ECD-0090 10-2001 REV 2

high pressure fuel injection

TM

HYDRAULIC SUPPORT SYSTEM MANUAL

Contact Information
CONT ACTING ENGINUITY CONTA
For replacement parts and service: Enginuity LLC 2643 Midpoint Dr., Suite A Fort Collins, Colorado 80525 Phone: (970) 224-0170 Fax: (970) 224-0171 or e-mail us at service@enginuityinc.com visit us at www.enginuityinc.com

SP ARE & REPL ACEMENT P AR TS SPARE REPLA PAR ARTS

Enginuity strives to maintain the best quality product available to the consumer. The individual components used in the HPFi have been carefully matched to provide optimum performance across all operating ranges. Use of components other than those specified by Enginuity LLC can result in degraded system performance and/or system failure. If you should have trouble with a component of the system, please see the specific portion of this manual for a description of how to send that component back to Enginuity LLC for repair or replacement. In the interest of minimizing downtime on your system Enginuity LLC advises stocking spare parts for the system on hand. Please contact Enginuity LLC for a list of recommended spare parts for your system.

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Table of Contents
System Specific ations Specifica Introductions Gener al Informa tion General Information Inst alla tion Installa allation Hydraulic Oil Supply Headers Hydraulic Oil Return Headers Gas/Oil Return Headers Branch Hoses Header Support and Mounting Hydraulic Header Bypass Valves Hydarulic Oil Gas/Oil Seperator Visual Gas Leak Indicator Hydraulic System Vent Engine Mounted Hydraulic Skid Hydraulic Oil Lever Sensor Oil Heater Hydraulic Oil Pump Auxiliary Hydraulic Oil Pump System St ar t Up Star art Filling the Reservoir Filling the Main Hydraulic Pump Line Flushing and Oil Pre-Filtering Setting System Operating Pressure Filling Visual Leak Indicator with Oil Hydraulic Oil Lever Sensor Cycling HPiVs 4 6 7 9 9 9 9 9 9 10 10 10 11 11 12 12 14 14 16 18 18 18 18 19 19 20 20

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Table of Contents
OPER ATION AND MAINTENANCE OPERA General System Reservoir Oil Level Changing Hydraulic Oil Adjusting the Oil Pressure Control Setting Engine Driven Hydraulic Pump Hydraulic Oil Return Line Gas/Oil Return Line Visual Leak Indicator Identifying Leaking HPiV Gas Seals Gas/Oil Separator Bypass Valves Engine Mounted Hydraulic Skid Hydraulic Return Filter Hydraulic Oil Supply Strainer Auxiliary Hydraulic Pump Oil Return Pressure Relief Valve Oil Return Filter Maintenance Schedule Troubleshooting Guide Main Engineering F igures Figures Overall System Schematic Hydraulic Infrastructure Schematic Engine Mounted hydraulic Skid Component Identification Main Pump and adapters (Exploded View) Visual Leak Indicator (Exploded View) Engine Mounted Hydraulic Skid Schematic Hydraulic Control Block Port Identification Hydraulic Control Block (Exploded View) 6 7 13 14 23 25 26 27 21 21 21 21 21 22 22 22 22 23 24 24 25 25 28 28 28 28 30 31

Page 3

System Specifications
Gener al Configur ation General Configura
Number of Power Cylinders Speed Range 5-20 220-500 rpm

Fuel Gas R equirements Requirements

Acceptable LHV Range Specific Gravity Operating Temperature Operating Pressure (nominal) Minimum Operating Pressure (<5% duty cycle) Particulate H2S Tolerance 850-1200 BTU/SCF 0.55-0.65 50-75F (10-24C) 480-520 psig 350 psig < 5 micron < 7 grains/BTU

Hydr aulic Suppor t System Hydraulic Support

Supply Pressure Return pressure Reservoir Pressure Pressure Relief Setting Reservoir Capacity Oil Temperature Minimum Starting Permissive Operating Main Pump (engine driven) HPiV Connections Supply Return Gas/Oil Return Fuel Gas Engine Mounted Hydraulic Skid Connections Supply Header Return Header Pump Discharge Pump Suction Shop Air (Maintenance Pump) Engine Driven Pump Connections Suction Discharge 750-850 psig 605 psig Vented to Atmosphere 1000 psig 8.5 U.S. Gallons SAE 10W per SAEJ300 40F (5C) 90-120F (3250C) Vickers PVQ32

-8 SAE/JIC 37 (3/4-16) -6 SAE/JIC 37 (9/16-18) -4 SAE/JIC 37 (7/16-20)

-8 SAE O-Ring (3/4-16 UNF)

-12 Female SAE O-Ring (1 1/16-12 UNC) -12 Female SAE O-Ring (1 1/16-12 UNC) -8 SAE/JIC 37 (3/4-16) 1 Female NPT 1/4 Female NPT

Case Vent

-20 Female SAE/JIC 37 (1 5/8-12) -20 Female SAE/JIC 37 (1 5/8-12) -8 Female SAE/JIC 37 (3/4-16)

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System Specifications
Electric al Electrical
EHV Cable Length Size Temperature Insulation 72 inches 16 AWG 221F (105C) PVC

In-Pulse+
Power

90-140VDC (110VDC Nominal) 300 Watts Nominal Source capable of providing 17amps for 2 milliseconds without dropping below 90VDC. -40 - 185F (-40 - 85C) -40 - 158F (-40 - 70C) 95% Non-condensing 4-20mA @ 250 ohms or 1-5 VDC @ 10 ohms 4-20mA @ 600 ohms max. or 20-160mA@ 50 ohms max. RS232, RS422, or RS485

Environment Temperature (Storage) Temperature (Operating) Relative Humidity Analog Input Channels (2)

Analog Output Channel Serial Communications Ports (2) Other Communication Ports

LON Network 21VDC nominal @ 3mA; 75VDC nominal @ 3mA; 110VDC @ 3mA 0.6 amp @115 VAC breaking; 4 amp @ 28 VDC breaking UL, CSA, Class 1, Division 2, Groups A, B, C, D

Discrete Inputs (2) Discrete Outputs (2)

Classification

Page 5

Introduction
HPFi is an electronically controlled, high-pressure fuel injection system that combines proven control components aimed at meeting stringent operating, performance, and emissions reduction requirements. HPFi eliminates many of the characteristic problems of direct injected, large-bore, natural gas-fired engines. reducing maintenance. The HPFi system maximizes the use of existing commercially available hardware including the Woodward Inpulse+, and EHV. These components were developed for OEM applications within the large and mediumbore engine industry. All components used in the HPFi With HPFi , poor air/fuel mixing and unbalanced fuel system are designed for long life in the pipeline-operatmetering between power cylinders are things of the past. ing environment throughout a wide range of applications. HPFi generates a high degree of air/fuel mixing via the energy of a high-pressure jet. Add to this energy precision control of the fuel gas injection event and you HPFi is another example of Technology that get an optimally mixed air/fuel charge that produces com- Works . bustion performance and emission characteristics equivalent to state-of-the-art IC engines. The commercial availability of HPFi is the result of Enginuity LLC commitment to turn advanced technology into applied solutions. Enginuity LLC has worked with key suppliers, including Woodward Industrial Controls, to bring to the industrial market a state-of-the-art system that provides a cost effective strategy for upgrading existing engines while improving operability and

Gener al HPF i system functional schema tic. Grey components are optional and General HPFi schematic. ude in all systems. Please refer to inst alla tion specific document ainclude installa allation documentanot incl tion to determine which options ha ve been inst alled. have installed.

