Effective Date

05-Feb-13 DW1039
Work Instruction

Page Revision
HPU Charge Field Conversion 1 of 7 A
Procedure

Refer to Hydraulic Schematic 631635 HPU Charge, Field Conversion Kit

PART I: CHARGE CONVERSION

1. Ensure that the HPU is turned off.
2. Remove the 3/4” hoses connecting the ‘J’ port of each P14 pump to the ‘1’ and ‘2’ ports of
the Check Manifold (MF03) See Figure 1 and Figure 2.

KG

Figure 1 - P14 pump Port Identification

3. Remove the 3/4” hoses (highlighted red in Figure 2) connecting the ‘K’ port of each P14
pump to the tee on the ‘K2’ port of the Charge Manifold (MF04).
4. Remove the tee on the ‘K2’ port of the Charge Manifold (MF04) and install the 3/4" ORB
plug (Item 3 in the BOM of 631635-HPU Charge Field Conversion Kit).

Remove 3/4” Hoses Charge Manifold (MF04)

Remove
3/4" Tee
Install 3/4"
ORB Plug

Figure 2 - Charge Manifold Change

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Work Instruction

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HPU Charge Field Conversion 2 of 7 A
Procedure

5. Connect each P14 pump ‘J’ port to its own ‘K’ port using Hose #3 and Hose #4
(highlighted green in Figure 3) as referenced in 631635H-Hose Kit.

NOTE: If the ‘J’ ports of the P14 pumps contain 1/2” MORFS fittings, replace
these fitting with the 3/4” MORFS fittings (Item 6 in the BOM of 631635)

Hose #3

Hose #4

Figure 3 - Installation of Hose #3 and #4

6. Remove the 1-1/4” hose connecting the Check Manifold (MF03) to the Charge Filter
(F02) and remove the Check Manifold.
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05-Feb-13 DW1039
Work Instruction

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HPU Charge Field Conversion 3 of 7 A
Procedure

7. Remove the 1-1/4” tee from the Charge Filter as indicated in Figure 4.

NOTE: Be sure to put the 1-1/4” to 1” reducer aside, as it will be re-used in Step 8.

8. Install the 1” 90° elbow fitting (Item 1 in the BOM of 631635) as indicated in Figure 4.

Charge Filter
Relocate existing Install 1" 90° Elbow
1-1/4 x 1” Reducer
Remove 1-1/4" Tee

Figure 4 - Charge Filter Change

9. Remove all the fittings from the ‘P’ port of the Charge Manifold (MF04) and install the 3/8”
ORB plug (Item 4 in the BOM of 631635).

NOTE: Make sure to put the 3/8” tee aside, as it will be re-used in Step 11.

10. Remove the 3/8” hoses from the ‘P’ ports of the Stroker Manifolds (VP10).
11. Install the Test Point, Adapter, and 3/8” Tee (items 5, 7, and 2 respectively in the BOM of
631635) on each Stroker Manifold (VP10) as illustrated in Figure 5.

3/8” Tee

Stroker Manifold

Adaptor
Test Point

Figure 5 - Stroker Manifold Change

Adapter Test Point

 Effective Date
05-Feb-13 DW1039
Work Instruction

Page Revision
HPU Charge Field Conversion 4 of 7 A
Procedure

12. Remove the existing Test Points from the ‘G’ ports of each P14 pump. See Figure 6.

NOTE: The ‘G’ ports are located on opposite sides of each P14 pump.

13. Install the 3/8” 90° elbow fittings on the ‘G’ ports of each P14 pump.
14. Connect the ‘G’ port of each P14 pump to the ‘P’ port of each Stroker Manifold (VP10)
using Hose #1 and Hose #2 as referenced in 631635H.

Figure 6 - P14 pump 'G' Port Identification

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Work Instruction

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HPU Charge Field Conversion 5 of 7 A
Procedure

PART II: CHARGE SET

1. Fully back out the adjustment screw of the External Charge Relief. See Figure 7 on the
Charge Manifold (MF04).

P14 Internal Charge Relief

Adjusting Internal Relief

External Charge Relief

Figure 7 - Charge Set

2. Install a 0-600 PSI pressure gauge on the “KG” port of each P14 pump. See Figure 1.
3. Remove both P14 Internal Charge Relief screws, and move their adjustment nuts to
approximately 0.100” from the end of the screw. See Figure 8.

Figure 8 - Internal Charge Relief Adjustment Setting

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05-Feb-13 DW1039
Work Instruction

Page Revision
HPU Charge Field Conversion 6 of 7 A
Procedure

4. Replace both Charge Relief screws.

5. Start the engine and allow it reach operating temperature.
6. Set the “TOP DRIVE” switch on the Operator’s Console to “ENABLE”, causing the engine
to speed up to working RPM.
7. Check that each 0-600 PSI gauge reads 300 ± 20 PSI. If required, remove and adjust the
P14 Internal Charge Relief.
8. Turn in the External Charge Relief until the "CHARGE" pressure gauge in the HPU
Gauge Panel reads 250 ± 10 PSI.
9. Lock the adjustment nut of the External Charge Relief.
10. Turn off the engine.
11. Ensure the 2” Forward and Reverse Closed Loop lines are connected to the Top Drive.
12. Fully back out the Balanced Poppet Valve, yielding a 200 PSI differential shuttle
activation. See Figure 9.

Hot Oil Shuttle Relief

Balanced Poppet Valve

Figure 9 - Hot Oil Shuttle

13. Start the engine and set the “TOP DRIVE” switch on the Operator’s Console to
“ENABLE,” the “SPEED RANGE” to “HIGH,” and the “DRILL THROTTLE” dial to
approximately 25% of “MAX”.
14. Confirm the “FORWARD” pressure gauge in the HPU Gauge Panel reads at least 200
PSI greater than the “REVERSE” pressure gauge. If not, increase the throttle.
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Work Instruction

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HPU Charge Field Conversion 7 of 7 A
Procedure

15. On the HPU Control Panel enter the “Diagnostic Screen Selection” menu, then select
“HPU Data” so that the “Hot Oil Shuttle Flow” rate may be monitored. See Figure 10.

Figure 10 - HPU Data Screen

16. Adjust the Hot Oil Shuttle Relief Valve until 70 GPM Hot Oil Shuttle flow rate is reached.

NOTE: The display will max out at 60 GPM for Hot Oil Shuttle flow, so monitor
what the Charge Relief flow is when the Hot Oil Shuttle flow reaches
60 GPM then continue adjusting until the Charge Relief flow
decreases by an additional 10 GPM.

17. Check the “HOT OIL SHUTTLE” pressure on the HPU Gauge Panel. It should read
approximately 150 PSI.