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1. GE 4 5 ____ 49 PARTIN MAINTENANCE vr 50 Aol LUBRICATION de _____ _ EE ERA 50 IRE NPN CAFO 5 5 45 55 5 5 E 50 4 1 2 GENERAL ADVICE ON LUBRICATION eene 50 RESEPT m m 51 4 1 5 LUBRICATION POINT e E 56 PART MN VING 57 PETN TEN 59 STEN T 59 TINN 59 TLAS EMBLY NN 60 MIT 60 TOPPENE _ gt ____________ 6_______ _ 61 APPENDIX A OVERALL DIMENSIONS Luse o teda Mg aret ved UR ERN 61 APPENDIX B HYDRAULIC SYSTEM sedlene 61 bg SPARTA Designing Solutions MANUFACTURING 702 1 Ave NW Linden AB Ph 403 546 3851 NOME Fax 403 546 2486 APPENDIX C ELECTRICAL vvs 61 APPENDIX D PIPING SANN 61 APPENDIX Ec PLUNGER PUMP NN 61 APPENDIX F CHARGER PUMP BOWIE PUMP sscosscteieouscucnsnsncteiusynctbeaosackeiubasonanansnctieiubyeetaeansocieiubaenenaesscuea 61 ING m T 61 APPENDIX E CHELEAA PTO NN nS 61 APPENDIX ERR Er 61 MANUFACTURING SPARTA Designing Solutions st 702 1 Ave NW Linden AB Ph 403 546 3851 TOM 1JO Fax 403 546 2486 PART I INTRODUCTION AND SPECIFICATIONS 1 1 USE OF THIS MANUAL This manual contains information for operation maintenance and troubleshooting Every effort was made to ensure accurate and complete information but it is not guaranteed If a situation of doubt or uncertainty a
2. 6 SPARTA Designing Solutions SPARTA ENGININEERING S This is a sample manual and includes the first 22 pages of the official SPARTA Pump Truck Manual The complete 61 page manual will be available from SPARTA after purchasing a unit MANUFACTURING st 702 1 Ave NW Linden AB Ph 403 546 3851 TOM 1JO Fax 403 546 2486 SPARTA Designing Solutions HYDRAULIC PUMP PARTS AND SERVICE MANUAL REVISIONS Person _________ 80 Gaby Ulloa Changes To manual 22 04 14 MANUFACTURING SPARTA Designing Solutions 702 1 Ave NW Linden AB Ph 403 546 3851 TOM 1J0 Fax 403 546 2486 Table of Contents PART I INTRODUCTION AND SPECIFICATIONS cccccccsccssccseceeccsecesecseeesccsecesececeecsaeeescseseeeeseceeesseeeeeeaes 5 EV EO TARN 5 1 11 REVISIONS AND AMENDMENTS Lassen 5 1 1 2 THIRD PATIENTS 5 LES DNEPR 5 PERES GE EEE ENE 5 ESTEN NVA 7 Lo UNITS PE MENN O E 8 13 1 TRIPLEX PLUNGER PUM 8 Et NN 8 1 33 BOWIE PUMP PN 9 LT NNN 10 EG GS EE ENE 11 TSN 12 TN 13 L3SBAITERYI REE EEE EE ENE 14 ES ERT ENN 14 1 35 10 TOOLBOX AND STORAGE c 14 13 11 MISCELLANEOUS ACCESSORIES aker 14 BPO PO C do RE EE EE 15 1 5 GENERAL DIMENSIONS 7 WEIGHT ___ __6 6____ 16 PART NT OP 3 24809 rr M m 17 TVETEN 17
3. All our products have full engineering support so if you don t see the exact specifications you are after we will design to meet your needs We utilize the 3D CAD software SolidWorks to model up our equipment before production We also have full finite element analysis capabilities to quickly and efficiently analyze and optimize design changes Let Us Design Your Next Pump Truck or Rig Jason is a partner and VP of Operations at Sparta Engineeringg located in Linden AB and has been designing and managing the manufacturing of various oil field equipment rangingdr m period one double service rigs down to hole tools 2005 Jason has a particular passion for optimizing design f r manufacturing He also specializes in various crane related activities including subframe design crane deck design load and stability testing and acting stamp engineer for Global Crane Inspection Connect with Jason on Linkedln or send Jason a note Jason Thompson P Eng jason spartaengineering com Office 587 315 0344 Ext 101 www spartaengineering com