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General Information

Schematic of the HPFi hydraulic infrastructure on a typical 10-cylinder integral compressor engine. Dashed box indicates the Hydraulic Control Block that is located on the engine mounted Hydraulic Skid. Please refer to the Operation & Maintenance section (page 27) of this manual for additional information.

The injection valve actuator used in the HPFi system are a hybrid electro-hydraulic valve (EHV). The combination of electric and hydraulic actuation provides the flexible, precise control of electronic actuation and the speed and power of hydraulics. Hydraulic power for HPFi is provided by an integrated, engine mounted hydraulic infrastructure. Electro-hydraulic actuation allows for the precise control of the fuel injection event with the large fuel valves used in industrial engines. This precise control gives HPFi its outstanding performance characteristics. The INPULSE+ electronic fuel injection driver and the injection valves perform the governing function, thereby allowing for the removal of the traditional governor. HPFi makes use of the available governor drive pad by installing a low volume hydraulic pump in place of the traditional mechanical governor. The pump provides hydraulic fluid, at the necessary pressure and flow, to the injection valve actuators. The hydraulic system is comprised of two major sections, the Engine Mounted Hydraulic Skid which controls the overall hydraulic system operation and the hydraulic distribution system which distributes hydraulic oil to each HPiV.

Engine Mounted Hydr aulic Skid Hydraulic The engine mounted hydraulic system is supported with an engine mounted hydraulic skid designed specifically for the HPFi system. The Engine Mounted Hydraulic Skid provides multiple functions within the HPFi system: Hydraulic oil reservoir Hydraulic oil filtration Filter maintenance by-pass Pressure regulation (internal to pump) Pressure relief Hydraulic oil level sensing Hydraulic oil routing between engine headers and pump. Hydraulic Maintenance Pump Hydraulic oil heating (optional)

Hydr aulic Distribution Hydraulic Hydraulic fluid is distributed to each of the injection valves via stainless steel headers routed such that routine engine maintenance is not impeded.

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General Information
Three hydraulic headers are used in the hydraulic support system: Hydraulic oil supply header Hydraulic oil return header Gas/ Oil return line Oil Hea ter (Optional) Heater In cold weather and/or exposed applications circulating and heating the hydraulic oil before attempting to start the engine is recommended when the hydraulic oil temperature is below 40F (5C) . Oil temperature above 40 F is satisfactory of engine starting, but oil operating temperature of 90 to 120 F (32 C) is recommended to achieve optimal performance of the HPFi system. A submersible heater sized specifically for use in the HPFisystem is available from Enginuity and can be retrofitted to the system at any time. Fuel Gas L eak Indic ation Leak Indica A visual gas leak indicator is incorporated into the HPFi hydraulic system to provide a visual indication of fuel gas leakage from the HPiV. The visual gas leak indicator is installed vertically in close proximity to the engine and within sight of the operating floor. The visual leak indicator is designed for service specifically in the HPFisystem without fouling from oil residue present in the vent stream. Hydr aulic F il tr ation Hydraulic Fil iltr tra The HPFi hydraulic support system is equipped with several levels of filtration to ensure trouble free operation of the system. Hydraulic oil is filtered to 10 micron to ensure that debris, moisture, and sediment are removed continuously during operation. A 140 micron strainer is located on the discharge of the hydraulic pumps to prevent debris from entering the system in the event of a catastrophic pump failure.

The hydraulic oil supply header carries oil at a nominal 800 psig to the individual HPiV where it provides the force required to actuate the valve. The hydraulic oil return header carries oil back to the hydraulic reservoir at a nominal 60 psig. A gas/oil return line is attached to the EHV adapter plate on each HPiV. This line carries small amounts of hydraulic oil, and any fuel gas that has migrated past the internal valve seals, to the gas/oil separator. The separator returns the hydraulic oil to the reservoir and directs the fuel gas through the visual leak indicator and into an appropriate vent system. This feature of the HPiV eliminates fuel gas leakage at the HPiV and prevents hydraulic oil from entering the combustion chamber. Purging Hydr aulic Lines Hydraulic Purge valves are installed between the oil supply and return headers at points farthest from the oil pump. These valves are kept closed normal operation, but can be used to temporarily short circuit the oil supply and return lines. This is helpful before engine starting, in removing contamination and air entrapped in the supply and return lines after system service. The auxiliary oil pump can be operated for a period of time when the purge valves are opened, but the purge valves need to be closed prior to and during engine operation.

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Installation
SYSTEM INFR A STRUCTURE INFRA
Hydr aulic Oil Suppl y Headers Hydraulic Supply
The HPiV oil supply header, specified by Enginuity Technologies to be O.D x 0.083 wall 304/316 stainless steel tubing, rout hydraulic oil from the hydraulic pump to each individual HPiV. Branch hose connections on the oil supply header are 3/4-16 SAE/JIC (-8) male fittings to which the 1/2 oil supply branch hoses are connected. The branch hoses connect directly to the male SAE/JIC -8 male inlet fitting on the EHV .

Hydr aulic Oil R eturn Headers Hydraulic Return

NOTE...
Enginuity LLC provides a specifialla tion of HPF i installa allation HPFi c a tion for inst and its as socia ted suppor aassocia sociated support infrat infr structure (HPF i-100). All inst al(HPFi-100). installa tions, and component replacelations, ment shall be performed in accordance with the most recent revision of this specific ation specifica

The HPiV oil return header, specified by Enginuity Technologies to be O.D x 0.083 wall 304/316 stainless steel tubing, connects each individual HPiV to the return port on the hydraulic oil reservoir. Branch hose connections on the oil return header are 9/16-18 SAE/JIC (6) male fittings to which the 1/2 branch hoses are connected. The branch hoses connect directly to the male SAE/JIC 6 male inlet fitting on the EHV .

