - hydraulic - friction - Rexroth 1-2TH6 pilot pressure
control valve - max inlet press 700 psi output range 14 to 185
psi - friction position lever control - max lever - swing adj - SAE
#6 O-ring ports
441.3069 100003351 1 Gauge - pressure - 0 to 5,000 psi - 0 to 34 500 kPa - 2-1/2 in -
2% - BRDN TB/CU BER - 1/4 NPT CBM - U-clamp - zytel nylon
case - GLY filled - back case relief
441.3068 100003350 1 Gauge - pressure - 0 to 3,000 psi and 0 to 20 000 kPa (or 0 to
200 bar) - 2-1/2 in - 2% - BRDN TB/ BER CU - 1/4 NPT CBM -
U-clamp - stainless or zytel nylon case - gly filled - case relief
70.06775 100010294 1 Gauge - pressure - 0 to 600 psi - 2-1/2 in - 2% - BRDN TB/PH
BR or equiv - 1/4 NPT CBM - stainless U-clamp - zytel nylon or
stainless steel case - silicon filled - back case relief
70.29259 100010294 2 Lamp - clearance - clear - 12 volt - spec
70.92476 100035116 1 Relay - solid state - spst - nc -4 amp - 3-32 volts input - 2-32
volts load
70.24124 100001751 3 Gauge - pressure - 0 to 30 psi - 1-1/2 in - 2% - BRDN TB/PH br
- 1/8 NPT CBM - stem mount - ABS plastic gray case - dry
70.23664 100024829 10 Fuse - 3A - 250V - 3AG
70.23851 100024929 10 Fuse - 15A
70.08486 100001505 2 Potentiometer - 10,000 ohm - 10 turn sealed shaft - precision
ww - standard except with 1.875 long flush shaft
N/A 100046107 1 Hand throttle
70.07628 100001497 1 Relay - solid state - spst - no - 20 amp - 3.5-32 volt input - 0 to
100V load
70.84697 100013180 1 Gauge - hydraulic oil temperature - 130 to 220°F - 160 to 180
green-yellow-red - 420 in capillary tube - internal contact
microswitch - 180°F make rising - 1/8 in. MPT back connection
- 2-1/16 in. dia hole panel mount - oil filled - Murphy dwg
10-35-1132

Table C.3—Spare Parts for 4700 OFS Transmission

SAP No. Qty Description
101363967 8 Filter, element, transmission, Allison, 4700 OFS, 4700 RDS, and HD4070
101242434 1 Gauge, oil pressure, 0 - 400 psi
101418785 1 Gauge, sight, 5.5 inch mounting centers, 7.125 inch total length
Table C.4—Spare Parts for Caterpillar C-11 Engines

— 101242356 2 Filter - fuel - primary - Cat 3176C and C10 industrial
106.00210 100002657 2 Filter - fuel - spin on - for Cat 3406 and 3176 and 3412
engines
106.00332 100002658 2 Filter - oil - caterpillar - 3400 series
70.95683 100002596 2 Filter - air - primary - replacement filter for 70.58041
(100029775) air cleaner
— 101397720 2 Filter - fuel - spin on - primary - C11
— 100047174 2 Belt - V - C Section - 82L - matched set of 2 (C11 engine)
— 101575970 4 Belt - V - 22/25 inch, 80 inch, C76
— 100012984 2 Filter - engine - coolant - spin on - service only - no DCA
units

Table C.5—Spare Parts for Cummins QSB6.7 Engine

SAP No. Qty Description
100029673 1 Filter, air, primary, replacement filter for 70.56023 air cleaner
101458292 4 Filter, lubrication, Cummins QSB6.7
101458325 4 Filter, fuel primary, Cummins QSB6.7
101458323 4 Filter, fuel secondary, Cummins QSB6.7
100012984 2 Filter, engine, coolant, spin on, service only, no DCA units
101458326 4 Fan belt, Cummins QSB6.7
Valve, shutdown, air, emergency kill, 4.0 in, with air cylinder, pressurize to
101302354 1
shut down
Gauge, oil pressure, 0-100 psi, General Motors engine, spec, Murphy
100001758 1
drawing 05-35-0094
Gauge, water temperature, 100-250°f, engine, 72 inch capillary tube, spec,
100001756 1
Murphy drawing 10-35-0115
Table C.6—Spare Parts for Hydraulics