4. G for more information 13 a MANUFACTURING SPARTA Designing Solutions st 702 1 Ave NW Linden AB Ph 403 546 3851 TOM 1JO Fax 403 546 2486 1 3 8 BATTERY BOX The battery box is mounted ahead of the fuel tank on the passenger side 1 3 9 ELECTRICAL SYSTEM A Pumptruck i Double fluorescent lighting over the truck on top of the headache rack Jackson Power RL 243 li Double fluorescent lighting over the manifold on top of the hydraulic tank B Mudtank i Jackson Power RL 483 is mounted on the side of the cabinet 4 switches 4 receptacles 30 Amp 120 V AC 1 3 10 TOOLBOX AND STORAGE e Underbody toolbox is installed behind the fuel tank on the driver passenger side of the truck e Cabinet is located under the control console e Pipe bin on the side of the mud tank 1 3 11 MISCELLANEOUS ACCESSORIES e wo sets of sliding chain racks were installed under the deck between the outriggers and the center kicker One set installed on each side of the truck e cord rack was mounted next to the control console 14 BI MANUFACTURING SPARTA Solutions 702 1 Ave NW Linden AB Ph 403 546 3851 TOM 1JO Fax 403 546 2486 1 4 PHOTOGRAPHS Figure 1 4 1 Front Driver view Pump Figure 2 Back Passenger view 15 bg SPARTA Designing Solutions x df MANUFACTURING st 702 1 Ave NW Linden AB Ph 403 546 3851 TOM 1JO Fax 403 546 2486 1 5 GENERAL DIMENSIO
5. The vehicle is equipped with ABS brakes 20 SPARTA Designing Solutions MANUFACTURING st 702 1 Ave NW Linden AB Ph 403 546 3851 TOM 1JO Fax 403 546 2486 2 4 PUMP TRUCK MAJOR COMPONENTS Pump Truck Major Components Pump Truck Control Console Electrical Box Triplex Plunger Pump Winch Center Kicker Charge Pump Bowie Pump Manifold Live Roller Tow Pin O I eee 21 bg SPARTA Designing Solutions MANUFACTURING st 702 1 Ave NW Linden Ph 403 546 3851 TOM 1JO Fax 403 546 2486 2 5 PUMP TRUCK CONTROLS AND INSTRUMENTATION 2 5 1 CONTROL CONSOLE TT FLOW 1 I 2 TEMP MC II FLOW ANALYZER HYDRA HYDRA TEMP __TRE PLEX TEMP EMERG KILL LATE BP CHARGE PUMP ON OFF gt Figure 2 5 1 Control console Pump Truck Pump Truck Control Console 1 Hydraulic Pressure Gauge 2 Hydraulic Temperature Gauge 3 Triplex Temperature Gauge 4 Triplex Pressure Gauge 5 Emergency Kill 6 Charge Pump Switch 7 Horn 8 Transmission Control 9 Throttle 10 Flow Analyzer Console 22 amp SPARTA Designing Solutions Thanks for having a look at the SNEAK PEAK of our Pump Truck Manual The complete 61 page manual is available after purchasing a unit and includes schematics and much more information Don t See Exactly What You Are After
6. 37 9 MPa 5 500 psi e Maximum Flow 10 6 bpm e Weight 4 800 Ibs NOTE Refer to APPENDIX E for more information 1 3 2 MANIFOLD The manifold is a seven valve 5000 psi assembly connected with assorted pipe fittings and unions The components installed are listed below e Seven 50 mm x 34 4 MPa 2 x 5000 psi gate valve e One 76mm x 1 6 MPa 3 x 230 psi wafer style butterfly valve w handle e One 50 x 34 4 MPa 2 x 5000 psi relief valve e One 50mm x 34 4 MPa 2 x 5000 psi swing check valve e One 50mm x 41 3 MPa 2 x 6000 psi Type D mud gauge NOTE Refer to APPENDIX D for more information bg SPARTA Designing Solutions MANUFACTURING 702 1 Ave NW Linden AB TOM 1JO 1 3 3 BOWIE PUMP Charge Pump The pump truck is equipped with a 300 Series Rotary Pump Model 4300 STDH Ph 403 546 3851 Fax 403 546 2486 e Max Speed 400 RPM e Pressure 827 kPa 120 psi e Flow 1 25 m3 min 330 gal min NOTE Refer to APPENDIX F for more information a MANUFACTURING SPARTA Designing Solutions st 702 1 Ave NW Linden AB Ph 403 546 3851 TOM 1JO Fax 403 546 2486 1 3 4 Hydraulic Motor The pump truck is equipped with a Sauer Danfoss 151F2202 hydraulic orbit motor specifications are included below Motor type OMS 125 Geometric displacement in 600 Max Speed int Max Torque int 3300 2 20 0 4400 Max starting pressure wit
