Gateway Procedures

Nabors USA “FMLR” Hydraulic Procedures (rev.‐3)

NABORS USA “FMLR” HYDRAULIC PROCEDURES Notice: The GFP raising and lowering control system may “ONLY” be setup and operated by trained and qualified personnel who have been instructed in the proper set-up, operation, maintenance, and troubleshooting of the GFP hydraulic system. These instructions are intended for use by those properly trained personnel experienced in common hydraulic practices. Although these procedures are designed to offer step – by – step instruction, they will not ensure that the personnel operating the controls will understand what to do in case of an emergency or equipment failure. Without proper experience and training on the actual GFP system in a training environment GFP does not recommend untrained or inexperienced personnel operating this system. The “Pyramid Bleeding Procedure” inserted into this document was supplied by Nabors Drilling USA training department. GFP assumes no liability related to the correctness, validity of, or functionality of that bleeding procedure. Mark Beaver President, Gateway Fluid Power

Hydraulic / Electrical Systems and Repair 7107 Belgold, Suite C 1301 West 1ST Street, Suite A Houston, Texas 77066 Granite City, IL 62040 Phone: 281-440-8031 Phone: 618-452-8955 Fax: 281-440-8172 Fax: 618-452-8956 www.gatewayfluidpower.com

Hydraulic / Electrical Systems and Repair 7107 Belgold, Suite C 1301 West 1ST Street, Suite A

Houston, Texas 77066 Granite City, IL 62040

Phone: 281-440-8031 Phone: 618-452-8955

Nabors USA “FMLR” Hydraulic Procedures (rev.‐4) Page 1

TABLE OF CONTENTS Section Pages Revision

Start-Up Preparation Check Fluid Levels A 2 - 4 A Open Ball Valves B 5 A Valve Stand Quick Disconnect Hoses C 6 - 7 A

Start-Up Procedures For Raise/Lower w/ Diesel Engine AC Disconnect D 8 A DC Disconnect E 8 A Diesel Engine Start-Up F 9 - 12 A Hydraulic Pressure/Return Filter Inspection G 13 - 16 A

Cables / Encoders / Control Power Interconnect Cables H 17 - 19 A Cable Encoders I 20- 22 A Encoder Feedback Cables J 23 A Control Power K 24 - 25 A

Cylinder Bleed Preparation For Cylinder Bleed Procedures L 26 A Bleed Procedures For Mast Cylinder M 27 - 32 A Bleed Procedures for Drill Floor Cylinder M 27 - 32 A

Raise / Lower of Mast and Drill Floor Raise Mast N 34 - 39 A Raise Drill Floor O 40 - 44 A Lower Drill Floor P 45 - 48 A Lower Mast Q 49 - 52 A

System Shutdown Diesel Engine R 53 A Interconnect Cables S 54 A Hoses T 55 A Encoders U 56 A

APPENDIX Lodar Remote Re-association / Tag Insertion A-1 57 - 63 A

BLEED PROCEDURES FOR PYRAMID CYLINDERS N-1 64 A

PROVIDED BY NABORS DRILLING


START-UP PREPARATION A. CHECK FLUID LEVELS

1. HYDRAULIC OIL- LEVEL • Inspect Air Breather on the hydraulic reservoir fill port for discoloration and replace if

necessary. 1. Desiccant gold in color is ok for use. 2. Desiccant dark green/black in color needs replacement.

• Fill the reservoir with the appropriate hydraulic fluid to the top of the upper sight level gauge.

1. Factory recommended hydraulic fluids for high temperature environments is Mobil DTE-26 or equivalent ISO 68. (Recommended Ambient temperatures of 40deg F through 130deg F) (Recommended fluid operating temperatures 80deg F through 140deg F with 180deg F being the max)

2. Factory recommended hydraulic fluids for low temperature environments is Mobil DTE-23 or equivalent ISO 32. (Recommended Ambient temperatures of 0deg F through 90deg F) (Recommended fluid operating temperatures 50deg F through 140deg F with 160deg F being the max)

Desiccant breather “MUST” be replaced after completely changing to this dark green/black color. Failure to do so could result in system contamination and possible component failure.


• Hydraulic reservoir should be filled with cylinders in the RETRACTED position. (Failure to do so could result in the reservoir spilling over when cylinders are cycled)

1. If cylinders cannot be fully retracted prior to cycling, fill hydraulic reservoir to half full. (approximately 600 gallons)

2. When cycling for the first time, ensure the reservoir does not trigger the low oil level lamp. (This is approximately 14” from the bottom of the reservoir or 400 gallons of oil)

• Reinstall air breather to hand tight.

2. FUEL LEVEL

• Inspect Air Breather on the fuel tank fill port for discoloration and replace if necessary. 1. Desiccant gold in color is ok for use. 2. Desiccant dark green/black in color needs replacement.

Fluid level Gauge


• Fill the diesel engine fuel tank with clean Agricultural-duty or #2 diesel fuels. • Ensure sight gauge needle valves are open. • Fill fuel tank to a “minimum” of half full allowing for approximately 6-8 hours run time. • Reinstall air breather to hand tight.

3. ENGINE OIL LEVEL

• Ensure engine oil level is filled with recommended engine manufacturer’s oil type to the appropriate level.

• Engines are shipped with oil from the manufacturer, but oil levels must be checked prior to each use. (See Engine Operator’s Manual shipped with the power unit for details)

Ensure this valve is open

Ensure this valve is open


B. OPEN BALL VALVES

1. FUEL

• Ensure 1/2” ball valve located at the bottom of the fuel tank is in the open position. (In the open position, valve handle is aligned with body of ball valve)

2. HYDRAULIC

• Ensure all four pump inlet ball valves located at the bottom of the hydraulic reservoir are open. (Open position = Handle is aligned with body of ball valve)

Fuel Ball Valve

Pump inlet shutoff

Pump inlet shutoff


C. VALVE STAND QUICK DISCONNECT HOSES

1. Driller Side

• Remove valve stand cover. • Locate the return hose with a 1-1/4” quick disconnect for connection between the HPU

Distribution Header manifold labeled (DS Return QD) and the driller side valve stand return port labeled (DS Outlet Return QD) - (driller side return hose is the shorter of two return hoses)

1. Connect this hose to the valve stand first and then to the distribution header manifold.

• Locate the pressure hose with a 1” quick disconnect for connection between the HPU Distribution Header manifold labeled (DS Pressure QD) and the driller side valve stand return port labeled (DS Inlet Pressure QD) - (driller side pressure hose is the shorter of two pressure hoses)


WARNINGS • REMOVE THE THREADED QUICK DISCONNECT CAP / PLUG. • INSPECT QUICK DISCONNECT FITTINGS FOR DAMAGE AND CONTAMINATION.

REPLACE ANY DAMAGED FITTINGS. • CLEAN OFF THE QUICK DISCONNECT FITTING PRIOR TO ATTACHING TO THE

MATING END. • VISUALLY INSPECT HOSES AND ADAPTER FITTINGS FOR APPARENT

DAMAGE. IF DAMAGE IS VISIBLE DO NOT USE AND REPLACE WITH NEW.


2. Off-Driller Side

• Remove valve stand cover. • Locate the return hose with a 1-1/4” quick disconnect for connection between the HPU

distribution header manifold labeled (ODS Return QD) and the off-driller side valve stand return port labeled (ODS Outlet Return QD) – (off-driller side return hose is the longer of two return hoses)


• Locate the pressure hose with a 1” quick disconnect for connection between the HPU

distribution header manifold labeled (ODS Pressure QD) and the off-driller side valve stand return port labeled (ODS Inlet Pressure QD) - (off-driller side pressure hose is the longer of two pressure hoses)


Pressure Return


START-UP PROCEDURES FOR RAISE / LOWER WITH DIESEL ENGINE

D. AC DISCONNECT POSITION

1. Ensure the 480 VAC disconnect, located on the left front of the power panel, is turned to the OFF position (handle in the “OFF” position is horizontal)

E. DC DISCONNECT POSITION

1. Ensure the DC disconnect, located on the right front of power panel, is turned to the ON position (handle in the “ON” position is vertical)

2. Ensure Emergency Stop (E-Stop) red mushroom button is pulled to the OUT position. (E-Stop pushbutton is located behind the control panel cover. The control panel’s cover can be swung open by releasing the cover’s flexible rubber latches on the left hand side of the control panel)

WARNING – IF AT ANY TIME ELECTRICAL CABINET DOORS ARE OPENED FOR TROUBLESHOOTING, ENSURE THEY ARE PROPERLY CLOSED AND SECURED BEFORE PROCEEDING TO THE NEXT STEP.

