How to Replace Debooster Seals

How to Replace O-Ring Seals in a 4:1 Debooster

https://www.DrillingInstruments.com
The 1502 4:1 gauge protector debooster (CWDB4X) is fitted with seals that assist the gauge protector in
sensing and transmitting pressure to a hydraulic pressure gauge. When the seals becomes worn or
damaged they will need to be replaced. Using a replacement seal kit (CKT204-1), follow these steps to
replace the seals in your CWDB4X 1502 gauge protector debooster.
Important Safety Notice
Proper service and repair is important to the safe and reliable operation of all Crown Oilfield Instrumentation equipment. The service procedures
recommended by Crown Oilfield Instrumentation and described in the service guide are recommended methods of performing service operations. Some of
these service operations require the use of tools specially designed for their purposes. These special tools should be used when and as recommended.
It is important to note that some warnings against the use of specific service methods stated in the guide can damage the equipment or render them unsafe. It
is also important to understand these warnings are not exclusive. Crown Oilfield Instrumentation could not possibly know, evaluate and advise service
personnel of all conceivable methods in which service might be done or of the possible hazardous consequences which may occur. Accordingly, anyone who
uses service procedures or tools, which are not recommended by Crown Oilfield Instrumentation, must first thoroughly satisfy himself that neither his safety
nor equipment safety will be jeopardized by the method selected.
How to Replace Seals in a 4:1 Debooster

What You Will Need:
1 2 3 4 5 6 7
1. Hex Cross (CJ100-1)
2. Plug with Teflon Tape
3. Check Valve (CC102)
4. Seal Kit (CKT204-1)
5. Debooster
6. Williams Adjustable Spanner Wrench
7. One Inch Socket
8. 5/8” Wrench
8

Step 1
Attach lower sub of debooster to
vice. Using a 5/8” wrench, remove
the brass plug from the hex cross at
the top of the debooster cap.
Brass Plug
Debooster Cap
Hex Cross
Debooster Lower
Sub in Vice.

Step 2
Using a 5/8” crescent wrench,
remove the check valve from hex
cross at the top of the debooster
cap.
Check Valve
Hex Cross Debooster Cap

Step 3
Using a 1” socket, remove the hex
cap.
Hex Cross
Debooster Cap

Step 4
Using a Williams adjustable spanner
wrench, remove the debooster cap.
Spanner wrench fits in debooster cap
hole as shown.
Debooster Cap
Hole
Williams Adjustable
Spanner Wrench in
Debooster Cap Hole

Step 5
Remove the debooster from the vice.
Turn the debooster right-side up,
and remove 1502 hammer union for
debooster housing by lifting the wing
nut over the housing until it is free of
the housing. Hammer union will only
slide one way, over the top of the
housing, not the bottom.
Debooster
Housing without
Cap
Removing 1502
Hammer Union

Step 6
Because the seals are located on the
piston, the piston will need
to be removed from the
housing. With the wing nut
removed, turn the housing
on its side to reveal the bottom
of the housing and piston. Using
your index finger or a small,
rounded backend of screw-
driver, push the piston up until
it can be removed from the top
of the housing.
Bottom of Piston
in Debooster
Housing in
“Down” Position
Pushing Piston up
and out of
Housing
Removing Piston
from Top of
Debooster

Step 7
Once the piston is removed from the
housing, remove old, worn T-seals
and O-ring with dental pick or a
small, pointed tool that will release
them from the designated groove.
With old seals removed, place small
O-ring on bottom of piston in O-ring
groove, then add one T-Seal above
and below the O-ring.
Place Small O-ring
in Groove on Top
of Piston.
Set-up Is T-Seal, O-
Ring, T-Seal.
T-Seal
O-Ring
T-Seal

Step 8
Turn the piston over to the top,
larger side. Place large O-ring seal on
top of the piston in designated
groove, then add one T-Seal above
and below the O-ring.
T-Seal
O-Ring
T-Seal
Place Large O-ring in Groove on Top
of Piston. Then Add T-Seal on Top and
Bottom of O-Ring.
Set-up Is T-Seal, O-
Ring, T-Seal.

Step 9
Using a silicon-based grease, brush
grease on inside of housing and on
upper and lower seals.
Cautio
n
Grease is important to movement of piston
and to keep seals intact during installation.
Failure to add grease could result in seals
being crimped or torn and/or piston seizing or
freezing in place.
Grease
Inside
Housing
Grease Top and
Bottom Seals
Grease Top and
Bottom Seals

Step 10
With new seals in place, slide smaller
side of piston into debooster
housing. Piston should be pushed
into the housing until it fits just
below flush with the housing top.
Piston will be flush with the bottom
of the housing and in the “down”
position prior to
pumping debooster up
with fluid.
Greased Piston
Being Pushed
into Housing
Piston in the Down
Position, Flush with
the Housing Bottom

Step 11
Place last seal on top of piston in
housing. Using extra grease that is
on the top of the housing and piston,
cover seal with grease. Doing to will
protect the seal when the debooster
cap is replaced. Notice the piston is
in the “down” position and just
below flush of the debooster
housing. Largest O-Ring Seal in
Kit CKT204-1
Piston Is in “Down”
Position.

Step 12
Replace hammer union.

Step 13
Replace debooster cap until finger
tight. Use Williams spanner wrench
to tighten. Do not over tighten.
Replacing Debooster
Cap.
Using William’s Spanner Wrench
to Replace Debooster Cap

Step 14
Using 1” socket, replace hex cross on
top of debooster cap. Do not over
tighten.
Debooster Cap.
Replace Hex
Cross.

Step 15
Using a 5/8” wrench, replace the
check valve on the side of the hex
cap. Do not overtighten.
Debooster Cap
Replace Check Valve

Step 16
Using a 5/8” wrench, replace the
brass plug onto top of hex cross at
the top of the debooster cap. Do not
overtighten.
Debooster Cap.
Replace Brass Plug

For any questions not covered in this guide, contact Crown at
Phone: 1-877-908-3790
Email: sales@drillinginstruments.com

How to Replace Debooster Seals

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