7. BI Manufacturing will assign the benefits of any manufacturer s warranty if possible e Equipment or parts that have come into contact with corrosive chemicals or materials e Equipment or parts customarily subjected to wear e Equipment or parts damaged due to improper use or inadequate maintenance CBI Manufacturing will not assume Liability or warranty for any death or injury caused to either directly or indirectly by this equipment to any person This includes the Purchaser and its employees as when as any agents or contractors of the Purchaser As well there is no direct or indirect coverage of any claim for damage or loss of property business which is caused or contributed to by the Equipment or any failure thereof regardless of whether directly or indirectly caused by CBI Manufacturing or by any default or negligence of CBI Manufacturing and its personnel agents or contractors a MANUFACTURING SPARTA Designing Solutions st 702 1 Ave NW Linden AB Ph 403 546 3851 TOM 1JO Fax 403 546 2486 1 3 UNIT SPECIFICATIONS 1 3 1 TRIPLEX PLUNGER PUMP The pump truck is integrated with an SJ300 Plunger Pump The SJ300 is a single acting triplex pump and the specifications are included below e Stroke 127 mm 5 in e Maximum Main shaft Speed 360 RPM e Maximum Pinion Shaft Speed 1555 RPM e Maximum Rod Load 110 000 lbs e Rated Hydraulic Horsepower 300 hp e Maximum Hydraulic Horsepower 350 hp e Maximum Pressure
8. NS WEIGHT Please look at Appendix A for general dimensions for the Pumptruck 6925 kg 15 267 lbs 16 a MANUFACTURING SPARTA Designing Solutions st 702 1 Ave NW Linden AB Ph 403 546 3851 TOM 1JO Fax 403 546 2486 PART II UNIT OPERATION 2 1 USE OF THIS INFORMATION The operating procedure outlined in this manual is meant only as a guideline for truck operation Because each application of this unit will be unique it is left to the operator and or owner of the equipment to establish an operating procedure for this equipment This procedure must adhere to American Petroleum Institute Standards or equivalent and applicable regulations in the region of operation The truck has been designed to function reliably in a wide range of conditions By following an effective preventative maintenance program having properly trained operators and treating the equipment with respect will reduce unnecessary equipment wear The maintenance program as well as the fluids and lubricants should reflect the climate and operating conditions of the truck The manual is intended only for the equipment supplied by CBI Manufacturing 2 2 SAFETY Although this equipment has been designed to minimize personnel hazards safe and proper operation of this truck is the responsibility of the Operating Company The following set of safety precautions along with the Operating Company s Safety Policies and Procedures must first
9. be read and understood by any and all personnel before they operate or perform maintenance on this unit 2 2 1 SAFETY PRECAUTIONS The operating conditions of each different job are unique and therefore must be assessed on an individual basis to minimize equipment damage and personnel hazards Before starting each job have a pre job discussion to ensure that employees are aware of their individual responsibilities as well as the hazards of the particular job site Have a briefing of the proper safety precautions and procedures that are to be followed This truck has a complex control system and only trained personnel should operate it 17 a MANUFACTURING SPARTA Designing Solutions st 702 1 Ave NW Linden AB Ph 403 546 3851 TOM 1JO Fax 403 546 2486 2 2 2 CONTROL LOCKOUTS To prevent injury due to unintentional operation of the equipment the controls are to be locked out during repair or maintenance procedures 2 2 3 ELECTRICAL CONNECTIONS Be certain to disconnect power to any electric cabling when it is being connected or disconnected 2 2 4 PRESSURIZED FLUIDS This truck has piping and hoses that contain pressurized fluids Proper safety precautions are required when working around these components 2 2 5 WARNING DEVICES The vehicle s back up alarm is the only warning device to alert personnel that the equipment is about to move It is recommended that procedures be developed by the operator owner for preve