480 VAC Electric

Disconnect (Off-Position)

12 VDC Diesel

Disconnect (On-Position)

E-Stop


3. Ensure vent valve coil LED’s (located on the diesel engine main and side loop pump) are lighted. (The LED on the DIN connection can be very dim out in the sun light. Shade the light with your hand to verify the coil in energized. If the vent valve is not enabled the engine will sound like it is under strain and stalling.)

F. DIESEL ENGINE START UP

1. JOHN DEERE ENGINE START UP (Instructions for use with JD-4045TF115 engine only)

• Locate Murphy Control Panel. (mounted directly above the battery towards the front of the diesel engine)

• Push and hold “Tattle Tale” push button. 1. Check electric fuel pump for actuation by feeling for vibration, or listening for

pumping noise. (Pump is mounted directly under the Murphy Panel. The fuel pump is a gold cylinder shaped pump mounted in line with the fuel line from the diesel engine fuel tank.)

Side Loop Vent

Main Loop Vent

Fuel Pump


• While still holding the Tattle Tale button, push the “ENGINE START” button to crank the engine.

• Release “ONLY” the ENGINE START button after engine has started. • Keep holding the Tattle Tale button for approximately 10-15 seconds until oil pressure has

been maintained to keep the engine running. (Standard oil pressure typically ranges between 50 – 60 psi)

• Release Tattle Tale button. • The delay timer in the power panel will de-energize the vent valve coils located on the

hydraulic pumps approximately 20 seconds after the engine begins to run. (This will be evident when the LED’s located on the connectors of the vent valve coils go out)

• Raise the engine running speed by turning the throttle control clockwise. 1. Recommended running speed is1900 - 2000 RPM

• Verify hydraulic system temperature via the temperature gauge reads between 90-170 degrees Fahrenheit. (located to the left of the power panel in the wall of the hydraulic reservoir)

WARNING – DO NOT ALLOW ENGINE TO CRANK FOR MORE THAN 20-30 SECONDS AT A TIME. THIS COULD CAUSE PERMANENT DAMAGE TO YOUR ENGINE VOIDING THE MANUFACTURER’S WARRANTY.

WARNING – LISTEN FOR ANY ABNORMAL SOUNDS ASSOCIATED WITH THE DIESEL ENGINE OR HYDRAULIC POWER UNIT TO OCCUR. IF SO, SHUT DOWN THE ENGINE IMMEDIATELY BY PUSHING THE EMERGENCY STOP BUTTON LOCATED ON THE MURPHY PANEL TO THE RIGHT OF THE TATTLE TALE BUTTON.

Temperature Gauge


• Verify hydraulic pump pressure reaches 3000 psi on the main pump and approximately 100 psi on the side-loop (rear) pump. (Line pressures are indicated on the 2-1/2” dial pressure gauges located on each pump’s outlet flange)

NOTE - IF THE HYDRAULIC POWER UNIT IS NOT BEING UTILIZED FOR ACCESSORY FUNCTIONS ON A DAILY BASIS AND IS ONLY USED FOR RAISING AND LOWERING OF THE DRILLING RIG, THE HPU WILL NEED TO BE STARTED AND RAN FOR A PERIOD OF 24 HOURS PRIOR TO USE IN ORDER TO BRING THE HYDRAULIC OIL UP TO A SAFE OPERATING TEMPERATURE OF 90+ DEGREES FAHRENHEIT. THIS IS TYPICALLY NECESSARY WHEN AMBIENT TEMPERATURES ARE BELOW 40 DEGREES FAHRENHEIT.

Murphy Panel


WARNING – IF CYLINDERS BEGIN TO MOVE AT THIS STAGE, SHUT DOWN THE ENGINE IMMEDIATLEY TO CONFIRM DIRECTIONAL CONTROL VALVES ARE FUNCTIONING PROPERLY. ALL VALVES ARE PRESSURE BLOCKED, THEREFORE; HYDRAULIC FLUID FLOW SHOULD NOT BE REACHING THE CYLINDERS WHILE VALVES ARE IN THE DE-ENERGIZED POSITION.

Side-Loop Pressure

Main System Pressure


G. HYDRAULIC PRESSURE / RETURN FILTER INSPECTION

1. Inspect Pressure filter elements for cleanliness. • View the (Delta-P) dirt alarm located on the base of the pressure filter for indication of

cleanliness. • Replace filter elements when “RED” indicator pops out. (Pop-Out is located underneath

plastic protective cover)

NOTE – REPLACEMENT ELEMENT PART NUMBERS ARE IDENTIFIED ON THE TAG OF THE PRESSURE FILTER.

WARNINGS: -SYSTEM PRESSURE MUST BE BLED FROM THE PRESSURE FILTER HOUSING PRIOR TO CHANGING THE FILTER ELEMENT. -HIGH PRESSURE OIL WILL BE PRESENT. ENSURE PROPER SAFETY PRECAUTIONS ARE FOLLOWED. -WEAR SAFETY GLASSES AND COVER THE BLEED SCREW WITH A RAG AS IT IS LOOSENED. -DO NOT ALLOW DIRT TO ENTER FILTER HOUSING WHILE CHANGING FILTER

NOTE: PRESSURE FILTER INDICATOR SHOULD ONLY BE READ WHILE SYSTEM FLOW IS BEING PRODUCED BY ACTUATING ANY FUNCTION.

Dirt Alarm Indicator (Do Not Remove Plastic Cap)


1. Replacement of Pressure Filter element. a. Ensure diesel engine and electrical motor are not running. b. Release pressure from filter housing.

1. If filter is equipped with a Bleed Screw, carefully and slowly loosen the bleeder screw in the top of the housing to release any trapped pressure. (Read warning above)

2. If filter is equipped with Test Point Bleed fitting, remove cap from fitting and with hose pointed into a bucket, screw hose onto fitting until oil is expelled from the filter releasing pressure.

c. Unscrew the hex head cap to access the filter element. d. Remove filter element from the housing. e. Install new filter element ensuring that it seats properly on the nipple in the

bottom of the housing. f. Re-install the head cap ensuring the nipple properly seats inside of the filter

element. g. Leave bleed screw partially cracked (no more than one full turn counter

clockwise from tight) and start the hydraulic pump.

h. Observe air and oil escaping from bleed screw until a solid stream of oil is

flowing. i. Close bleed screw

WARNINGS: HIGH PRESSURE OIL COULD CAUSE BLEED SCREW TO BLOW OUT IF LOOSENED TOO MUCH. ENSURE PROPER SAFETY PRECAUTIONS ARE OBSERVED.

Bleed Screw

Test Point Bleed Fitting


2. Inspect Return filter elements for cleanliness

• View the differential pressure gauge connected to the side of the filter for indication of cleanliness.

• Replace element when indicator needle enters the “red zone” of the gauge.

NOTE: ONLY CHECK GAUGE WHEN OIL IS AT OPERATING TEMPERATURE (BETWEEN 80 – 140 deg. F. IF OIL TEMPERATURE IS COLD, GAUGE MAY INDICATE IN THE RED ZONE DUE TO INCREASED PRESSURE DROPS WITH LOW TEMPERATURE OIL.

NOTE: DIRT ALARM GAUGES WILL ONLY INDICATE A READING WHILE CYLINDERS ARE BEING ACTUATED AND FLUID IS BEING RETURNED THROUGH THE FILTERS.

Replace element in Red zone

Return Filter

Cover bolts


1. Replacement of Return Filter element. a. Ensure diesel engine and electrical motor are not running. b. Remove two cover bolts cross corner from each other. c. Loosen, DO NOT REMOVE, the remaining two bolts allowing the cover to rise

off of its seat.

d. Turn cover out of the slotted holes and remove from filter housing.

e. Remove the filter element and replace with new. f. Reinstall cap in opposite manner as described above for removal. g. Bleeding is not required for replacement of the Return Filter elements.

WARNINGS: DO NOT ALLOW DIRT TO ENTER FILTER HOUSING WHILE CHANGING FILTER ELEMENT.

NOTE: DO NOT LOSE OR DAMAGE O-RING WHICH SEALS THE COVER TO THE FILTER HOUSING.

WARNINGS: COVER IS SPRING LOADED – REMOVE WITH CAUTION.


CABLES / ENCODERS / CONTROL POWER H. INTERCONNECT CABLES

1. Driller Side Cables • Connect driller side interconnect cables between the control panel and the valve stand

junction box. (Cables are labeled and color coded as DRILLER SIDE MJ-SIG and DRILLER SIDE MJ-CONTROL) Reference pictures below.