! WARNING!
The Hydr aulic Suppor Hydraulic Support t Headers are equipped with different size AN/JIC fit tings on the oil suppl fittings supply, y, return and g as/oil return por ts gas/oil ports to minimize the chance of reversing the flow of hydr aulic fl uid hydraulic due to erroneous connection of the hoses. Reversal of the hydr aulic flow resul ts in unconraulic results trolled actu at i o n o f t h e f u e l ua ve which c an resul t in severe alve can result val personal injur y or dea th. injury death.

Gas/Oil Return Headers

The HPiV gas/oil return headers, specified by Enginuity Technologies to be 3/8 O.D x 0.065 wall 304/316 stainless steel tubing, connects each individual HPiV to the gas/oil separator located in close proximity to the engine (see installation drawings for specific location). Branch hose connections on the gas/oil return header are 7/16-20 SAE/JIC (4) male fittings to which the 1/4 branch hoses are connected. The branch hoses connect to SAE/JIC 4 port located in the EHV mounting block.

Br anch Hoses Branch

The branch hoses used in the hydraulic support system are an industrial grade flexible hydraulic hose. Although the hoses include a stainless steel over-braid for abrasion resistance, care should be taken in routing to avoid unnecessary contact with surrounding engine hardware and/or unnecessarily long hose lengths between the header and the EHV.

Header Suppor t and Mounting Support

The hydraulic headers are to be supported at every engine cylinder using an elastomer (urethane, polypropylene, etc.), or equivalent mounting device to isolate the headers from engine vibration and to avoid fretting, and possible failure of the tubing.

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Installation
Hydr aulic Header Byp as s V al ves Hydraulic Bypas ass Val alves Half-inch, quarter-turn ball valves are installed between the oil supply and return headers on each bank at the farthest point from the hydraulic oil pump. These bypass valves, closed during normal operation, are used to temporarily bypass the HPiVs following system maintenance. Bypassing the HPiVs allows quick removal of air trapped in the supply lines after installation or service. The bypass valves are to be closed prior to and during engine operation. Hydr aulic Oil Hydraulic

NOTE...
When the engine driven HPF i hyHPFi dr aulic p ump is first inst alled draulic pump installed or ser viced, it is ad vis able serviced, advis visable to prime the p ump and p urge apped air pump purge entr entrapped from the oil lines b y cr anking by cranking the engine with the b y p as sv al ves by pa ssv sval alv open. While this is not an essential requirement, it will make the sub sequent engine st ar t bs tar art smoother b y r e m o v n g a i r e n by tr apped in the EHVs. trapped

The recommended oil to be used in the HPFi hydraulic system is a high quality, petroleum based, low viscosity, hydraulic oil, having a rated viscosity below 35 centistokes at 104F (40C). Hydraulic oils are formulated with desirable additive packages that deal with moisture, air, foam, corrosion, oxidation, etc., and are necessary to maximize pump and EHV life. Hydraulic oils approved for HPFi systems include: Texaco R&O 32 Exxon Univis 32 Mobile DTE 24 or DTE 22 Citco A/W 32 Shell Tellus T32

Gas/Oil Sep ar ator Separ ara The gas/oil separator vessel must be positioned so that oil in the HPFi hydraulic reservoir seeks its own level by way of the interconnecting tubing, resulting in proper oil level within the gas/oil separator. When the visual oil level indicator in the hydraulic reservoir is at the full mark, the proper separator oil level is 2-4 inches below the gas/oil inlet port.
Correct Oil Level

2-4

The oil line connecting the separator and the reservoir should drop to nearly floor level. The recommended location for a convenient hydraulic system drain valve is at the lowest point of the oil line. This drop in line height is very important in maximizing the oil head that must be lifted by gas pressure in the separator, which will minimize the possibility that vented fuel gas will enter the reservoir as a result of back pressure in the gas vent line.

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Installation
1 NPT Outlet Fill Po rt

The 3/8-inch diameter gas/oil line, interconnecting the engine gas/oil headers and the separator gas/oil inlet, can follow any convenient route. It is not important if this line rises above or falls below the reservoir oil level because oil & gas pressure in the HPiV will cause the gas & oil leakage to flow to the separator. The gas/oil separator gas outlet port is to be connected to the visual gas leak indicator described in the next section. Visu al Gas isual L eak Indic ator Leak Indica

FLOW

FRONT

Oil Level

A visual gas leak indicator is installed in the HPFi hydraulic system to provide a visual indication of gas leakage from the HPiV. The visual gas leak indicator must be installed vertically so that its outlet port is at the top (marked on upper flange). As described above, a line must connect the gas outlet port of the gas/oil separator to the inlet port of the visual gas leak indicator. This line diameter at 1 inch. Like the gas vent line discussed below, it should be as direct and as short as possible to minimize back pressure in the event of excessive gas flow through the indicator. To ease maintenance it is recommended that the indicator be mounted at least 3 inches above the gas/oil separator. Removal of the indicator can be facilitated through the use of a 1 inch union be installed directly above the indicator or alternatively, between the indicator and the gas/oil separator. The indicator should be located such that it is easily viewed by the operator on a regular basis. Once the indicator is installed it should be filled with the proper oil as described in the System Start-Up section of this manual. Hydr aulic System V ent Hydraulic Vent

! caution!
If the clear housing of the indicator needs to be cleaned use a mild, non-abr asive soap sol ution non-abrasive to clean the clear housing of the visu al leak indic a tor. Sol vents Solvents visual indica twill degr ade the pol polymer resultdegrade ymer resul ing in clouding and/or fail ure. ailure.

! caution!
The open end of the vent line atel y protected to adequa tely should be adequ prevent it from being plugged in any wa y b y wa ter, ice, cont aminaway by water, contamination, or b y bird, rodent, by animal, or insect actions.

A 1 inch vent line is connected to the outlet of the visual gas leak indicator. This vent line carries gas leakage to an acceptable disposal location outside the building. It is important that a 1 inch diameter gas vent line (specified the HPFi Installation Specification HPFI-100) is used to minimize back pressure resulting from potential gas flow. The amount of back pressure the gas vent line creates must not overcome the isolation head of oil in the line interconnecting the separator and the reservoir. If gas vent line back pressure overcomes this oil head, gas will pass through the gas/oil separator directly into the reservoir and into the atmosphere near the en-