70.78717 100032533 2 Pump - hydraulic - axial piston - 3.32 in.3 disp - 14T
12/24P spline shaft - SAE 4-bolt c flange - SAE 1 in
6,000 psi split flange ports - with spec. 70.77566
(120072774) protective coating -
ACL05414L0BGGFF00HAFMM011AC000A
70.78714 100032530 1 Motor - hydraulic - axial piston - 4.59 in.3 disp - 14T
6,000 psi split flange ports - spec. 70.77566
(120072774) protective coating - HHD463114BG1H00A
70.78715 100032531 1 Motor - hydraulic - axial piston - 3.32 in.3 disp - 14T
6,000 psi split flange ports - with spec. 70.77566
(120072774) protective coating - HHD333114BG1H00A
70.99408 100036313 1 Pump - hyd - gear - 2.18 cir - LH rotation EA SAE B 2
bolt mtg - SAE B spline 13T shaft - #20 ORB inlet - #16
ORB outlet tru shaft drive for SAE A pilot 9T spline shaft
70.51034 100029369 1 Motor - hydraulic - gear - 2.6 cir - 3,000 psi max - SAE b
spline - SAE a 2 bolt mount - #16 SAE o-ring port
100012649 1 Motor - hydraulic - gerotor - 17.1 cir - 3,000 psi max -
intermittent - bi-rotational - wheel mount - 1.25 dia
tapered shaft with 0.31 Woodruff key - 7/8-14 SAE
O-ring ports - with spec 70.77566 protective coating
70.77535 100002365 6 Element - filter - hyd - single - beta 3/7/9 - 1 micron com-
posite media du - flow

Table C.6—Spare Parts for Hydraulics

70.09836 100021969 12 Element - filter - hyd - 10 micron - 350 psi collapse -
microglass Q media - for Parker 30P-2
441.3148 100060959 1 Gauge - pressure - 0 to 60 psi - 2-1/2 in - 2% - BRDN
TB/PH BR - 1/4 NPT CBM - stem mount zytel nylon case
- gly filled - back case relief
70.99457 100036346 1 Valve - hyd - directional control - 2 pos/2 way - normally
open - 12 V DC 30 watt solenoid - manual override - #16
ORB cartridge body
70.99458 100036347 1 Valve - hyd - directional control - 2 pos/ 2 way - normally
closed - 12 V DC 30 watt solenoid - manual overide -
#16 ORB cartridge body
Table C.7—Spare Parts for Centrifugal Pumps/Low-Pressure Manifold

70.80609 100002400 8 O-ring - 70D - 2-1/8 × 2 × 1/16 568-033 - spec. 70.33000 -
spec. 70.72000 (100031262)
350.12435 100003087 4 Sleeve - shaft - metco 136F - pump - cent - Halliburton
350.12431 100003085 1 Impeller - 11.0 dia - pump - cent - 6 × 5 × 10 × 11 - Hallibur-
ton
350.20501 100003127 1 Impeller - 12 in dia - pump - cent - 4 × 4 × 12 - Halliburton
70.34019 100001993 4 O-ring - 70D - 12-1/2 × 12 × 14 568-453 - spec. 70.33000 -
spec. 70.72000 (100031262)
70.80608 100002399 8 O-ring - 70D - 2 × 1-7/8 × 1/16 568-032 - spec. 70.33000 -
spec. 70.72000 (100031262)
70.80614 100013143 4 Screw - set - 3/4 - 10UNC-3A × 2 - cup PT - hex soc - HT
alloy steel - zinc PL - 40 RC max - Holokrome only - spec
70.80613 100013142 4 Screw - set - 3/4 - 10UNC-3A × 3 - cup PT - hex soc - HT
alloy steel - zinc PL - 40 RC max - Holokrome only - spec
70.80607 100002398 40 Seal - oil - 2.500 B × 3.500 OD × .437 W
350.16677 100008200 2 Gasket - 6 in. nom - 125# STD flange - 1/16 neoprene full
face - 3-M Deming pump
70.80603 100013140 4 Seal - oil - 21159 - 2.125B × 3.000 OD × 2.50 W - CR only

Table C.7—Spare Parts for Centrifugal Pumps/Low-Pressure Manifold (Continued)