SEE DIAGRAM (D-1) BELOW FOR DETAILS

1. Match color coded label on cable end to the corresponding connection and color coded tag on the control panel mounted on the HPU.

2. Match color coded label on cable end to the corresponding connection and color coded tag on the valve stand junction boxes JB1 mounted in the Sub.

• Connect driller side FB-70 feedback cable between the valve stand junction box and the

encoder feedback junction box located near the Drill Floor Cylinder mounted on the outside of the Sub. Reference pictures below.


1. Match color coded label on cable end to the corresponding connection and color coded tag on the driller side Valve stand junction box.

2. Match color coded label on cable end to the corresponding connection and color coded tag on the driller side Encoder feedback junction box.

2. Off-Driller Side Cables

• Connect off-driller side interconnect cables between the control panel and the valve stand

junction box. (Cables are labeled and color coded as OFF DRILLER SIDE MJ-SIG and OFF DRILLER SIDE MJ-CONTROL) Reference pictures below.

1. Match color coded labels on each cable end to the corresponding connection and

color coded tag on the control panel mounted on the HPU. 2. Match color coded labels on each cable end to the corresponding connection and

color coded tag on the valve stand junction boxes JB2 mounted in the Sub.

• Connect off-driller side FB-70 feedback cable between the valve stand junction box and the encoder feedback junction box located near the Drill Floor Cylinder mounted on the outside of the Sub. Reference pictures below.


NOTE: IF CABLE CONNECTIONS ARE DIRTY, ONLY CLEAN WITH NON-CONDUCTIVE ELECTRO WASH PRODUCT THAT IS SAFE FOR PLASTIC.


1. Match color coded label on cable end to the corresponding connection and color coded tag on the off-driller side Valve stand junction box and Encoder feedback junction box.

Encoder Feedback Junction Box

Control Panel


DIAGRAM D-1


I. CABLE ENCODERS

1. Mast Cylinder Cable Encoders

• Installation 1. Part number: PT9420-0550-212-1110 is installed on the Mast Cylinder (Quantity two

total, one per cylinder) a. Position and bolt the encoder to cylinder mounting plate with cable facing

upward and located away from cylinder barrel. (Mounting plate is located towards the rod end of the cylinder near the upper ring) **Ensure washers and locking nuts are used to prevent bolts from loosening

b. Connect the encoder’s stainless steel braided cable to the rod end connection point.

WARNINGS - DO NOT DROP CABLE ENCODER - DO NOT ALLOW THE SPRING LOADED CABLE TO FREE-SPOOL BACK INTO THE

ENCODER HOUSING - PER LABELED INSTRUCTIONS ON THE ENCODER, ENSURE SPOOL LOCKING

SCREW IS REMOVED PRIOR TO INITIAL OPERATION.

Spring Loaded Cable

REMOVE PRIOR TO USE


2. Drill Floor Cylinder Cable Encoder

• Installation (H.S.I INC CYLINDERS OLY) (see picture above) 1. Part number: PT9420-0400-122-1110 is installed on the Drill Floor Cylinder

(Quantity two total, one per cylinder) a. Position and bolt the encoder to cylinder mounting plate with cable facing

upward and located away from cylinder barrel. (Mounting plate is located

WARNINGS - DO NOT DROP CABLE ENCODER - DO NOT ALLOW THE SPRING LOADED CABLE TO FREE-SPOOL BACK INTO THE ENCODER HOUSING

- PER LABELED INSTRUCTIONS ON THE ENCODER, ENSURE SPOOL LOCKING SCREW IS REMOVED PRIOR TO INITIAL OPERATION.

WARNING - DO NOT ALLOW THE SPRING LOADED CABLE TO RELEASE AND FREE-SPOOL BACK INTO THE ENCODER HOUSING. THIS COULD CAUSE PERMANENT DAMAGE TO THE ENCODER AND VOID MANUFACTURER’S WARRANTY.

NOTE – VERIFY STYLE OF CYLINDER WHEN MOUNTING ENCODER. DETERMINE IF MANUFACTURER IS H.S.I. INC OR CLOVER INC. AND REFERENCE THE APPROPRIATE INSTALLATION INSTRUCTIONS BELOW.

Connection Point


towards the rod end of the cylinder below the tang mounting arm) **Ensure washers and locking nuts are used to prevent bolts from loosening.

b. Connect the encoder’s stainless steel braided cable to the rod end connection point.

• Installation (CLOVER INC. MAST CYLINDERS OLY) (see picture below)

1. Part number: PT9420-0400-122-1110 is installed on the Drill Floor Cylinder (Quantity two total, one per cylinder)

a. Position and ratchet-strap the encoder custom mounting plate to the cylinder with cable facing upward and located away from cylinder barrel.

b. Align top of encoder bracket to the top of the machine groove on the cylinder and ensure strap is located inside the undercut (machined groove) of the o.d. in the barrel.

c. Tighten strap. d. Ensure Driller Side and Off-Driller side are positioned in the same spot on

each cylinder. e. Connect the encoder’s stainless steel braided cable to the rod end connection

point.

NOTE – ENSURE ENCODER CABLE IS ALIGNED DIRECTLY BELOW CONNECTION POINT ON THE ROD.

WARNING - DO NOT ALLOW THE SPRING LOADED CABLE TO RELEASE AND FREE-SPOOL BACK INTO THE ENCODER HOUSING. THIS COULD CAUSE PERMANENT DAMAGE TO THE ENCODER AND VOID MANUFACTURER’S WARRANTY.


J. ENCODER FEEDBACK CABLES

1. Driller Side

• Connect driller side Mast encoder feedback cable (P/N: FB-6-30) between the encoder junction box (FB-JB1) and the encoder 6-pin connector.

• Connect driller side Drill Floor feedback cable (P/N: FB-6-30) between the encoder junction box (FB-JB) (mounted on the sub structure) and the encoder 6-pin connector.

2. Off-Driller Side

• Connect off-driller side Mast encoder feedback cable (P/N: FB-6-30) between the encoder

junction box (FB-JB2) and the encoder 6-pin connector.

• Connect Drill Floor feedback cable (P/N: FB-6-30) between the encoder junction box (FB-JB) (mounted on the sub structure) and the encoder 6-pin connector.


K. CONTROL POWER

1. With Diesel engine running the operator will see that the touch screen (located on the control panel) is on.

2. Enable the control power by depressing the green “Control Power” button. (Power On is verified if the green “Control Power” button is lighted)

WARNING – IF CYLINDERS BEGIN TO MOVE AT THIS STAGE, SHUT DOWN THE ENGINE IMMEDIATLEY BY DEPRESSING THE E-STOP BUTTON LOCATED ON THE CONTROL PANEL. ALL VALVES ARE PRESSURE BLOCKED, THEREFORE; HYDRAULIC FLUID FLOW SHOULD NOT BE REACHING THE CYLNDERS WHILE VALVES ARE IN THE DEENERGIZED POSITION.

Power On Indicator


3. Verify system pressure and flow displayed on the touch screen panel. (located on the control panel)

• Typical readings at this stage should display approximately 3000 psi and between 0-3

GPM. (0-3 GPM is a nominal min value based on the calibration of the flow meter)

NOTE – ANY READINGS ABOVE 3 GPM INDICATES FLUID IS FLOWING THROUGH THE SYSTEM. SHUT DOWN AND VERIFY VALVES ARE NOT ENERGIZED AND THE CYLINDERS HAVE NOT MOVED.


CYLINDER BLEED L. PREPARATION FOR CYLINDER BLEED PROCEDURE

1. Adjust Diesel hydraulic pump pressure compensator setting down to 1200 psi.

• Locate main pump mounted to rear of Diesel engine. • Remove acorn nut on pressure compensator. • Loosen, DO NOT REMOVE, lock nut on pressure compensator by turning counter

clockwise. • Lower pump compensator setting by turning the adjuster screw counter clockwise until the

pump’s pressure gauge reads approximately 1200 psi. (compensator adjuster screw requires a 3/16” hex key drive)

• While maintaining 1200 psi on the pump’s pressure gauge, snug down the locking nut. • Re-install the acorn nut hand tight.

Pressure Compensator Adjustment Valve

WARNING – FAILURE TO COMPLETE THE ABOVE COMPENSATOR ADJUSTMENT STEP PRIOR TO BLEEDING THE CYLINDER COULD RESULT IN INJURY TO PERSONNEL FROM HIGH PRESSURE HYDRAULIC SPRAY.