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Installation
minimize pump suction pressure depression. In no instance should the bottom surface of the hydraulic reservoir bottom be below the pump inlet by more than 24 inches. When establishing the reservoir location, the gas/oil separator must be located at the same elevation as the reservoir. The engine mounted hydraulic skid is designed with mounting flanges on the flanks of its base. Using steel angle (1.5 to 2) results in the oil drain of the reservoir bottom being accessible when the hydraulic skid is set in place. The mounting frame can be mounted on a level plane using custom fabricated brackets, as required, to attach the frame to the engine or other structure. The reservoir has an internal baffle and special outlet and return port locations to enhance air, moisture, and contaminant separation. Extra return oil ports have been provided to ease piping in restricted locations, but the two return ports that are on the same side of the reservoir as the outlet ports are the preferred return oil port locations. When connecting the gas/oil separator to the reservoir consider making the interconnection to the reservoir at its bottom drain port, if a drain valve is being installed at the bottom of the U tube (as recommended). Doing so will result in a convenient means to fully drain the oil reservoir using the floor level U tube drain valve. If a drain valve is not installed in the U tube, the reservoir bottom drain port should be left accessible for reservoir draining in addition to a capped tee located in the lowest section of the U tube. (See Figure11 on pg. 14) Hydr aulic Oil L evel Sensor Hydraulic Level An oil level sensor is installed in the 2 NPT port provided in the top of the oil reservoir. The dual level settings of the GEMS Model LS-800 unit are factory set for use with the HPFihydraulic reservoir. This level sensor unit is CSA listed for hazardous locations (Class I, Div 1, Group D) and has an explosion proof wiring conduit enclosure containing a terminal strip. The two independent level switches are SPST type and do not share a common lead. The level switch designated L2 is a low oil warning switch that is closed at normal oil levels, but opens when the oil level drops to approximately 3 gallons below the full level. The level switch designated L1 is a low oil shut down switch that is closed at normal oil levels, but opens when the oil level drops to approximately 6 gallons below the full level. These switch contacts

< 24

! caution!
Fail ure to position the hydr aulic ailure hydraulic voir/engine mounted hydr aureservoir/engine hydraureser lic skid within the specified 24 ver tic al dist ance from the sucvertic tical distance tion por t of the hydr aulic p ump port hydraulic will resul t in sever d damage result amage to the p ump. rendering it inoper able inoperable

L2

L1

Engine Mounted Hydr aulic Skid Hydraulic The HPFi hydraulic oil reservoir, contained in the engine mounted hydraulic skid (Figure10) must be installed close to the engine driven HPFi oil pump to

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Installation
Engine Mounted Hydr aulic Skid Hydraulic Component Identific ation Identifica

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Installation
NOTE...
tes the hydr aulic resin cold clima climates hydraulic er voir oil should be hea ted and ervoir heated the warm oil circula ted through circulated the HPF i oil lines before a ttemptHPFi at t. Enginuity ing a cold engine st ar star art. LLC provides a specific ation for specifica oil hea ters tha t ha ve the physic al heaters that have physical size and performance char actercharacteristics suit able F or this applic ation. suitable For applica
should be connected with the main engine control to provide the necessary warning and shut down functions. In the event of significant hydraulic oil loss, the L1 low oil shut down level switch will shut down the HPFi equipped engine, before the hydraulic pump begins ingesting air. Oil Hea ter ( Optional ) Heater An optional electrically powered oil heater can be installed in the pre-existing 2 NPT port provided in the side of the HPFi reservoir. This heater is necessary in cold climate locations where the HPFi hydraulic oil temperature may fall below 40F (5C). In installations prone to this condition, it is recommended that the heater be employed to raise the oil temperature prior to issuance of the engine start command. The Chromolox heater specified by Enginuity is specifically sized for the HPFi reservoir and is UL and CSA listed for hazardous location use. The heater is available for use with several input voltages so please specify the desired input voltage when ordering the heater from Enginuity LLC.. The integral thermostat should be set to provide an oil temperature of about 90F (32C). In all but extremely cold environments, the hydraulic oil will remain at acceptably warm temperatures due to pump induced work and radiant heat from warm engine components.
UG8 Adapter Flange
( Enginuity P/N 1005 0)

Vicker s PVQ32 Main Hydraulic Pump

Hydr aulic Oil Pumps Hydraulic The main engine-driven hydraulic pump for the HPFi system is a Vickers model PVQ32 (Figure10), which is a variable displacement, pressure compensated unit. The pump is typically installed on the vacant governor drive pad of HPFi equipped engines. Installation requires using a specially designed adapter plate, an SAE adapter flange, and a specially designed shaft coupling manufactured by Enginuity LLC.. The adapter plate is first installed on the engine drive pad. The adapter flange is piloted on the drive pad to accurately align the pump shaft with the governor drive shaft in the engine. Next the mating splines of the pump drive shaft and the engine drive shaft should be coated with high quality petroleum base grease. The SAE adapter flange and the shaft coupling, which adapts the straight, keyed pump shaft with the splined governor drive shaft in the engine, should now be installed on the pump.

Clar k TCV Pump Coupler

Cooper-Bessemer GMW Pump Coupler

( Enginuity P/N 1005 1)

Figure 11 - Main engine driven hydraulic pump and governor drive adapters (exploded view with both styles of cou

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Installation
! WARNING!
Care should be t aken in adjusttaken ing the PVQ32 pres ting. pressure setting. sure set If the adjusting screw is turned out too f ar, it will be expelled b y far, by sure potentiall y resul tpressure potentially resultoil pres ing in severe personal injur injury y.
In engine applications where the shaft is not splined the mating shafts should be coated with high quality petroleum base grease and assemble before inserting the tapered retaining pin. The pump, flange adapter assembly, and shaft coupling can now be attached to the adapter plate. When the pump/coupling/flange adapter assembly is installed on the engine, the coupling must float on the splined shaft and not be bottomed (axially compressed) as the pump is installed. The Vickers PVQ32 pump is designed to have its case drain port connected to the hydraulic reservoir via a case drain line. Hydraulic oil that passes through clearances in the pump is returned to the hydraulic reservoir via this line. The case drain line should not be pressurized or blocked, and should be connected to one of the return line ports on the hydraulic reservoir.

! caution!
Fail ure to position the hydr aulic ailure hydraulic reser voir/engine mounted hydr aureservoir/engine hydraulic skid within the specified 24 ver tic al dist ance from the suction vertic tical distance por t of the hydr aulic p ump will port hydraulic resul t in severe d amage to the da lt p ump. rendering it inoper able. inoperable.

The bottom surface of the hydraulic reservoir must not be positioned more than 24 inches below the PVQ32 pump inlet. When establishing the reservoir location keep in mind that the gas/oil separator must be located such that the oil level is maintained at a location 2-4 inches below the gas/oil return line inlet. It is recommended that the pump suction port be below the oil outlet on the reservoir where possible. The PVQ32 pump is factory set to control output pressure at 800 50 psig. If the outlet pressure is out of compliance, adjust the pressure compensator on the pump housing while the engine is running. Care should be taken in adjusting the PVQ32 pump pressure setting. If this adjustment is turned outward too far, it will be expelled by oil pressure. It is important to note that the main engine driven PVQ32 oil pump does not control the HPFi system oil pressure when the auxiliary HPFi oil pump is operating. When the auxiliary oil pump is operating (whether the main pump is or is not operating), the HPFi system pressure is controlled by the in-line pressure relief valve which is factory set at approximately 1000 psig. The auxiliary pump must not be operating when the main pump pressure setting is being adjusted.