70.80604 100002396 4 Seal - oil - 21163 - 2.125 B × 3.000 OD × .375 W - CR or
472015 natl only
70.80606 100002397 4 Seal - oil - 9189 LPD - 1.875 B × 2.750 OD × .375 W - Johns
Manville only
280.20024 100002739 12 Diaphragm - gauge protector - boost pump - spec. 70.72000
(100031262)
350.16426 100011819 1 Sleeve - coupling - woods 8H - Hytrel
70.42092 100028025 1 Ring - retaining - N5000-112 - int
70.34001 100001984 12 O-ring - 90D - 6/12 × 6 × 1/4 568-437 - spec. 599.33001
12.5082 100001149 1 Valve - BTFL - 4 in - D*D*H BNO - 12N - nitrile seat - DI disc
- DI body - 410 SS 5/8 in.2 stem - 175# WP - gen. service -
supersedes 12.5084 - BA040 012N D*D*H BNO
supersedes 13.1320 - BA 050 012N D*D*H BNO
- DI body - 410 SS 5/8 in sq stem - 175# WP - gen. service -
supersedes 13.1931- BA060 012N D*D*H BNO
11.7516 100001137 1 Valve - BTFL - 3 in. - D*D*H BNO - 12N - nitrile seat - DI disc
supersedes 11.7517 - BA030 012N D*D*H BNO
10.03465 100001095 2 Seat - BTFL V - 3 in. - BNO - 12N - nitrile - supersedes
10.03466 - BP030 012N seat NIT
11.03461 100001101 2 Disc - BTFL V - 3 in. - BNO - 12N - nitrile - supersedes
10.03472 - BP030 0120 disc DI
70.33817 100001916 2 O-ring - 70D - 3/4 × 9/16 × 3/32 - 568-113 - spec. 70.33000 -
spec. 70.72000 (100031262)
70.92142 100002566 2 Pin - roll - 79-040-187-1500 - 3/16 × 1-1/2 - stainless
12.50695 100001146 2 Seat - BTFL V-4 in - BNO - 12 - nitrile - supersedes 12.50702
- BP040 0120 seat BUNA-N
12.50721 100001147 2 Disc - BTFL V-4 in - D* - 12 - ductile iron - supersedes
12.50728 - BP040 0120 disc DI
70.33817 100001916 2 O-ring - 70D - 3/4 X 9/16 X 3/32 - 568-113 - spec. 70.33000 -
spec. 70.72000 (100031262)
70.92143 100013228 2 Pin - roll - 79-040-187-1500 - 3/16 × 1-3/4 - stainless
13.03145 100001168 4 Seat - BTFL V - 5 in. - BNO - 12 - nitrile - supersedes
13.13145 - BP050 0120 seat BUNA-N
13.03191 100001173 4 Disc - BTFL V - 5 in. - D* - 12 - ductile iron - supersedes
13.13202 - BP050 0120 disc DI
70.33393 100001883 4 O-ring - 70D - 15/16 × 3/4 × 3/32 - 568-116 - spec. 70.33000
- spec. 70.72000 (100031262)

Table C.7—Spare Parts for Centrifugal Pumps/Low-Pressure Manifold (Continued)

70.90045 100002537 4 Pin - roll - 79-040-187-1875 - 3/16 X 1-7/8 - stainless
13.19085 100001183 2 Seat - BTFL V - 6 in. - BNO - 12 - nitrile - supersedes
13.19126 - BP060 0120 seat BUNA-N
13.19081 100001182 2 Disc - BTFL V - 6 in. - D* - 12 - ductile iron - supersedes
13.19312 - BP060 0120 disc DI
70.33393 100001883 2 O-ring - 70D - 15/16 × 3/4 × 3/32 - 568-116 - spec. 70.33000
- spec. 70.72000 (100031262)
70.90045 100002537 2 Pin - roll - 79-040-187-1875 - 3/16 X 1-7/8 - stainless
27.02623 100001217 12 Gasket - victaulic type - 2 in. - grade T - nitrile - for style
75,77,78 - spec. 70.72000 (100031262)
75,77,78 - spec. 70.72000 (100031262)
75,77,78 - spec. 70.72000 (100031262)
75,77,78 - spec. 70.72000 (100031262)
75,77,78 - spec. 70.72000 (100031262)
Table C.8—Spare Parts for the High-Pressure Manifold