M. CYLINDER BLEED PROCEDURES FOR MAST AND DRILL FLOOR (GATEWAY CYLINDERS)

1. “Standard” Bleed Procedure

• All Articulate cylinders need to be bled. • For the Mast cylinder only, orientate cylinder in a vertical or near vertical position with the

rod facing up and in the fully retracted position. Drill Floor cylinder should be bled in the fully retracted position.

• Ensure all hydraulic connections between the hydraulic cylinder and valve stand are properly connected and tightened.

1. Attach extend (A-port) and retract (B-port) hoses from the valve stand to the extend and retract ports of the cylinder (cylinder ports are labeled “RET” for retract and “EXT” for Extend and are located on the plunger of the cylinder)

2. Connect bleeder hose from the HPU distribution block port “Drain Bleed QD-1” to the cylinder extend bleed connection labeled “E-Bleed”. (cylinder extend bleed connection is a SAE-6 port and located on the Mast cylinder at the rod end nearest the retract port).

NOTE: ON NEW INSTALLATIONS CYCLE CYLINDERS FULLY BETWEEN FULL EXTEND AND FULL RETRACT IF POSSIBLE.

NOTE: THE BLEED PROCEDURES LISTED BELOW ARE INTENDED TO BE USED FOR THE MAST AND DRILL FLOOR CYLINDERS INTERCHANGEABLY. SPECIAL NOTES WILL BE INDICATED WHERE AND IF THERE ARE MINOR DIFFERENCES BETWEEN THE TWO PROCEDURES.

WARNING – THESE BLEED PROCEDURES ARE ONLY TO BE USED ON CYLNDERS SUPPLIED BY GATEWAY FLUID POWER AND BUILT BY H.S.I. CORPORATION! IF OTHER CYLINDERS ARE BEING USED, REFER TO THE BLEED PROCEDURES PROVIDED BY NABORS IN APPENDIX (N-1) AT THE BACK OF THIS MANUAL.

WARNING – FAILURE TO PROPERLY LOWER COMPENSATOR SETTING TO 1200 PSI FOR CYLINDER BLEED” COULD RESULT IN INJURY TO PERSONNEL FROM HIGH PRESSURE HYDRAULIC SPRAY OR DAMAGE TO EQUIPMENT.


3. Crack open (DO NOT REMOVE) the 1/8” NPT bleed port plug located 10-12” down from the top of the cylinder barrel near the rod end. (For new installation of cylinders ONLY)

• Switch control panel display to “Hand Control” on the HPU touch screen.

• Ensure hand control speed setting for both raising and lowering of the cylinders are set to 100% on the hand control screen in the control panel touch screen.

NOTE: BLEED PROCESS CAN BE PERFORMED FROM LOCAL OPERATOR SWITCHES LOCATED ON THE CONTROL PANEL OR BY REMOTE CONTROLS. SEE DETAILS BELOW FOR EACH METHOD OF BLEED PROCESS.

Drain Bleed QD-1 Drain Connection

Drain Connection


• “LOCAL” Control Mode for bleed process 1. At the control panel activate the following control switches.

a. Local b. Hand c. D.S. or O.D.S (depending on which side is being bled)

2. Activate the “Lower” control switch and hold for 2-3 seconds. a. Repeat switching from the “Lower” position to “OFF” position for 2-3 seconds

at a time allowing air to escape during the bleed process.

3. Close the 1/8” cylinder barrel bleed port after a steady stream of fluid begins to escape from the port.

4. Locate the bleeder sight gauge on the HPU. (located on the wall of the hydraulic

reservoir above the main distribution manifold) a. While energizing the retract port of the cylinder, air bubbles should become

less evident as the air is purged from the cylinder. b. Continue cycling of the “Lower” selector switch as mentioned above until

bubbles are no longer visible through the sight gauge. 5. Release the control switch “Lower” back to the center position. 6. Remove hose from the cylinder extend bleed connection and reconnect it to the

retract bleed connection (cylinder retract bleed connection is a SAE-6 port and located on the cylinder at the rod end nearest the extend port)

NOTE: THE BLEED PROCESS MUST CONTINUE UNTIL THERE ARE NO LONGER AIR BUBBLES PRESENT IN THE SIGHT GLASS

Bleeder sight glass


7. Begin cycling the cylinder by activating the “Raise” selector switch for 2-3 seconds at a time similar to the procedures used for the “Lower” bleed procedures.

a. The cylinder may extend some during this procedure, but should not extend completely.

8. Locate the bleeder sight gauge on the HPU. a. While energizing the extend port of the cylinder, air bubbles should become

less evident as the air is purged from the cylinder. b. Continue cycling of the “Raise” selector switch as mentioned above until

bubbles are no longer visible through the sight gauge.

9. Release the control switch “Raise” back to the center position. 10. Fully retract cylinders after bleeding process is complete.

• “REMOTE” Control Mode for bleed process

NOTE: AT ANY TIME DURING THE BLEEDING PROCESS A FUNCTION DOES NOT WORK PROPERLY, TURN OFF REMOTE AND RE-ENABLE.


DRILL FLOOR MAST


1. Locate the control switch “Local - Remote” at the HPU’s control panel and turn to the “Remote” position.

2. Locate the “Mast Controls” and “Drill Floor Controls” remote control. 3. Enable Mast remote or Drill Floor remote control by momentarily depressing the

“Green” button and releasing.

a. The remote’s “RED” Led will blink once remote is enabled and ready for use.

4. Momentarily depress and release the “Hand” button on the remote control. a. (Verify “Hand” mode is enabled by viewing the “Hand Enabled” indicator light

located on the hand control screen at the HPU. 5. Press and hold the “D.S.” or “O.D.S.” button on the remote control. 6. Press and hold the “Mast Lower” or “Drill Floor Lower” button for 2-3 seconds on

the remote control. a. Repeatedly press and release the “Lower” position button for 2-3 seconds at

time with 2-3 seconds between cycles allowing air to escape during the bleed process.

7. Close the 1/8” cylinder barrel bleed port after a steady stream of fluid begins to escape from the port.

8. Locate the bleeder sight gauge on the HPU. (located on the wall of the hydraulic reservoir above the main distribution manifold) see picture referenced in “Local” mode

a. While energizing the retract port of the Mast or Drill Floor cylinder air bubbles should become less evident as the air is purged from the cylinder.

b. Continue cycling the Mast or Drill Floor “Lower” button as mentioned above until bubbles are no longer visible through the sight gauge.

9. Release both “Lower” and “D.S.” remote control buttons. 10. Remove hose from the cylinder extend bleed connection and reconnect it to the

retract bleed connection (cylinder retract bleed connection is a SAE-6 port and located on the Mast or Drill Floor cylinder at the rod end nearest the extend port)

11. Press and hold the “D.S.” or “O.D.S.” button on the remote control. 12. Press and release the “Mast Raise” or “Drill Floor Raise” button on the remote

control for 2-3 seconds at a time with 2-3 seconds between cycles similar to the procedures used for the “Lower” bleed procedures.

a. The cylinder may extend some during this procedure, but should not extend completely.

WARNING: DO NOT HOLD BUTTON FOR MORE THAN 5 CONSECUTIVE SECONDS. IF HELD FOR MORE THAN 5 SECONDS THE REMOTE WILL DE-PROGRAM AND NO LONGER WORK. SEE APPENDIX A-1 FOR REPROGRAMMING INSTRUCTIONS.



13. Locate the bleeder sight gauge on the HPU. a. While energizing the extend port of the cylinder, air bubbles should become

less evident as the air is purged from the cylinder. b. Continue cycling of the “Raise” button as mentioned above until bubbles are

no longer visible through the sight gauge.

14. Release both “Mast Raise” or “Drill Floor Raise” and “D.S.” remote buttons. 15. When bleeding is complete, return the cylinder to the fully retracted position. 16. Turn off the remote control by depressing the “RED” button at the top of the remote.



RAISE / LOWER OF MAST AND DRILL FLOOR N. RAISE MAST

1. Adjust Diesel hydraulic pump pressure compensator setting to 3000 psi. • Locate main pump mounted to rear of Diesel engine. • Remove acorn nut on pressure compensator. • Loosen, DO NOT REMOVE, lock nut on pressure compensator by turning counter

clockwise. • Raise pump compensator setting by turning the adjuster screw clockwise until the pump’s • pressure gauge reads approximately 3000 psi. (compensator adjuster screw requires a • 3/16” hex key drive) • While maintaining 3000 psi on the pump’s pressure gauge, snug down the locking nut. • Re-install the acorn nut hand tight.