Discharge pressure adjustment

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Installation
Connection Points Once the engine mounted hydraulic skid, main hydraulic pump and distribution headers are mounted on the engine the individual components can be connected. The main hydraulic pump is connected to the hydraulic skid using flexible hoses rated for hydraulic duty. The discharge of the PVQ32 pump (Figure13) is identified on the pump casing and is connected to the 8 Male 37 SAE/JIC fitting located on the lower right hand corner of the hydraulic skid. The suction side of the PVQ32 pump (Figure 13) is connected to the 1 Female NPT tee fitting on the right hand side of the hydraulic skid. Like the hydraulic pump supply and return headers (Figure 14) are connected to the hydraulic control block located on the hydraulic skid using flexible hydraulic hoses. The supply header is connected to port A3 on the hydraulic control block. The return header is connected to port A5 which is slightly above and to the right where the 140 micron filter connects to the block. Both the ports (A3 and A5) are female 12 SAE O-Ring (1 1/1612 UNC). A uxiliar y Pump uxiliary An auxiliary hydraulic pump is included in the engine mounted hydraulic skid to allow purging of the oil lines and servicing of the HPFi system while the engine is stopped. The auxiliary pump is placed in parallel with the engine driven pump and is powered by compressed air. The auxiliary pump is not necessary to support engine starting. When the auxiliary oil pump is operating, the HPFi system oil pressure will be controlled by the pressure relief valve in the oil supply line as discussed in the preceding paragraph. The auxiliary hydraulic pump is driven with 90 psig, dry shop air. The shop air is connected to the 1/4 NPT port located on the end of the auxiliary pump on the far left side of the hydraulic skid (Figure15). A manual 1/4 quarter-turn ball valve should be installed at the inlet to allow the auxiliary pump to be turned on and off without disconnecting the shop air hose.
Figure 15

Figure 13

NOTE...
Fail ure to isola te the main hyisolate dr aulic p ump (PVQ32) with flexdraulic pump ible hoses c an resul t in f ure result fail ailure can ail of connections, fit tings, and the fittings, p ump c asing due to vibr ation incasing vibra duced stress.

Figure 14

Page 16

Installation Notes

Page 17

System Start Up
The oil should be circulated through the system using the auxiliary pump while monitoring the oil level in the reservoir (Figure16). Additional oil should be added until a constant level is maintained in the sight glass. The specific oil to be used in the hydraulic system will be agreed upon by Enginuity LLC and the client. This oil shall be high-quality, petroleum-based, lubricating oil as specified in the HPFi Installation Specification and in the System Specifications section of this manual. Filling the Main Hydr aulic Pump Hydraulic Before the main hydraulic pump (PVQ-32) is turned over for the first time it should be filled with oil. The pump can be filled by disconnecting both the inlet and outlet hoses and filling the housing with the same oil approved for the application. Once filled, reconnect and properly tighten the flexible hoses connecting the pump to the hydraulic skid. Line Fl ushing and Oil Pre-F il terFlushing Pre-Fil iltering The greatest risk of incurring damage due to oil contamination occurs during the initial start-up of the hydraulic system due to the presence debris and fluids from the installation process. The increased potential to damage system components at this time warrants that special precautions be implemented. Prior to making the final connections to the HPiVs the hydraulic system must be flushed and the oil pre-filtered. This can be easily accomplished by jumpering the supply and return hoses together at each cylinder (Figure 17). Use the fittings called out in the installation section for this purpose.

Oil Full Level

Figure 16

Figure 17

Filling the R eser voir Reser eservoir During storage and handling, oil containers must be tightly sealed to exclude moisture and other contamination. All containers and oil transfer equipment must be free of contamination. The reservoir is equipped with a screened oil filler port designed to trap coarse contaminates. Despite the screened filler port, all oil should be filtered prior to being introduced to the system. While not a requirement, it is recommended that a commonly available filtering/pumping unit specifically designed for oil transfer and filtering be utilized.

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System Start Up
This circulates oil through each branch line and through the supply and return headers. Operating the system in this configuration for 10 minutes is sufficient for removing fabrication related debris and pre-filtering the system. To maintain sufficient oil velocities required to clean the system, jumper the headers in pairs only. Repeat this procedure in pairs until all of the system has been cleaned. When flushing is complete, connect the HPiVs and the system can be started with a reduced risk of damage due to contamination.
Figure 18

! WARNING!
Care should be t aken in adjusting taken the p ump outlet pres sure set ting. pump pressure setting. If the adjustment screw is turned too f ar outward it will be expelled far sibl y resul ting by oil pres resulting pressure possibl sibly sure pos in personal injur injury. y.

The gas/oil return header(s) should simply be blown out with compressed shop air. Each branch connection should likewise be blown out prior to connection to the HPiV. Set ting System Oper at i n g P r e s tt ra sure The main engine driven hydraulic pump is factory set to 800 psig. Adjustment of this setting is not required under normal installation conditions. Likewise, the factory set pressure relief valve located in the hydraulic distribution block controls the outlet pressure of the auxiliary maintenance pump and should not be adjusted. Once the system is operating the hydraulic supply pressure should be verified to be 800+/- 50 psig using the hydraulic supply pressure gauge. If necessary, the supply pressure can be adjusted using the pressure adjusting screw located on the engine driven pump (consult the pump technical manual provided separately). The system supply pressure should be closely monitored while the adjustment is being made. Filling V isu al L eak Indic ator with Visu isual Leak Indica Oil

Figure 19

Once the visual gas leak indicator is installed in the HPFi hydraulic system a small quantity of low viscosity, translucent oil such as SAE 10W engine oil can be added through the 1/4 filler plug in the top flange of the indicator. The indicator has an oil level indicator line on its inner wall, visible through the transparent outer housing. The oil level should be at this level line when no gas is flowing through the visual gas leak indicator.

Page 19

System Start Up
! WARNING!
When c ycling the HPivs to p urge cy purge any entr apped air from the hyrapped dr aulic system the on-engine ra header should be isola ted via the isolated manu al block v al ve, locked out manual val alve, and the vent open. F ure to vent Fail ailure ail the header during this oper ation opera will resul t in fuel being injected result ylinders which cylinders into the power c c an resul t in explosion, c ausing result causing personal injur y. injury.
Hydr aulic Oil L evel Sensor Hydraulic Level The hydraulic reservoir is equipped with an oil level sensor with two switches for sensing two oil levels. The switch contacts are monitored by the engine controller and serve as warning and shut down alarms. The output signal of the level sensor should be confirmed during system start up to ensure the correct functionality. Cy cling Cycling the EHVs

Once the reservoir, headers and main hydraulic pump system have been filled with hydraulic oil the system should be operated on the auxiliary pneumatic pump while the fuel valves are being actuated. Operating the system in this manner removes air trapped in the various system components and the EHVs. Please refer to the Enginuity Manual HPFi-102, Inpulse Software Manual for directions on how to activate the EHV test mode.