9.12794 100015529 2 Kit - repair - 1 in. type cert Lo-torc plug valve - std serv - Monel plug
iron inserts - nitrile seals
9.82604 100015708 2 Kit - Repair - 2 in. - std serv - type certified - Lo-torc plug valve -
monel plug - iron inserts - nitrile seals
9.12613 100015507 4 Kit - repair - 1-3/4 in. - std serv - type certified - Lo-torc plug valve -
Monel plug - AL BRZ inserts - nitrile seals
38.09472 100001276 20 Ring - seal - with back-up ring - 2 in. 1502 union
70.71490 100031190 1 Transducer - pressure - 15,000 psi - 4 to 20 MA - 0.25% accuracy -
1/4 NPT female press port - 1/2 NPT male elec fitting - 15-5PH SS
wetted parts standard unit - no certifications
444.05122 100003370 2 Valve - check - gauge protector - spec
70.48694 100002200 2 Snubber - pressure - model 9 - 20000# - 1/2 IPT - 02, 03 1 piston -
RAY - spec
446.05415 100003376 12 Diaphragm - gauge protector - F/2 in FIG 1502 union conn - viton
with stainless backup ring - spec 70.72000 (100031262)
444.00901 100003358 1 Pump - hand - for pressure gauge systems - with swivel union - stain-
less steel ball and brass seats - all metal pump - ref: 446.00024 for
plastic body - ref: 444.00954 for repair kit

Table C.9—Spare Parts for the Electronics

106.00043 100011065 1 Starter - electric - 12 volt - #1 housing - CW rotation - 8-10 pitch -
12/13 no. teeth - 12 position nose houseing 215 deg nose opening -
model 37MT300 - for Cat 3116
107.00074 100047094 1 Alternator - 14 volt D.C. - 100 amp - self excited - includes regulator -
requires battery charging and ground connections - pulley not
included
458.70077 100003470 1 Kit - repair - calibrated - 316 stainless vanes - CD4-MCU rotor - 3 in.
flow meter
70.70687 100002304 1 Connector - cable - MS type 14S-6S - spec 70.70682
70.70685 100002302 1 Connector - cable - MS type 10SL-4S - spec 70.70682
70.29222 100001803 1 Lamp - clear - flood - 12V - sealed beam - spec
70.88884 100002505 2 Lamp - stop, tail, and turn - factory sealed - grommet mount - lamp
only - no grommet or pigtail supplied
70.93948 100035349 2 Light - backup - sealed unit
70.87140 100034292 2 Lamp - license with one 12V bulb and plug in pigtail
70.89362 100002525 2 Lamp - clearance - factory sealed - with red lens - 5.88 L × 2.06 H -
4.81 screw centers - with Lexan reflex lens
70.52736 100002220 1 Switch - circuit breaker - 35 amp - panel mount
70.52735 100007787 1 Switch - circuit breaker - CDM-15 - Klixon CMTG unit
458.81348 100003481 1 Module - power filter - 12VDC - Lanmarc
Table C.10—Spare Parts for HT-400™ Pumps

316.22252 100007270 6 Spring - lock - suction stop - HT-400 - 4.0, 4.5 in.
316.22047 100002874 6 Seat - valve - HT-400 - #4 frac - tapered
316.23026 100002934 6 Retainer - guide bushing - HT-400 - 4.5 in - tapered seat bore
316.22005 100002868 12 Liner - two piece bushing - valve guide - HT-400 - #4 frac -
brass - spec
316.22049 100002876 24 Insert - valve - HT-400 - #4 frac - urethane - standard service
316.22051 100002877 6 Ring - spacer - #4 discharge valve and cylinder head cover -
4-1/2 HT400 fluid end
316.22052 100002878 12 Gasket - #4 discharge valve and cylinder head cover - 4-1/2
HT-400 fluid end
316.23031 100002935 6 Plunger - HT-400 - 4.5 in. - hard surface - L-spacer - type certi-
fied
316.23503 100002948 6 Adapter - header ring - 4-1/2 × 5-1/2 - HT-400 FE
316.2547 100002975 6 Seal - discharge passage - HT-400 - 3.375 OD
316.23525 100002951 12 Packing set - 4-1/2 × 5-1/2 × .50 STK HT - 3 rings - hard - acid
service - SBR with cotton-poly duck - spec

Table C.10—Spare Parts for HT-400™ Pumps (Continued)