2. Verify hand speed is 100% at touch screen for cylinder to mate with mast.

• While “NOT” attached to a load, ensure hand control speed setting for both raising and

lowering of the Mast cylinders are set to 100% in the hand control screen on the control panel touch screen.

WARNING: WHILE RAISING OR LOWERING MAST OR DRILL FLOOR, ENSURE HOSES ARE FREE OF OBSTRUCTION.

WARNING: VERIFY THE CYLINDER BLEEDING PROCESS IS COMPLETE. FAILURE TO DO SO COULD RESULT IN COMPONENT OR SYSTEM FAILURE AND CAUSE SERIOUS INJURY OR DEATH.


3. Mate mast cylinder with mast

• Extend Rear Articulate cylinder to full out position. • Extend Front Articulate cylinder until Rear Articulate cylinder meets with the shoe mounted

on the cylinder. • Retract rear while extending front mast articulate cylinders to align mast cylinder claw with

mast pin. • Extend mast cylinder to mate claw with mast pin.

• Verify hand speed is 50% at touch screen for cylinder to mate with mast. 1. Ensure hand control speed setting for both raising and lowering of the Mast cylinders

are set to 50% on the hand control screen in the control panel touch screen. • Retract both front and rear articulate cylinders to fully retracted position. • Rotate front and rear mast articulate cylinders away from the mast cylinder to ensure mast

cylinder clearance during operation.

WARNING: DO NOT ALLOW MAST CYLINDER TO FALL ONTO REAR OR FRONT ARTICULATE CYLINDER DURING TRANSITION.

NOTE: AFTER ATTACHING THE CLAW TO THE MAST, RETURN THE HAND SPEED AT THE TOUCH SCREEN TO 50% FOR BOTH THE RAISING AND LOWERING VALUE.

WARNING: CYLINDERS SHOULD OPERATE AND TRANSITION SMOOTHLY BETWEEN STAGES WHILE EXTENDING TO MATE WITH MAST OR DRILL FLOOR PINS. IF CYLINDERS OPERATE IN AN ERRATIC OR JERKING MOTION OR SKIP STAGES WHILE BEING EXTENDED, RETRACT CYLINDERS TO THE FULLY RETRACTED POSITION AND REPEAT BLEED PROCEDURES FROM THE BEGINNING.


4. Verify both encoder feedback signals via the touch screen.

• Go to Mast Control screen on the HPU’s touch screen display. • Ensure both feedback signals are present and within 1” of each other.

• If feedback signals are more than 1” out of tolerance perform the following steps. 1. Verify encoder mounting brackets and cable connections to the rod side of the

cylinder are not bent or damaged. a. If either bracket or mounting point is damaged, repair or reposition. Ensure

distance between the encoder mounting bracket and cable mounting point to the rod end on both the driller and off-driller side are equal distance.

2. If mounting brackets are not damaged and readings are still out of tolerance (more than 1” and less than 3”) the encoders will need to be zeroed out.

a. Determine which encoder is giving the false reading by measuring actual distance of cable extended from the encoder. The encoder with a false reading must be zeroed out.

i. Remove the “ZERO” adjustment cap screw from the side of the encoder.

Feedback Reading


ii. Using a small flat head screw driver adjust the small trim pot inside the housing (located inside the screw hole of the adjustment cap screw just removed)

1. Turn the trim pot screw clockwise to increase feedback signal and counter clockwise to decrease the feedback signal.

iii. Verify the adjustment on the mast control screen by looking at the feedback signal reading.

iv. Replace zero adjustment cap screw.


3. If the encoder brackets are not damaged, measure equal distances on both sides and the encoder is still out of tolerance more than 3” REPLACE ENCODER WITH NEW.

5. Verify Mast is holding position

• Raise mast in “Hand” operation mode until the mast position feedback signal is greater than the “Auto Mast Full Down Stop” reading indicated on the touch screen’s display.

• Hold the mast’s position for ONE to TWO minutes to verify any drifting of the mast cylinders.

6. Auto Mast Raise

• Ensure “Set Point Going UP” on the Mast Control screen display is not greater than 45% for a smooth and safe operating speed.

• Ensure cylinder feedback positions displayed on the mast control screen are within .250” of each other.

• Turn the “Hand – Off – Auto” control switch at the HPU’s control panel to the “Auto” position.

• Verify “Mast Auto Enabled” is active via the HPU’s touch screen indicator light. (RED=Disabled, GREEN=Enabled)

WARNING: IF ZERO ADJUSTMENT CAP SCREW IS NOT REPLACED, CONTAMINATION OR WATER DAMAGE WOULD RESULT IN FAILURE OF THE ENCODER.

WARNING: IF THE CYLINDER FAILS TO HOLD POSITION WHEN THE VALVE IS DE-ENERGIZED, ACTUATE THE EMERGENCY STOP BUTTON ON THE CONTROL PANEL. INSPECT THE CYLINDER AND BLEEDER PORTS TO ENSURE OIL IS NOT LEAKING. (If no oil leakage is evident, contact Gateway Fluid Power)

Indicator Lights


• Turn the “Mast Auto Raise – Off – Mast Auto Lower” control switch at the HPU’s control panel to the “Mast Auto Raise” position.

• Verify “Mast Start UP Enabled” is active via the HPU’s touch screen indicator light. (RED=Disabled, GREEN=Enabled)

• Clearing Alarm (if needed) 1. Turn the “Hand – Off – Auto” control switch at the HPU’s control panel to the

“Hand” position. (On screen alarm description will go away at this time) 2. Select cylinder to be realigned. 3. Via “D.S” or “O.D.S” selector switch, move cylinders back into alignment. 4. Turn the “Hand – Off – Auto” control switch at the HPU’s control panel back to the

“Auto” position. 5. Turn the “Mast Auto Raise – Off – Mast Auto Lower” control switch at the HPU’s

control panel to the “Mast Auto Raise” position to continue Auto raising of the mast cylinders.

• Automatic Stop of Mast raising 1. Mast cylinders will automatically stop at preset “Auto Mast Full Up Stop” position as

set on the HPU’s mast control screen. a. Mast automatically stops approximately one foot before entering shoe.

• Pinning Mast To The Floor 1. Turn the “Hand – Off – Auto” control switch at the HPU’s control panel to the

“Hand” position. 2. Ensure Mast clevises are aligned with their mating shoe for pinning.

a. If either leg is out of alignment from side to side, extend or retract “D.S.” or “O.D.S” cylinder to align.

b. Turn the “D.S. – BOTH – O.D.S.” control switch at the HPU’s control panel to the “Both” position.

c. Turn the “Hand Mast Raise – Off – Hand Mast Lower” selector switch to “Hand Mast Raise” until pinning holes are aligned.

d. Pin Mast to the drill floor.

NOTE: ONCE “AUTO START UP” IS ENABLED THE MAST RAISING SPEED WILL INCREASE FROM ZERO UNTIL IT REACHES THE “SETPOINT GOING UP” PERCENTAGE SET ON THE HPU’S TOUCHSCREEN.

NOTE: WHILE OPERATING IN “AUTO MODE” AN ALARM WILL AUTOMATICALLY STOP SYSTEM OPERATION ANY TIME THE D.S AND O.D.S. MAST CYLINDER POSITION FEEDBACK READING DEVIATES 3/4” FROM EACH OTHER. THE ALARM INDICATOR LIGHT WILL BEGIN FLASHING AND AN ALARM DESCRIPTION WILL DISPLAY ON THE SCREEN.

NOTE: “POSITION FEEDBACK ALARM” PREDOMINATELY OCCURS DURING THE CYLINDER STAGE TRANSITIONS, DURING MODERATE WIND GUSTS, FROM INTERFERENCE FROM HOLES/CABLES ETC…


• Disconnecting Mast Cylinders from Mast 1. Turn the “Hand – Off – Auto” control switch at the HPU’s control panel to the

“Hand” position. 2. Extend the rear articulate cylinder until it mates up to the Mast Cylinder. (Extend just

until the load of the mast cylinder is taken off of the claw.) 3. Disconnect the mast claw from the mast pin and fully retract the mast cylinders. 4. Once the mast cylinder is fully retracted, extend the front articulating cylinder to its

fully extended position. 5. Extend the rear articulating cylinder until the front articulating cylinder mates up to

the mast cylinder. Extend the rear cylinder and retract the front cylinder in a step process until all the weight of the mast cylinder is resting on the front articulating cylinder.