10. eases M eH IM itm nM MEME M E een 17 2 21 SAFETY PRECAUTION T 17 22 2 CONTROL LOCKOUT jr 18 ELECTRICAL CONNECTION S 5 5 O AE 18 2 2 A PRESSURIZED FLUIDS cairo theo 18 2 29 WARNING DEVIC ES E 18 a MANUFACTURING SPARTA Designing Solutions 702 1 Ave NW Linden AB Ph 403 546 3851 TOM 110 Fax 403 546 2486 Do WING TAF ONTT C 19 2 4 PUMP TRUCK MAJOR COMPONENTS eaeseenernnnnnnnnssennsrnnnnnnnnevennssnnnnnnnnnsennssnnnnnnnnssenessnnnnnnnnssenessnnnnnnne 21 2 5 PUMP TRUCK CONTROLS AND 22 PASMERSIU NN SNC LS c 22 ZO SETUP PROCEDURE c _ _ ____ 23 2 6 1 PRE ARRIVAL TASKS FOR THE PUMP TRUCK AND TANK eese 23 2 6 2 UNLOADING THE 23 2563 MANIFOLD USAGE c M 28 2 6 3 1 LINE PIPE AND HIGH PRESSURE HOSE SETUP 28 NPE _ _4____6_6_6_6____________ e 30 ex PUMP STARTUP PROCEDURES 31 2 9 PUMP SHUTDOWN PROCEDURES vvs send 34 2 _ _ ___ ____ 35 PARTI HANDRAIL STORAGE 2 05 55 8 5 _ _ _____ 49
11. for the period of TWELVE 12 months starting from the Date of Delivery CBI Manufacturing also reserves the right to inspect the Equipment to determine the validity of the warranty prior to repairs If the warranty remains valid CBI Manufacturing will at its option 1 Replace the defective Equipment or part thereof 2 Authorize the return of the Equipment or part to be repaired at an authorized repair facility or 3 Authorize the repair of the Equipment or part at your own facility CBI Manufacturing will not be accountable for transportation costs Repair or replacement of the Equipment or parts will be done without charge Removal and installation of other parts including additional parts furnished will be made at the Purchaser s expense No charges will be accepted on returns repairs or modifications made by the Purchaser without the written consent of CBI Manufacturing It is accepted by the Purchaser that all design specifications for the Equipment have been met or surpassed and that no other warrantees of any form are in effect other than stated herein This includes any warranties of fitness for a particular use or merchantability which CBI Manufacturing hereby disclaims The Purchaser is to pay for all charges for travel time kilometer charges and travel expenses for warranty work performed away from CBI Manufacturing s fabrication facility NOT COVERED UNDER THIS WARRANTY e Equipment or parts manufactured by others But C
12. h 403 546 3851 Fax 403 546 2486 The hydraulic system is equipped with the following equipment e One Chelsea Hydraulics 859 Series Power Take Off One Spicer 792 e A Two stage hydraulic pump assembly to operate the lube pump winch and charge pump orbit motor e One 190 liter 50 gallon hydraulic tank e Flow meter refer to APPENDIX for more information e Flow Sensor Refer to APPENDIX L for more information e Kicker Air bags e Pressure relief NOTE Refer to APPENDIX B for more information on the hydraulic schematics 12 bg SPARTA Designing Solutions MANUFACTURING st 702 1 Ave NW Linden AB Ph 403 546 3851 TOM 10 Fax 403 546 2486 1 3 7 WINCH The pump truck is equipped with a H34 SLRFODX Tulsa Winch The specifications are as follows Recommended 74 x 75ft Safety Splice AMOUNT OIL TYPE GEARBOX SECTION 3 00 QTS SEE CHART BELOW BRAKE SECTION TO LEVEL LIGHTWEIGHT NON EP SAE 20W AUTOMATIC TRANSMISSION FLUID OR MOST HYDRAULIC OILS PREVAILING AMBIENT TEMPERATURE 40 30 20 10 0 10 20 30 40 50 60 70 80 90 100 110 120 130 F DUE RR UR UE ERREUR E eee S Pu RS LUE E RO Are MOBILUBE HD80WI14O X XX x X X X X X XX GH AJ 10 g 20 30 4C 30 C All oils must meet MIL PRF2105E standards Substitution from a reputable manufacturer is allowed as long as type and grade are maintained NOTE Refer to APPENDIX