316.22004 100002867 24 Insert - two piece bushing - valve guide - HT-400 - #4 frac -
spec. 70.72000 (100031262)
8.34041 100000970 24 O-ring - 90D - 4-1/2 × 4-1/4 × 1/8 - 568-244 - spec. 8.33001 -
spec. 70.72000 (100031262)
8.34047 100000975 6 O-ring - 90D - 5-1/4 × 5 × 1/8 - 568-250 - spec. 8.33001 -
spec. 70.72000 (100031262)
8.34049 100000977 24 O-ring - 90D - 5-1/2 × 5-1/4 × 1/8 - 568-252 - spec. 8.33001 -
spec. 70.72000 (100031262)
8.34001 100000977 6 O-ring - 90D - 6-1/2 × 6 × 1/4 - 568-437 - spec. 8.33001
316.2330 100002940 6 Seal - plunger nose assy - HT-400 - 4.5 in.
316.23393 100002945 12 Ring - backup - packing - HT-400 - 4.5 in.
70.35817 100002081 6 Pin - groove - 1/2 × 1-1/4 - type 5 - SAE 6150 - hardness RC
50-55 - groove - pin corp GP5-500X1250-74
316.23501 100002947 12 Ring - header - 4-1/2 × 5-1/2 packing
316.25233 100002972 24 Boot - suction and stop - HT-400 - #3, #4, & #5 frac
316.2308 100002936 12 Spring - valve - HT-400 - 4.0, 4.5 in. - stainless steel - 25 lb/in.
316.2308 100002881 6 Retainer assy - stop and spring - #4 suction valve
316.23022 100002931 12 Valve - HT-400 - 4.5 in. - frac - type certified
70.20831 100001698 24 Element - oil filter - 25 micron - 4-1/2 dia × 9-1/4 LG
70.33991 100001978 4 O-ring - 90D - 5-1/4 × 4-3/4 × 1/4 568-427 - spec. 599.33001 -
spec. 70.72000
316.23981 100002956 2 Sleeve - packing - HT-400 - 4.5 in.
1.131 100000592 2 Valve - check - 1/8 - female inlet - male outlet - with 70 duro
o-ring
316.23395 100002946 6 Seal - lube - packing - WQ - 4-1/2 × 5 × 9/16 - HT-400 fluid end
70.88352 100002493 2 Gauge - oil press - 0 to 150 psi - Cummins engine - 40-50
red-yellow-green - internal contact microswitch - 40 psi make
falling - 1/8 in MPT back connection - 2.06 in. dia hole panel
mount - oil filled - dual scale - KPA
70.88359 100002496 2 Gauge - oil temp - 100 to 250°F - pump oil - 200-220
green-yellow-red - 108 in. capillary tube - internal contact
microswitch - 220°F make rising - 2-1/16 in. dia hole panel
mount - oil filled
8.33963 100000952 4 O-ring - 90D - 1-9/16 - 1-5/16 × 1/8 - 568-219 - spec. 8.33001
- spec. 70.72000 (100031262)
8.34026 100000963 4 O-ring - 90D - 2-5/8 × 2-3/8 × 1/8 - 568-229 - spec. 8.33001 -
spec. 70.72000 (100031262)
8.34041 100000970 4 O-ring - 90D - 4-1/2 × 4-1/4 × 1/8 - 568-244 - spec. 8.33001 -
spec. 70.72000 (100031262)

Table C.10—Spare Parts for HT-400™ Pumps (Continued)

8.34047 100000975 4 O-ring - 90D - 5-1/4 × 5 × 1/8 - 568-250 - spec. 8.33001 -
spec. 70.72000 (100031262)
70.33432 100001891 8 O-ring - 70D - 4-7/8 × 4-1/2 × 3/16 - 568-349 - spec. 70.33000
- spec. 70.72000 (100031262)
70.33639 100026734 20 O-ring - 90D - 3/4 × 5/8 × 1/16 - 568-016 - spec. 8.33001 -
spec. 70.72000 (100031262)
70.33946 100001943 20 O-ring - 90D - 1/2 × 3/8 × 1/16 - 568-012 - spec. 8.33001 -
spec. 70.72000 (100031262)
70.33960 100012948 4 O-ring - 90D - 1-3/8 × 1-1/8 × 1/8 - 568-216 - spec. 599.33001
- spec. 70.72000 (100031262)
70.34020 100001994 8 O-ring - 90D - 1-7/8 × 1-5/8 × 1/8 - 568-223 - 599.33001
70.34056 100002023 8 O-ring - 90D - 6-1/2 × 6 × 1/4 × 1/8- 568-259 - spec.
599.33001 - spec. 70.72000 (100031262)