6. Fully retract the front articulating cylinder and the rear articulating to the fully retracted position.

WARNING: DO NOT ALLOW THE MAST CYLINDER TO FALL ONTO THE FRONT OR REAR ARTICULATING CYLINDER IN THE TRANSITION. THIS COULD RESULT IN CYLINDER OR EQUIPMENT FAILURE AND CAUSE SERIOUS INJURY OR EVEN DEATH.


O. RAISE DRILL FLOOR

1. Adjust Diesel hydraulic pump pressure compensator setting to 3000 psi. • Locate main pump mounted to rear of Diesel engine. Remove acorn nut on pressure

compensator. • Loosen, DO NOT REMOVE, lock nut on pressure compensator by turning counter

clockwise. • Raise pump compensator setting by turning the adjuster screw clockwise until the pump’s

pressure gauge reads approximately 3000 psi. (compensator adjuster screw requires a 3/16” hex key drive)


2. Verify hand speed is 100% at touch screen for cylinder to mate with mast. • While “NOT” attached to a load, ensure hand control speed setting for both raising and


3. Close “Rear Articulate Vent Valve” • Verify drill floor articulating float valve is closed by turning clockwise until it bottoms out.

(located on the valve stands under the “Drill Floor Articulate” directional control valve stack) WARNING – DO NOT OVER TIGHTEN.


WARNING: VERIFY THE CYLINDER BLEEDING PROCESS IS COMPLETE. FAILURE TO DO SO COULD RESULT IN COMPONENT OR SYSTEM FAILURE AND CAUSE SERIOUS INJURY OR DEATH.

Vent Valve


1. To ensure valve is closed and seated properly, bump and release the “Drill Floor Articulate Extend” button and verify Drill Floor Articulate gauges on the valve stand holds pressure and the cylinder holds position.

4. Mate Drill Floor cylinder with the drill floor. • Extend or Retract drill floor articulate cylinders to align drill floor cylinder to the connection

clevis mounted in the floor. • Extend drill floor cylinder and mate up to the drill floor connection point.

• Extend the drill floor locking pin until fully engaged. • Verify hand speed is 50% at touch screen for cylinder to mate with mast.

1. Ensure hand control speed setting for both raising and lowering of the Mast cylinders are set to 50% on the hand control screen in the control panel touch screen.

5. Open “Rear Articulating Vent Valve” • Open drill floor articulating float valve by turning the knob counter clockwise until it stops.


1. To verify the valve is open, double check both pressure gauges above the valve to “ENSURE” each gauge needle drops to “ZERO” psi.

6. Verify both encoder feedback signals via the touch screen. • View Drill Floor Control screen on the HPU’s touch screen display. • Ensure both feedback signals are present and within 1” of each other. • If feedback signals are more than 1” out of tolerance perform the following steps.

1. Verify encoder mounting brackets and cable connections to the rod side of the cylinder are not bent or damaged.

a. If either bracket or mounting point is damaged, repair or reposition. Ensure distance between the encoder mounting bracket and cable mounting point to the rod end on both the driller and off-driller side are equidistant.

WARNING: VERIFY THAT THE REAR ARTICULATING VENT VALVE IS OPEN. FAILURE TO DO SO COULD RESULT IN COMPONENT OR SYSTEM FAILURE AND CAUSE SERIOUS INJURY OR DEATH.


WARNING: VERIFY THAT THE REAR ARTICULATING VENT VALVE IS CLOSED. FAILURE TO DO SO COULD RESULT IN COMPONENT OR SYSTEM FAILURE AND CAUSE SERIOUS INJURY OR DEATH.



a. Determine which encoder is giving the false reading by measuring actual distance of cable extended from the encoder. The encoder with a false reading must be zeroed out. Reference pictures above in “Raising of Mast” section

i. Remove the “ZERO” adjustment cap screw from the side of the encoder. ii. Using a small flat head screw driver adjust the small trim pot inside the

housing (located inside the screw hole of the adjustment cap screw just removed)



iv. Replace zero adjustment cap screw. 3. If the encoder brackets are not damaged, measure equidistant on both sides and the

encoder is still out of tolerance more than 3” REPLACE ENCODER WITH NEW.

7. Verify Drill Floor is holding position

• Raise Drill Floor in “Hand” operation mode until the mast position feedback signal is greater than the “Auto Drill Floor Full Down Stop” reading indicated on the touch screen’s display.

• Hold the drill floor position for ONE to TWO minutes to verify any drifting of the drill floor cylinders.

8. Auto Drill Floor Raise • Ensure “Set Point Going UP” on the Drill Floor Control screen display is not greater than

45% for a smooth and safe operating speed. • Ensure cylinder feedback positions displayed on the Drill Floor control screen are within

0.250” of each other. • Turn the “Hand – Off – Auto” control switch at the HPU’s control panel to the “Auto”

position. • Verify “Drill Floor Auto Enabled” is active via the HPU’s touch screen indicator light.

(RED=Disabled, GREEN=Enabled) • Turn the “Drill Floor Auto Raise – Off – Mast Auto Lower” control switch at the HPU’s

control panel to the “Drill Floor Auto Raise” position. • Verify “Drill Floor Start UP Enabled” is active via the HPU’s touch screen indicator light.

(RED=Disabled, GREEN=Enabled)

WARNING: IF THE CYLINDER FAILS TO HOLD POSITION WHEN THE VALVE IS DE-ENERGIZED, ACTUATE THE EMERGENCY STOP BUTTON ON THE CONTROL PANEL. INSPECT THE CYLINDER AND BLEEDER PORTS TO ENSURE OIL IS NOT LEAKING. (If no oil leakage is evident, contact Gateway Fluid Power)

NOTE: IF THE ENCODER BRACKETS BECOME DAMAGED, IT SHOULD BE REPORTED TO GATEWAY FLUID POWER.



“Hand” position. (On screen alarm description will go away at this time) 2. Select cylinder to be realigned. 3. Via “D.S” or “O.D.S” selector switch move cylinders back into alignment. 4. Turn the “Hand – Off – Auto” control switch at the HPU’s control panel back to the

“Auto” position. 5. Turn the “Drill Floor Auto Raise – Off – Mast Auto Lower” control switch at the

HPU’s control panel to the “Drill Floor Auto Raise” position to continue Auto raising of the drill floor cylinders.

NOTE: ONCE “AUTO START UP” IS ENABLED THE DRILL FLOOR RAISING SPEED WILL INCREASE FROM ZERO UNTIL IT REACHES THE “SETPOINT GOING UP” PERCENTAGE SET ON THE HPU’S TOUCHSCREEN.


NOTE: POSITION FEEDBACK ALARM PREDOMINATELY OCCURS DURING THE CYLINDER STAGE TRANSITIONS.

Alarm Indicator Light


• Automatic Stop of Drill Floor raising 1. Drill Floor cylinders will automatically stop at preset “Auto Drill Floor Full Up Stop”

position as set on the HPU’s Drill Floor control screen. a. Drill Floor automatically stops approximately one foot before standing full

vertical. • Pinning Drill Floor Brace Cylinders To The Sub

1. Turn the “Hand – Off – Auto” control switch at the HPU’s control panel to the “Hand” position.

2. Extend the Drill Floor Brace Cylinder with “Drill Floor Brace Extend- Retract” selector switch and position brace so that it will slide into the mounting bracket.

3. Ensure Drill Floor clevises are aligned with their mating clevis for pinning. a. If either leg is out of alignment from side to side, extend or retract “D.S.” or

“O.D.S” cylinder to align. b. Turn the “D.S. – BOTH – O.D.S.” control switch at the HPU’s control panel to

the “Both” position. c. Turn the “Hand Drill Floor Raise – Off – Hand Drill Floor Lower” selector

switch to “Hand Drill Floor Raise” until pinning holes are aligned. d. Pin Drill Floor Brace to the sub structure.

• Disconnecting Drill Floor Cylinders from Drill Floor. 1. Close rear “Articulate Vent Valve”

a. Verify drill floor articulating float valve is closed by turning clockwise until it bottoms out. (located on the valve stands under the “Drill Floor Articulate” directional control valve stack) WARNING – DO NOT OVER TIGHTEN.


3. Extend the rear articulate cylinder. (Extend until the load of the drill floor cylinder is taken off of the pin.)

4. Retract the Drill Floor Locking Pin until fully disengaged. 5. Retract Drill Floor cylinder to the fully retracted position.