Page 20

Operation & Maintenance

GENER AL SYSTEM GENERAL
R eser voir Oil L evel eservoir Level When the HPFi system is operating, the oil level in the HPFi hydraulic oil reservoir should be maintained at the full mark of the visual oil level indicator, located on the side of the reservoir (Figure 20). Changing Hydr aulic Oil Hydraulic It is recommended that the hydraulic oil be routinely replaced every 12 months, or every 8,750 hours of operation. Oil replacement may be required more frequently if contamination or overheating occurs. The hydraulic system is equipped with a drain port, located on the bottom of the reservoir, for convenient removal of the system contents. The recommended type of oil to be used in the HPFi system is a low viscosity hydraulic oil, having a rated viscosity below 35 centistokes at 104F (40C). Hydraulic oils are formulated with desirable additive packages to deal with moisture, air, foam, corrosion, oxidation, etc. that will maximize pump and valve life. A good quality SAE 10W engine oil (grades SC, SD, SE, SF, SG) will work satisfactorily. Circulating and heating the hydraulic oil before attempting to start the engine is recommended if oil temperature is below 40F (5C). Oil operating temperatures between 90 and 120F (32C) is recommended. In the event of severe oil contamination or oil overheating, it is advisable to drain the hydraulic oil from the distribution headers. This requires removal of the hoses at the engine mounted skid and at each HPiV. An alternate method of removing the contaminated oil in the lines is to drain the reservoir. Then partially refill the reservoir with clean oil and operate the hydraulic system on the auxiliary pump for a short time. Repeat this procedure until the system is filled with clean oil.

Oil Full Level

Figure 20

NOTE...
All fil ter elements should be lt t the at replaced and/or cleaned a time tha t the system oil is at changed.

! WARNING!
Fail u r e t o r e t u r n t h e 3 - w a ay y al ve to the fil tered va lv lt selector v position immedia at ly tel y following fil an resul t in filter can result ter replacement c acceler ated wear and pre-ma ture pre-mature accelera fail u r e o f t h e E H V s a n d o t h e r as socia ted hydr aulic system ss at ra components.

Page 21

Operation & MAintenance

NOTE...
Remember tha t when the auxiliar y that auxiliary HPF i o i l p ump is oper at i n g , t h e Fi opera HPF i system oil pres sure will be HPFi pressure approxima tel y 1000 psig, and is approximatel tely controlled b y the in-line pres sure by pressure al ve, not b y the main oil val alve, by relief v pump pressure control. The main oil pump will again control the system oil pressure when the auxiliar y p pump iliary ump is shut off .
Adjusting the Oil Pressure Control Set ting Setting When the main engine driven pump is operating the pressure is controlled by the regulator that is integral to the pump. This pressure setting is factory adjusted to be 800 +/- 50 psig, but it should be periodically checked by observing the gage installed in the HPFi hydraulic system. If this pressure is not correct, when only the main engine pump is being operated, adjust the pressure compensator on the engine driven pump as discussed in System Start Up. Main Engine Pump Driven Hydr aulic ra

! WARNING!
R estricting the hydr hydraulic aulic oil return line will cause all of the HPiVs opening simul y and simult aneously taneousl remain open, flooding the engine sure fuel cylinders with high pres pressure an resul t in severe megas which c can result y, chanic al d amage, personal injur chanical damage, injury, or dea th. death.

The pump output pressure setting should be checked, and adjusted if necessary. The PVQ32 pump requires a case drain line between the pump and the hydraulic reservoir. Maintenance of the PVQ-32 is to be cared out in accordance with manufacturers recommended practices and procedures. Hydr aulic Oil R eturn Line Hydraulic Return The oil return lines are pressurized to about 605 psig by a relief valve installed just upstream of the oil filtration unit. This back-pressure is necessary to prevent voiding in the pulsating return lines and to reduce cavitation in the EHV. The hydraulic oil return lines should be inspected regularly for signs of damage. Restriction of the hydraulic oil return lines significantly impacts the operation of the valve. Damaged portions of the system should be immediately replaced with new components. Gas/Oil Return Line The gas/oil oil return lines should be inspected regularly for signs of damage. Restriction of the gas/oil oil return lines will eliminate the ability to detect HPiV seal leakage resulting in a potentially hazardous operating condition. Damaged portions of the system should be immediately replaced with new components.

Page 22

Operation & Maintenance

Visu al Gas L eak Indic ator isual Leak Indica
Top Cap
(Eng inuity P/N 10055)

Upper Si ght Gl ass O-Ring Sleeve O-Ring

The visual gas leak indicator should need no routine service unless the oil within it becomes contaminated or is lost. The oil can be drained using the drain plug in the bottom flange of the indicator. If the indicator needs to be cleaned to eliminate contamination, the transparent outer tube should be removed and rinsed with detergent and water, followed by a thorough drying. If cleaning becomes necessary, the indicator can be disassembled by securing the Lower Cap in a vise and unscrewing the Upper Cap. All o-rings should be replaced following maintenance and prior to re-assembly. The o-rings should be lubricated with a light coat of SAE 10W oil to prevent binding during assembly. The assembly should be tightened until snug. Over tightening will result in failure of the polycarbonate sight glass. If necessary, oil can be added to the indicator using the oil filler plug in the upper flange. The proper oil level is marked on the indicators inner housing. The gas leak indicator directs gas thru a shallow pool of oil, causing bubbles to form that are visible through the transparent housing of the indicator. The relative rate of gas flow can be observed as the level of bubble activity in the indicator. Large gas flows force the small amount of oil into the outer housing until the gas flow rate is reduced and the oil returns to a shallow pool in the housing where bubbling resumes for small gas flows. When an HPiV is newly installed, and for many thousands of operating hours thereafter, no significant gas leakage is expected. In the event of a gas valve o-ring failure, or simply a gas valve seal wearing, gas leakage will become evident in the gas leak indicator and corrective measures can be taken. Identifying Leaking HPiV Gas Seals If significant gas flow is observed in the visual gas leak indicator, the following procedure can be used to identify which HPiVs have leaking gas seals.

Sleeve
(Eng inuity P/N 10054)

Si ght Glass
(Eng inuity P/N 10056)

Lower Si ght Gl ass O-Ring

Bottom Cap
(Eng inuity P/N 10057)

Visual Leak Indicator (Enginuity p/n 10053) used to indicate leaking gas valve stem seals (exploded view).