SECTION
Appendix
1
D
Preface
Repair and Service Manuals

Manuals Reprinted in Appendix D
Appendix D includes the following repair and service manuals for individual components:
• AAA Products International
• Murphy
– Model JV-1 J-View (Operation Manual)
– PowerView Installation and Operations Manual. Current copies available at:
www.fwmurhpy.com
• Dynalco Model MTH-103 Tachometer/Hourmeter/Trip (Installation and Operation Manual)
• Hendrickson HT Series Trailer Air Suspensions (Operators Guide)
• Funk Manufacturing Company, Pump Drives (Service Manual)
• Mannesmann RexRoth, Typ.-2 TH 6L, Series 1X (Service & Repair Manual)
• Haldex, G20 & G30 Series Hydraulic Gear Pumps (Service Manual)
• White Hydraulics, RE Series Motors (Service Procedures)
• Eaton Hydraulics:
– Hydrostatic Fixed Motors Models 33 thru 76 (Parts Information)
– Hydrostatic Transmissions (Start-up Procedure)
– Heavy Duty Hydrostatic Pumps (Parts & Repair Information)
– Heavy Duty Hydrostatic Transmissions (Application Information)
• Parker:
– Fluidpower, PVP Series Variable Volume Piston Pump
– Fluidpower, D1VW Series Solenoid Operated Directional Control Valves
– Hydraulics, Parker Threaded Cartridge Valves Selection Guide
– Electrohydraulics, D1FH Proportional Directional Control Valves
– Electrohydraulics, Series D1FH Installation Guide
• HTR Series Actuators (Maintenance Instructions and Parts List)
• Webasto Thermosystems, Thermo 90S Coolant Heater (Operating & Installation
Instructions)
October 2008 Repair and Service Manuals D-1

Additional Repair and Service Manuals

The manuals listed in Table D.1 are separate and not included in this manual but can be ordered using
the part numbers shown. At least one copy of each of these manuals should accompany the HCR
Elite® trailer when it is shipped from Duncan. Consult these manuals for detailed repair and
maintenance information not included in this manual.
Table D.1—Additional Repair and Service Manuals
SAP No. Description
100003124 Manual, pump, centrifugal, Halliburton
Manual, operators, transmission, 4700 RDS, Allison, English, paperback

101489205 E13828 United engines OM3752EN
E15637 Allison transmissions OM3752EN
Manual, parts, C11, Caterpillar, serial number prefix GLS1-UP, paperback

101397641
E10017 Caterpillar SEBP4127
Manual, service, Caterpillar, C11, C13, Acert, truck engines, KCA1 and up, KCB1 and
101368726 up, binder
E10017 Caterpillar SENR9700
Manual, service Allison, 4000, Gen IV controls

101489258 E15637 Allison transmissions SM4014EN
E13828 United engines SM4014EN
Manual, service, pump drives, Funk 61000-59000-56000-28000 series

100032617
E10537 Funk 4028958
Manual, service, Leece-Neville/ Prestolite, alternators, 8mr, 2500jb, 12 & 24 volt, binder
100047095 E10272 Prestolite LN200
E10058 Leece-Neville LN200
Manual, parts, Leece-Neville/ Prestolite, alternators, 8mr, 2500jb, 12 & 24 volt, binder
100047096 E10272 Prestolite LN100
E10058 Leece-Neville LN100
Manual, HT-400 pump, information & maintenance, repair & overhaul, parts catalog,
100002809
replaces single volumes 316.13294, 316.13295, & 316.13296, 8th edition
Manual, parts, Allison, 4000, binder, English

101489259 E15637 Allison transmissions PC2456EN
E13828 United engines PC2456EN
D-2 Repair and Service Manuals October 2008

Table D.1—Additional Repair and Service Manuals (Continued)
SAP No. Description
Manual, troubleshooting, Allison, 3000 and 4000, Gen IV controls

101489261 E15637 Allison transmissions TS3989EN
E13828 United engines TS3989EN
Manual, parts, Allison, 4000, compact disc, English