WARNING: VERIFY THAT THE REAR ARTICULATING VENT VALVE IS CLOSED. FAILURE TO DO SO COULD RESULT IN A FAILURE AND CAUSE SERIOUS INJURY OR DEATH.


P. LOWER DRILL FLOOR








3. Close “Rear Articulate Vent Valve”

• Verify drill floor articulating float valve is closed by turning clockwise until it bottoms out. (located on the valve stands under the “Drill Floor Articulate” directional control valve stack) WARNING – DO NOT OVER TIGHTEN.

1. To ensure valve is closed and seated properly, bump and release the “Drill Floor Articulate Extend” button and verify Drill Floor Articulate gauges on the valve stand holds pressure and the cylinder holds position.

4. Mate Drill Floor cylinder with the drill floor. • Extend or Retract drill floor articulate cylinders to align drill floor cylinder to the connection

clevis mounted in the floor. • Extend drill floor cylinder and mate up to the drill floor connection point.


NOTE: FOR PICTURE REFERENCES THROUGHOUT THE “LOWERING OF DRILL FLOOR” SECTION, SEE “RAISING OF DRILL FLOOR” SECTION.

WARNING: VERIFY THE CYLINDER BLEEDING PROCESS IS COMPLETE. FAILURE TO DO SO COULD RESULT IN A FAILURE AND CAUSE SERIOUS INJURY OR DEATH.

WARNING: VERIFY THAT THE REAR ARTICULATING VENT VALVE IS CLOSED. FAILURE TO DO SO COULD RESULT IN COMPONENT OR SYSTEM FAILURE AND CAUSE SERIOUS INJURY OR DEATH.


• Extend the drill floor locking pin until fully engaged. • Verify hand speed is 50% at touch screen for cylinder to mate with mast.

1. Ensure hand control speed setting for both raising and lowering of the Mast cylinders are set to 50% on the hand control screen in the control panel touch screen.

5. Open “Rear Articulating Vent Valve” • Open drill floor articulating float valve by turning the knob counter clockwise until it stops.


1. To verify the valve is open, double check both pressure gauges above the valve to “ENSURE” each gauge needle drops to “ZERO” psi.

6. Verify both encoder feedback signals via the touch screen. • View Drill Floor Control screen on the HPU’s touch screen display. • Ensure both feedback signals are present and within 1” of each other.


• Go to Drill Floor Control screen on the HPU’s touch screen display. • Ensure both feedback signals are present and within 1” of each other. • If feedback signals are more than 1” out of tolerance perform the following steps.









WARNING: VERIFY THAT THE REAR ARTICULATING VENT VALVE IS OPEN. FAILURE TO DO SO COULD RESULT IN COMPONENT OR SYSTEM FAILURE AND CAUSE SERIOUS INJURY OR DEATH.




encoder is still out of tolerance more than 3” REPLACE ENCODER WITH NEW. 8. Verify Drill Floor is holding position

• Lower the Drill Floor in “Hand” operation mode until the Drill Floor position feedback signal is greater than the “Auto Drill Floor Full Up Stop” reading indicated on the touch screen’s display.

• Hold the drill floor position for ONE to TWO minutes to verify any drifting of the drill floor cylinders.

9. Auto Drill Floor Lower • Ensure “Set Point Going Down” on the Drill Floor Control screen display is not greater than

40% for a smooth and safe operating speed. • Ensure cylinder feedback positions displayed on the Drill Floor control screen are within

0.250” of each other. • Turn the “Hand – Off – Auto” control switch at the HPU’s control panel to the “Auto”

position. • Verify “Drill Floor Auto Enabled” is active via the HPU’s touch screen indicator light.

(RED=Disabled, GREEN=Enabled) • Turn the “Drill Floor Auto Raise – Off – Drill Floor Auto Lower” control switch at the

HPU’s control panel to the “Drill Floor Auto Lower” position. • Verify “Drill Floor Start Down Enabled” is active via the HPU’s touch screen indicator light.

(RED=Disabled, GREEN=Enabled)



“Auto” position.



NOTE: ONCE “AUTO START DOWN” IS ENABLED THE DRILL FLOOR RAISING SPEED WILL INCREASE FROM ZERO UNTIL IT REACHES THE “SETPOINT GOING UP” PERCENTAGE SET ON THE HPU’S TOUCHSCREEN.


5. Turn the “Drill Floor Auto Raise – Off – Mast Auto Lower” control switch at the HPU’s control panel to the “Drill Floor Auto Lower” position to continue Auto raising of the drill floor cylinders.

• Automatic Stop of Drill Floor lowering. 1. Drill Floor cylinders will automatically stop at preset “Auto Drill Floor Full Down Stop”

position as set on the HPU’s Drill Floor control screen. Drill Floor automatically stops approximately one foot before the subs pinning connections are made.

• Pinning Drill Floor To The Sub. 1. Turn the “Hand – Off – Auto” control switch at the HPU’s control panel to the

“Hand” position. 2. Lower the Drill Floor Cylinders so that the pinning connections will slide into each

other. 3. Ensure Drill Floor pinning connections are aligned.

a. If either leg is out of alignment from side to side, extend or retract “D.S.” or “O.D.S” cylinder to align.

b. Turn the “D.S. – BOTH – O.D.S.” control switch at the HPU’s control panel to the “Both” position.

c. Turn the “Hand Drill Floor Raise – Off – Hand Drill Floor Lower” selector switch to “Hand Drill Floor Lower” until pinning connections are aligned.

d. Pin Drill Floor to the sub structure. • Disconnecting Drill Floor Cylinders from Drill Floor.

1. Close rear “Articulate Vent Valve” a. Verify drill floor articulating float valve is closed by turning clockwise until it

bottoms out. (located on the valve stands under the “Drill Floor Articulate” directional control valve stack) WARNING – DO NOT OVER TIGHTEN.


3. Extend the rear articulate cylinder. (Extend until the load of the drill floor cylinder is taken off of the pin.)

4. Retract the Drill Floor Locking Pin to the full retracted position. 5. Fully retract the Drill Floor cylinder to the fully retracted position.

WARNING: VERIFY THAT THE REAR ARTICULATING VENT VALVE IS CLOSED. FAILURE TO DO SO COULD RESULT IN A FAILURE AND CAUSE SERIOUS INJURY OR DEATH.


Q. LOWER MAST








3. Mate mast cylinder with mast • Extend rear while retracting front mast articulate cylinders to align mast cylinder claw with

mast pin. • Extend mast cylinder to mate claw with mast pin.

• Retract both front and rear articulate cylinders to fully retracted position. • Rotate front and rear mast articulate cylinders away from the mast cylinder to ensure mast

cylinder clearance during operation. 4. Verify hand speed is 50% at touch screen for cylinder to mate with mast.

• Ensure hand control speed setting for both raising and lowering of the Mast cylinders are set to 50% on the hand control screen in the control panel touch screen.



NOTE: FOR PICTURE REFERENCES THROUGHOUT THE “LOWERING OF DRILL FLOOR” SECTION, SEE “RAISING OF DRILL FLOOR” SECTION.

WARNING: VERIFY THE CYLINDER BLEEDING PROCESS IS COMPLETE. FAILURE TO DO SO COULD RESULT IN A FAILURE AND CAUSE SERIOUS INJURY OR DEATH.



• Go to Mast Control screen on the HPU’s touch screen display. • Ensure both feedback signals are present and within 1” of each other. • If feedback signals are more than 1” out of tolerance perform the following steps.










encoder is still out of tolerance more than 3” REPLACE ENCODER WITH NEW. 6. Unpinning Mast To The Floor

• Turn the “Hand – Off – Auto” control switch at the HPU’s control panel to the “Hand” position.

• Utilizing the “D.S. – BOTH – O.D.S.” and “Hand Mast Raise – Off – Hand Mast Lower” controls, jog the mast cylinders to relieve the load on the mast pins.

• Knock out the mast pins. 7. Verify Mast is holding position

• Lower mast in “Hand” operation mode until the mast position feedback signal is less than the “Auto Mast Full Down Stop” reading indicated on the touch screen’s display.

• Hold the mast’s position for ONE to TWO minutes to verify any drifting of the mast cylinders.

8. Auto Mast Lower • Ensure “Set Point Going Down” on the Mast Control screen display is not greater than 40%

for a smooth and safe operating speed. • Ensure cylinder feedback positions displayed on the mast control screen are within 0.250”

of each other. • Turn the “Hand – Off – Auto” control switch at the HPU’s control panel to the “Auto”

position.

WARNING: IF AT ANY TIME EITHER OF THE TWO MAST CYLINDERS DRIFT OR DO NOT HOLD POSITION, LOWER MAST BACK ON TO THE FLOOR.