Use a mild, non-abr asive soap sonon-abrasive lution to clean the clear housing of the visu ator. visual indica al leak indic Sol vents will degr ySolvents degrade polyade the pol mer resul ting in clouding and/or resulting fail ure.

Gas/Oil Retur n

Each HPiV has a gas/oil drain fitting (-4 Male SAE/ JIC 37) attached to the EHV mounting block. Do not confuse this line with the larger oil lines connected to the EHV. This gas/oil drain line carries small amounts of oil and HPiV gas seal leakage (if present) to the gas/oil separator.

Page 23

Operation & Maintenance

If appreciable gas leakage is suspected, it can be verified when the gas/oil drain fitting is loosened and removed (while the engine is running). If gas leakage is not discernible, a closer check can be made in the following way. Attach a short length of flexible line to the gas/oil drain fitting on the EHV mounting block. Submerge the free end of the hose in a vessel of oil. Gas leakage will be indicated by a continuous stream of bubbles emitted from the submerged end of the hose. Repeat the procedure on each cylinder until the leaking HPiV is identified. Gas/Oil Sep ar ator Separ ara The HPFi hydraulic system includes a gas/oil separator to separate oil and fuel gas leakage from HPiV internal seals. The gas/oil separator is a small vessel connected to and positioned at the level of the hydraulic oil reservoir. The bottom of the separator is connected to the reservoir by a line having a U tube configuration that drops to near floor level and then back up again to the elevated reservoir. Oil in the reservoir seeks its own level in both reservoir and separator via the U tube interconnecting line. A hydraulic system oil drain valve is installed at the lowest point in the U tube portion of the gas/oil return line to facilitate draining the hydraulic system. Under normal operating conditions the gas/oil separator requires no maintenance but should be visually inspected on a regular basis for signs of damage. as s V al ves Byp Bypas ass Val alves Purge valves are installed between the oil supply and return headers at points farthest from the oil pump. These valves are normally kept closed but can be used to temporarily short together the oil supply and return lines. This is helpful, before engine starting, in removing contamination and air from the supply lines after installation or service, and in warming the hydraulic oil in cold climates. The purge valves can be opened and the auxiliary oil pump can be operated for a period of time. The purge valves are then closed prior to and during engine operation.

Page 24

Operation & Maintenance

Engine Mounted Hydrauilc Skid Schematic: Valve callouts are detailed on page 29.
ENGINE SKID HYDR A U L I C The filter element can be easily replaced without shutRA ting down the engine or HPFi system. This is done by temporarily repositioning the 3-way valve (upstream of The engine mounted hydraulic skid used in theHPFi the filter unit) to the bypass position, and by directing hyddraulic support system is manufactured for Eninuity the returning oil around the filter unit. This method is by Motion Industries. Replacement parts for the skid recommended, even when changing the filter with the are available directly from Motion Industries or Vikers HPFi system stopped, because the 3-way valve will Hydraulics as identified in the associated Hydraulic Skid keep oil in the lines from running out when the filter manual. Please refer to the skid manual for replace- canister is removed. A check valve downstream of the ment part information. filter unit prevents oil from back flowing to the filter, so the filter can be removed with little oil spillage. The Hydr aulic Oil R eturn F il ter Hydraulic Return Fil ilter used filter canister can simply be unscrewed and a new canister screwed on in its place, tightening the new canThe oil filter unit installed in the HPFi hydraulic sys- ister per instructions accompanying or printed on the tem oil return line is a spin-on type filter. Replacement new filter. elements are available through the distributors listed in Once the new filter is in place, the 3-way valve must the back of this manual. be returned to the normal (filtering) position to assure The filter units indicator displays when the filter is dirty that the return oil passes through the filter element. A and needs to be replaced. If the filter is not replaced simple observation can be made if it is uncertain which and becomes plugged with contamination, a bypass position is the normal position on the 3-way valve. When pressure relief valve in the filter unit will open to pre- the HPFi system is operating, the pressure gage readvent excessive back pressure. In this instance, the by- ing upstream of the filter unit can be observed as the 3passed oil will not be filtered until the dirty filter is re- way valve is alternately switched from one position to placed. the other. The pressure reading will be slightly higher when the 3-way valve is in the normal (filtering) position. MOUNTED

Page 25

Operation & Maintenance

The hydraulic oil return filter is equipped with an integral differential gauge indicator which indicates the need for maintenance and cleaning. See manufacturers recommendations for optimum performance. Hydraulic Hydr aulic Oil Suppl y Str ainer Supply Strainer

The purpose of the in-line strainers, located in the outlet lines of the two HPFi oil pumps, is to catch coarse particulate contamination that passes through or is expelled by the pumps, and prevent it from reaching the HPiV. Under normal operating conditions, these strainers should seldom, if ever, need servicing. However, if the hydraulic oil becomes badly contaminated, or if an oil pump fails, the strainers should be cleaned per manufacturers recommendations. The supply oil strainer is equipped with an integral differential pressure indicator which indicates the need for maintenance and cleaning. A uxiliar y Hydr aulic Pump uxiliary Hydraulic Maintenance of the PVQ-32 is to be cared out in accordance with manufacturers recommended practices and procedures. Oil R eturn Pres sure R elief V al ve Return Pressure Relief Val alve The oil returning to the HPFi system oil reservoir from the HPiVs flows through a pressure relief valve, which creates a 605 psig back pressure in the return line. The relief valve is factory set. No field service or adjustment of this valve is required, other than replacement in the event of failure or damage. Oil R eturn F il ter Return Fil ilter The oil returning to the HPFi hydraulic oil reservoir from the HPiVs is directed through a disposable 10micron oil filter element. The filter unit is piped so that a 3-way, open center, manually operated valve can be used to bypass the filter, in the event that the filter element needs replacement without shutting down the engine. It is very important that this 3-way valve is an open center type to assure that the HPiV return line is never blocked during engine operation.

! WARNING!
The hydr aulic str an onl y hydraulic strainer can only ainer c viced when the system is serviced be ser oper ating. Opening the str ainer opera strainer during oper at i o n c t in opera ca lt an resul y, or dea th. personal injur injury, death.