13. h unloaded shaft psi in lbs at max Press Drop cont at max Press Drop int 2700 Min speed 8 Port Size 10 SAE Mount Flange 4 Bolt Shaft 1 25 Min starting torque 1 Intermittent operation the permissible values may occur for max 10 of every minute 2 Peak load the permissible values may occur for max 1 of every minute NOTE Refer to APPENDIX J for more information 10 x df MANUFACTURING 702 1 Ave NW Linden AB TOM 1JO 1 3 5 TRANSFERCASE The Transfercase is the Spicer 792 Specifications 792 Model Number Construction Remote Mount 792 1M 2 M4 Basic Model T Upper Rear Output See flange listing below 0 thru 9 P X Y N Upper Rear Output Shifter options M Manual Shift with switch E Air Shift with switch Lower Rear Output L Less Shifter See flange listing to right 0 thru 9 P X Y N Lower Rear Output Shifter options M Manual Shift with switch E Air Shift with switch L Less Shifter LL Forced Lube F CW Forced Lube G CCW Upper Front Output See flange listing to right 0 thru 9 P X Y Lower Front Output Shifter options M Manual Shift with switch E Air Shift with switch Lower Front Output flange listing to right 0 thru 9 P X Y NOTE Refer to APPENDIX 1 for more information OPTIONAL PTO FABCO 170 Specifications All ratings nominal Actual capacities determined based u
14. nting the equipment from being engaged at an unsafe time 18 bg SPARTA Designing Solutions MANUFACTURING st 702 1 Ave NW Linden AB Ph 403 546 3851 TOM 1JO Fax 403 546 2486 2 3 DRIVING THE UNIT It is up to the owner and or operator of this unit to develop proper driving and operation procedures that conform to regional law regulations and conditions In order to drive this truck the operator should have all of the necessary training as well as an understanding of all of the mechanical aspects of the unit s operation oome general guidelines associated with driving this truck are e Because of the unit s long wheelbase it has a wide turning radius and requires someone on the ground to guide the driver in confined areas e When the Mud Tank is being transported on the pumptruck the pumptruck top is heavy Extra CAUTION is needed in order to prevent roll over e When stuck the unit should be pulled out rather than trying to drive out as the vehicle has sufficient power to damage its drive train in such a case Rated tow points provided Look at the following picture for towing points 19 bg SPARTA Designing Solutions MANUFACTURING st 702 1 Ave NW Linden AB Ph 403 546 3851 TOM 1JO Fax 403 546 2486 e When driving the unit seatbelts must be worn at all times e Monitor the truck s gauges closely to ensure everything is running properly and to avoid mechanical failure