• Verify “Mast Auto Enabled” is active via the HPU’s touch screen indicator light. (RED=Disabled, GREEN=Enabled)

• Turn the “Mast Auto Raise – Off – Mast Auto Lower” control switch at the HPU’s control panel to the “Mast Auto Lower” position.

• Verify “Mast Start Down Enabled” is active via the HPU’s touch screen indicator light. (RED=Disabled, GREEN=Enabled)



“Auto” position. 5. Turn the “Mast Auto Raise – Off – Mast Auto Lower” control switch at the HPU’s

control panel to the “Mast Auto Lower” position to continue Auto lowering of the mast cylinders.

• Automatic Stop of Mast lowering. 1. Mast cylinders will automatically stop at preset “Auto Mast Full Down Stop” position

as set on the HPU’s mast control screen. Mast automatically stops approximately one foot before setting down on the headache rack.

• Disconnecting Mast Cylinders from Mast 1. Turn the “Hand – Off – Auto” control switch at the HPU’s control panel to the

“Hand” position. 2. Extend the front and rear articulate cylinder until they mate up to the Mast Cylinder.

(Extend either the front or the rear until the load of the mast cylinder is taken off of the claw.)

3. Disconnect the mast claw from the mast pin and fully retract the mast cylinders. 4. Extend the rear cylinder and retract the front cylinder in a step process until all the

weight of the mast cylinder is resting on the front articulating cylinder.

NOTE: ONCE “AUTO START DOWN” IS ENABLED THE MAST LOWERING SPEED WILL INCREASE FROM ZERO UNTIL IT REACHES THE “SETPOINT GOING DOWN” PERCENTAGE SET ON THE HPU’S TOUCHSCREEN.




5. Fully retract the front articulating cylinder and the rear articulating to the fully retracted position.

WARNING: DO NOT ALLOW THE MAST CYLINDER TO FALL ONTO THE FRONT OR REAR ARTICULATING CYLINDER IN THE TRANSITION. THIS COULD RESULT IN A CYLINDER FAILURE AND CAUSE SERIOUS INJURY OR EVEN DEATH.


SYSTEM SHUTDOWN R. DIESEL ENGINE

1. Reduce RPM’s of diesel engine by turning the engine throttle control clockwise until engine idles near 1000 RPM’s

2. Turn diesel engine off by either method listed below • E-Stop mushroom button on control panel can be depressed • E-Stop button on engine’s Murphy panel can be depressed

• Switch the DC disconnect, located on the right front of power panel, is turned to the OFF position (handle in the “OFF” position is horizontal)

WARNING: IF DC DISCONNECT IS NOT TURNED TO THE “OFF” POSITION, IT IS POSSIBLE FOR THE BATTERY POWER TO DRAIN.

E-Stop

E-Stop

12 VDC Diesel Disconnect

(OFF-Position)


S. INTERCONNECT CABLES

1. Disconnect all interconnect cables from the HPU to the valve stand junction boxes. • Ensure all cable ends and panel connection points are capped with the provided

covers.

WARNING: IF PROVIDED ELECTICAL CONNECTION CAPS AND PLUGS ARE NOT UTILIZED, POSSIBLE SYSTEM AND COMPONENT FAILURE COULD OCCUR.

Disconnect cables and close covers

Disconnect cables and close covers


T. HOSES

1. Disconnect all “Pressure” and “Return” hoses between the HPU and valve stands. • Ensure all hose quick disconnects are capped and plugged with the attached QD

caps and plugs.

WARNING: IF QD CAPS AND PLUGS ARE NOT UTILIZED, POSSIBLE SYSTEM AND COMPONENT FAILURE COULD OCCUR.

Caps and Plugs MUST

BE USED

Caps and Plugs MUST

BE USED


U. ENCODERS

1. Unbolt, remove and safely store all cylinder cable encoders and FB-6-30 cables.

WARNINGS - DO NOT DROP CABLE ENCODER - DO NOT ALLOW THE SPRING LOADED CABLE TO FREE-SPOOL BACK INTO THE

ENCODER HOUSING. THIS COULD CAUSE PERMANENT DAMAGE TO THE ENCODER AND VOID MANUFACTURER’S WARRANTY.


APPENDIX (A-1) Remote replacement instructions

1. Remove these six screws from back of remote.

2. Carefully remove plug from rear of transmitter allowing front and rear cover to be separated.


3. Choose correct tag set to insert. (See Spec sheet guidelines provided for tag locations) 4. Grab white edges of tag and carefully slide into rear of board until they are completely down

inside of board slot. 5. Repeat until all tags are inserted.


6. Remove 3M backing from board. 7. Align pins through slot on front cover. 8. Affix board to front cover.

9. Connect battery provided with remote.


10. Carefully reattach connector to pins on board.

11. Reattach front cover to rear cover with screws. 12. Finished product should resemble remotes below.

Drill Floor (Spec-1067) Mast (Spec-1068)


13. Associate transmitter with receiver on HPU. a. Switch OFF or DISCONNECT the power to the receiver by turning selector switch on

front of controls panel to “LOCAL” position. b. Disconnect power plug inside of the receiver box opposite the side being re-associated

(This will ensure the proper receiver pairs up with the remote being replaced.) **Remove four plastic retaining screws from front of receiver panel.

**Side NOT being paired with replacement remote


c. Disconnect the power plug from the rear of receiver panel by removing the green plug shown below.


d. Switch ON power to the receiver being paired by returning selector switch to the “Remote” position.

i. This opens a 20 second registration window in the receiver processor. ii. If you are looking at the receiver PCB, the Fault LED flashes.

e. Immediately PRESS and HOLD the transmitter reset button (The Green Button) for a minimum of 10 seconds during this 20 second window.

f. When the transmitter is registered, the “Fault” LED goes and the “Set” LED comes on. g. The Transmitter is now operating the receiver. h. Reconnect the power to the receiver board disconnected in step “C”. Replace screws

removed in step “B”. i. Association is now complete and your replacement remote should be functioning

properly.

** Lodar legend for reference only.


(N-1) Bleeding procedures for Pyramid cylinders – (Instructions provided by Nabors Drilling)

1. MAST RAISING AND LOWERING A. Bleed Rear Mast Articulating Cylinders

1. Open bleed valve while extending cylinder, close bleed valve when solid fluid stream is visible.

2. Retract cylinder. 3. Repeat steps 1 and 2 on the other articulating cylinder.

B. Bleed Front Mast Articulating Cylinder 1. Open bleed valve while extending cylinder, close bleed valve when solid fluid

stream is visible. 2. Retract cylinder. 3. Repeat steps 1 and 2 on the other articulating cylinder.

C. Bleed Mast Cylinder (Final stage double acting; all others single) 1. Using front mast articulating cylinders stand cylinders near vertical. 2. Open bleed valve on stage 4, retract cylinder, close bleed valve when solid fluid

stream is visible. 3. Open bleed valve on stage 5, retract cylinder, close bleed valve when solid fluid stream is visible. 4. Open bleed valve on cylinder barrel, extend cylinder, close bleed valve when solid fluid stream is visible. 5. Open bleed valve on stage 1, extend cylinder, close bleed valve when solid fluid stream is visible. 6. Open bleed valve on stage 2, extend cylinder, close bleed valve when solid fluid stream is visible. 7. Open bleed valve on stage 3, extend cylinder, close bleed valve when solid fluid stream is visible. 8. Repeat steps 1 through 7 on the other mast cylinder.

2. DRILL FLOOR RAISING AND LOWERING

A. Bleed Drill Floor Articulating Cylinders 1. Open bleed valve while extending cylinder, close bleed valve when solid fluid stream is visible. 2. Retract cylinder. 3. Repeat steps 1 and 2 on the other articulating cylinder. B. Bleed Drill Floor Pinning Cylinders 1. Extend and retract cylinders. C. Bleed Drill Floor Cylinders (3rd stage double acting; all others single) 1. Using drill floor articulating cylinders stand cylinders near vertical. 2. Open bleed valve on stage 2, retract cylinder, close bleed valve when solid fluid stream is visible. 3. Open bleed valve on stage 3, retract cylinder, close bleed valve when solid fluid stream is visible. 4. Open bleed valve on cylinder barrel, extend cylinder, close bleed valve when solid fluid stream is visible.

5. Open bleed valve on stage 1, extend cylinder, close bleed valve when solid fluid stream is visible.

Date post:	23-Jan-2016
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Gateway Procedures

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