NOTE...
All fil ter elements should be refilter t the time placed and/or cleaned a at tha t the system oil is changed. that

Page 26

Notes

Page 27

Operation & Maintenance

HYDRAULIC CONTROL BLOCK: PORT IDENTIFICATION

G1 G2 G3

Supply Pressure Gauge Port for Low Pressure Alarm Switch Backpressure Gauge Port

A1 A2 A3 A4 A5 A6 A7 Filter A7 A8 A9

Supply from Pneumatic Auxiliary Pump Supply from PVQ Pump Oil Supply to Engine Oil Supply Return From Pressure Relief Oil Return from Engine Oil Supply to 10 Micron Hydraulic Filter Oil Return From 10 Micron Hydraulic Oil Return to Reservoir Oil Supply From 140 Micron Strainer Oil Supply to 140 Micron Strainer

INTERNAL CONTROL VALVES 1 CV3-10-P-0-40 (Check Valve) 2 MRV3-10-D2-0 (Manual 3-Way Valve) 4 CV3-10-P-0-10 (Check Valve) 5-1 CV3-10-P-0-3 (Check Valve) S-2 CV3-10-P-0-3 (Check Valve) 7 RV3-10-S-0-18 (Relief Valve)

Page 28

Operation & Maintenance

MRV3-10-D2-03 9 31-F-08620

CV3-10-P-0-40

CV3-10-P-0-10

CV3-10-P-0-3 RV3-10-S-0-18

111 Z 60000

CV3-10-P-0-3

HYDRAULIC CONTROL BLOCK (Exploded View)

INTERNAL CONTROL VALVES Tag Part Number Manufacturer

1 4 5-1 5-2 7

CV3-10-P-0-40 (Check Valve) MRV3-10-D2-0 (Manual 3-Way Valve) CV3-10-P-0-10 (Check Valve) CV3-10-P-0-3 (Check Valve) CV3-10-P-0-3 (Check Valve) RV3-10-S-0-18 (Relief Valve) 931-F-08620 1 I Z 60000

Vickers 2 Vickers Vickers Vickers Vickers Vickers Wika SPI/Motion Industries

*Replacement seal kits available directly from Vickers. Please refer to the manufacturers info mation contained it the site documentation package.

Page 29

Maintenance Schedule
Daily operator Checks

Hydraulic oil supply pressure (80050 psig) Hydraulic oil return pressure (605 psig) Hydraulic oil strainer differential (red or green) Hydraulic oil return filter differential Hydraulic oil operating temperature Visual leak indicator Check system oil level Visual inspection of hydraulic connections for leaks

Monthly Maintenance

Inspect/replace hydraulic branch hoses (note wear marks and abrasions if not replaced) Cycle hydraulic maintenance pump )without PVQ32 operating) Cycle 3-way diverter valve

Annual Maintance

Change hydraulic oil and filter Remove and clean or replace hydraulic strainer element Replace oil in visual indicator with SAE 10W Check tightness of all hydraulic fittings Inspect hydraulic supply, return and gas/oil return headers and lines for damage

Inspect/replace hydraulic pump hoses Verify oil level sensor operation Inspect hydraulic reservoir for sediment Inspect and/or replace hydraulic line mounting hardware Check hydraulic heated function (if applicable) Calibrate hydraulic oil pressure switch

Page 30

Troubleshooting Guide
The following table is provided to the user to assist in determining the possible causes of unsatisfactory system performance and to suggest corrective actions to resolve the problem. This information, coupled with engine operating data will provide a complete picture of the problem being addressed. This information is provided as a diagnostic tool for the user. Information contained in this section should not be viewed as a reflection of Enginuity experience with this system.

PROBLEM
Engine will not start

PROBABLE CAUSE
Air trapped in hydraulic lines Bypass vales open System leak Broke pump drive coupler No Hydraulic pressure

SOLUTION
Cycle hydraulic oil with bypass valves open Close bypass valve Tighten fitting or replace defective component Replace coupler

No hydraulic pressure Main hydraulic pump failure

Bubbles in Visual Leak Indicator Excessive oil consumption Erratic HPiV operation

Bypass valves open Main hydraulic pump failure Main pump pressure adjustment screw backed out Damaged hydraulic pressure relief valve Excessive strainer differential Excessive filter differential System leak component Leaking HPiV stem seal Systemleak Insufficient hydraulic supply Increase hydraulic return pressure Air trapped in hydraulicx lines

Close bypass valves Replace pump Readjust Replace Clean strainer Replace filter Tighten fitting or replace defective Identify worn HPiV and replace valve/cartridge Inspect system and repair or replace defective component(s) Increase hydraulic supply pressure Insufficient hydraulic return pressure Cycle hydraulic oil with bypass valves open

Premature gas seal failure HPiV remains open

Excessive hydraulic supply pressure Hydraulic rturn line restricted Seized valve stem

Inspect system and repair or replace defective component(s) Identify damaged HPiV and replace valve/cartridge

Page 31

Common Abbreviations
ABLS AO A/D ATDC AWG BDC BHP BMEP BOM CPM CPU DI DO DSP DUART FOPS EFI EGAV EHV EMI FPGA FTIO GAP HHT HPFi HPiV IMEP I/O JIC LED LPP MAP MGAV MIL MPU MUX Applications Block Language Software Analog Output Analog to Digital Degrees After Top Dead Center American Wire Gage Bottom Dead Center Break Horsepower Rating Break Mean Effective Pressure Bill of Material Continuous Pressure Monitor Central Processor Unit Discrete Input Discrete Output Digital Signal Processing Dual Universal Asynchronous Receiver Transmitter Fiber Optic Pressure Sensor Electronic Fuel Injection Electronic Gas Emission Valve Electro-Hydraulic Valve Electromagnetic Interference Field Programmable Gate Array Fault Tolerant Input/Output Graphical Applications Programmer Hand Held Tool High-Pressure Fuel Injection High Pressure Injection Valve Indicated Mean Effective Pressure Input/Output Joint Industrial Council Light Emitting Diode Location of Peak Pressure Engine Manifold Air Pressure Mechanical Gas Admission Valve (OEM) Military Magnetic Pickup Multiplexer

Page 32

Common Abbreviations
NC NEC NO OCP PC PCC PCB PCI PLC PP PSI PSIA PSIG PWM QSPI QSM RFI RAM rpm SAE SCADA SCE SIO SYSCON TBD TBS TDC TPU UL UV VAC VDC VI VME XCVR Normally Closed National Electric Code Normally Open Operator Control Panel Personal Computer Pre Combustion Chamber Printed Circuit Board Personal Computer Interface Programmable Logic Controller Cylinder Peak Pressure Pounds per Square Inch Pounds per Square Inch Absolute Pounds per Square Inch Gauge Pulse Width Modulation Queued Serial Peripheral Interface Queued Serial Module Radio Frequency Interference Random Access memory Revolutions Per Minute Society of Automotive Engineers Supervisory Control and Data Acquisition Signal Conditioning Electronics Serial Input/Output Systems Controller To Be Determined To be Supplied Top Dead Center Time Processor Unit Underwriters Laboratory EPROMS Ultra-violet Light Erasable Read Only Memory Volts Alternating Current Volts Direct Current Voltage Input Versa Module Eurocard Transceiver Alarm Philosophy

Page 33

Notes

Page 34