101489260 E15637 Allison transmissions CD2456EN
E13828 United engines CD2456EN
Manual, operators, shift pad, Allison, 4700 RDS transmission, includes diagnostic code
table, procedure for checking oil level, paperback, English, available via the internet at
101511857 allisontransmission.com
E15637 Allison transmissions SA3360EN
E13828 United engines SA3360EN
Manual, service, Cummins, ISBE, ISB, and QSB (common rail fuel system) series
101458278 engines
E10026 Cummins 4021271
Manual, parts, Cummins, QSB6.7, generic

101458284
E10026 Cummins 4056556
Manual, operation and maintenance, Cummins, QSB (common rail fuel systems)
101458286 engines
E10026 Cummins 4021531
Diagram, wiring, QSB4.5, QSB6.7, QSC803 and QSL9 electronic control module
101458287
E10026 Cummins 4021524
Manual, troubleshooting and repair, CM850 electronic control system, ISB, ISBE4,
101458290 QSB4.5, QSB5.9, QSB6.7, ISC, QSC8.3, ISL and QSL9 engines
E10026 Cummins 4021416
100048144 Manual, parts, TU-FLO 500 compressor

E10008 Bendix heavy vehicle syst 01-D-1
101324382 Manual, Flexible Electronic Control System (FLECS) manuals
October 2008 Repair and Service Manuals D-3

D-4 Repair and Service Manuals October 2008

Elite Cement Truck

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The HCR Elite® Cementing Trailer

Part No. 101622692

Part No. 101622692

Chapter 2—Major Components and Systems

Chapter 3—Prejob Inspection

Chapter 5—Mixing System Problems and FLECS

Chapter 6—Test/Setup Procedures

Chapter 7—Pressure-Volume Curves

Appendix A—Low-Pressure Manifold Flow-Path Schematics

Appendix C—Spare Parts Lists

Appendix D—Repair and Service Manuals

Basic Equipment Report

October 2008 Introduction 1-1

Features of the HCR Elite® Cementing Trailer

• larger, more powerful, emission-certified, 420-bhp deck engine

1-2 Introduction October 2008

Figure 1.1—HCR Elite® trailer, passenger’s side

Figure 1.2—HCR Elite trailer, driver’s side

October 2008 Introduction 1-3

Figure 1.3—HCR Elite® unit, top view

1-4 Introduction October 2008

October 2008 Introduction 1-5

1-6 Introduction October 2008

Major Components and Systems

• Basic operation for each of the trailer’s major components

The standard chassis includes:

October 2008 Major Components and Systems 2-1

Table 2.1—Part/Spec. Nos. for HCR Elite Trailer Deck Engines

2-2 Major Components and Systems October 2008

Air to air Air cleaner

Figure 2.1—Caterpillar deck engine package mounted on the trailer

October 2008 Major Components and Systems 2-3

Figure 2.2—Engine and transmission gauges

2-4 Major Components and Systems October 2008

4700 OFS Transmission

Figure 2.3—Transmission oil cooler

October 2008 Major Components and Systems 2-5

Figure 2.4—Transmission shift pad

2-6 Major Components and Systems October 2008

Figure 2.5—Transmission fluid fill port

October 2008 Major Components and Systems 2-7

Cummins QSB6.7 Auxiliary Engine

Figure 2.6—Cummins QSB6.7 auxiliary engine package

2-8 Major Components and Systems October 2008

• 4 × 4 Hydraulic Circuit—This circuit is powered by an Eaton ACL054 hydrostatic pump. The

October 2008 Major Components and Systems 2-9

• ADC® Mixing System Circuit—This circuit is powered by a Parker PVP1630

Figure 2.7—Pump drive and hydraulic pumps

2-10 Major Components and Systems October 2008

6 × 5 and 4 × 4 Hydraulic Circuits

October 2008 Major Components and Systems 2-11

• 6 × 5 hydraulic circuit = approximately 1,600 to 2,200 psi

2-12 Major Components and Systems October 2008

Figure 2.9—6 × 5 and 4 × 4 process and instrumentation diagram (PID)

October 2008 Major Components and Systems 2-13

Start/Agitator Hydraulic Heat Exchanger Circuit

2-14 Major Components and Systems October 2008

#16 #16 #16 #20

Figure 2.10—Start/agitator hydraulic PID

Major Components and Systems

ADC® Mixing System Circuit

2-16 Major Components and Systems October 2008

Micro Motion® F300 Mass Flowmeter