15. pon review of application by FABCO Engineering NOTE Refer to APPENDIX H for more information Ratings Nominal Output Torque filter Output Torque Rear Axle Input Horsepower Input Speed Ratio Gear Type Helical Case Hardened bg SPARTA Designing Solutions Ph 403 546 3851 Fax 403 546 2486 Flange and End Yoke Listing N No output Blanked off P z No flange output Paper sleeve 0 5 1 2541 1610 Series Flange 1 5 1 4641X 1610 Series Flange with Slinger 2 6 1 1731 1710 Series Flange 3 6 1 4091X 1710 Series Flange with Slinger 4 6 5 1 481 1810 Series Flange 5 6 5 1 1471X 1810 Series Flange with Slinger 6 6 4 3031 1710 End Yoke 7 6 4 3461X 1710 End Yoke with Slinger 8 6 5 4 1971 1810 End Yoke 9 6 5 4 2831X 1810 End Yoke with Slinger X 5 4 4751X 1610 End Yoke with Slinger Y 6 1 1481 1710 Series Flange NOTE CW Input Pump 378889 1 F CCW Input Pump 378853 1 G 10 000 Lb Ft 15 000 Lb Ft 350 HP 2 600 RPM 1 1 Gear Type Helical Case Hardened 2 50 Inch 10 Parallel Input and Rear Axle Output Spline Shaft Spacing Drop Shift Mechanism Bearings Housing Lubrication Lubricant Oil Capacity Weight Dry Lubrication Pump amp Spin on Filter SAE 50 or SAE 90 6 50 Quarts 400 Lb 11 bg SPARTA Designing Solutions MANUFACTURING 702 1 Ave NW Linden AB TOM 1JO 1 3 6 HYDRAULIC SYSTEM P
16. rises please consult the Engineering and or Service Department at CBI Manufacturing 1 1 1 REVISIONS AND AMENDMENTS Manufacturers constantly aim to improve their products and ultimately their design will change resulting in amendments or revisions of manuals When this occurs relevant pages or documents shall be delivered to each manual holder for update by inserting the pages or documents in the correct location and by noting the revision or amendment in the Revisions and Amendment page at the front of this manual 1 1 2 THIRD PARTY INFORMATION his manual encloses information of components manufactured or provided by other companies This information is included to aid identification operation maintenance and service of the equipment CBI Manufacturing does not guarantee the accuracy or completeness of this information Additional information may be found by contacting the Engineering and or Service Department at CBI Manufacturing 1 1 3 MODIFICATION OR REPAIR Please do not modify or repair this equipment without consultation with the Engineering and or Service Department at Manufacturing 1 1 4 SAFETY SUMMARY This manual uses the following standard safety terms and conventions which span all areas of industry A WARNING A Warning is used when an operating procedure practice etc which if not correctly implemented could result in personnel injury and or and equipment damage a MANUFACTURING SPARTA Designing Solu
17. tions st 702 1 Ave NW Linden AB Ph 403 546 3851 TOM 1JO Fax 403 546 2486 CAUTION A Caution is used when an operating procedure practice etc which if not correctly implemented could result in equipment damage NOTE A Note provides information necessary to properly complete a procedure or information which will make the procedure easier to understand Only qualified personnel should be allowed to operate and maintain the equipment Personnel should not operate the unit unless they are thoroughly familiar with all unit operating controls functions and have read the equipment manual Do not attempt equipment operation with inadequate visibility suitable lighting provisions are available Operating and maintenance personnel should wear suitable protective clothing and equipment Promote good safety measures at all times around the equipment throughout all operating phases It is the equipment owner s operator s responsibility to establish good safety measures including personnel training and enforce safety practices Before performing maintenance on or disconnecting any electrical connections ensuring electrical power is locked out before attempting maintenance MANUFACTURING SPARTA Designing Solutions st 702 1 Ave NW Linden AB Ph 403 546 3851 TOM 1JO Fax 403 546 2486 1 2 STATEMENT OF WARRANTY CBI Manufacturing warrants the Equipment to be free from defects in material and workmanship

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