Technical and Maintenance Manual

Technical and Maintenance Manual
Airline Hydraulics Corporation

Document Number: SM00249-A-1057-4
EHC Cooling and Conditioning System Assembly
103T4244P0100
GE Energy
Drawing Number: 288D2342
Document Revision: None

Create Date: April 8, 2014
Revision Date: None
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Document No: SM00249-A-1057-4
Table of Contents
Safety and Important Installation Information ........................................................ page 1
General Considerations for Maintenance .............................................................. page 2
Introduction........................................................................................................... page 5
Theory of Operation.............................................................................................. page 8
Storage and Preservation ................................................................................... page 11
Installation Instructions ....................................................................................... page 11
Field Commissioning the Conditioning System ................................................... page 14
Normal Operation ............................................................................................... page 21
Service, Troubleshooting and Repair .................................................................. page 25
Bill of Material ..................................................................................................... page 38
List of Recommended Spare Parts ..................................................................... page 42
Contact Information.page 43
Appendix A: Airline Hydraulics Drawings .........................................................................
Appendix B: Application-Related Technical Data .............................................................
Appendix C: Diagrams .....................................................................................................
Appendix D: Manufacturers Data Sheets ........................................................................
List of Relevant Documents

x Assembly drawing and hydraulic schematic: Airline Hydraulics Drawing
(See Appendix A)
x General Electric Energy specification: 103T4244
x Manufacturers data sheets (See Appendix D)
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NOTICE
The information contained in this document is subject to change without notice.
Airline Hydraulics Corporation, its affiliates, employees, agents, and authors of
and contributors to this publication specifically disclaim all liabilities and
warranties, express and implied (including warranties of merchantability and
fitness for a particular purpose), for the accuracy, currency, completeness
and/or reliability of the information contained herein and/or equipment selected
in whole or in part with use of/or in reliance upon information contained herein.
Selection of materials and/or equipment is at the sole risk of the user of this
publication.
This document contains proprietary information of Airline Hydraulics Corporation
and is issued in strict confidence. Its use or reproduction for use, for the
reverse engineering, development or manufacture of equipment described
herein is prohibited. No part of this document may be photocopied or
reproduced without prior written consent from Airline Hydraulics Corporation.
Safety and Important Installation Information

Please read to understand the manner in which the following notation is applied in this
manual:
x WARNING! Indicates the potential for personal hazard or injury.
x CAUTION! Indicates the potential for property or equipment damage.
x IMPORTANT! Indicates a specific point or an item needs particular attention.
1. WARNING! Do not install, operate or service this equipment without reading and
thoroughly understanding this manual. Thoroughly read the associated manufacturers
data sheets and take all applicable safety precautions. This includes adhering to all
applicable plant Lockout/Tagout (LOTO) procedures and all warnings and safety
precautions in the manufacturers data sheets. Personnel unfamiliar with hydraulic and
electrical systems and hydraulic component maintenance practices should not attempt to
diagnose or repair a suspected malfunction, perform maintenance, or adjust any
component.
2. IMPORTANT! The assembly and hydraulic schematic drawing (Airline Hydraulics
Corporation Drawing No. 8711003M, See Appendix A) includes valuable information. All
personnel interacting with this equipment should thoroughly study these drawings prior
to undertaking any installation, maintenance or troubleshooting activities.
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3. CAUTION! It is vital that all personnel attempting to install, maintain, diagnose,

troubleshoot or repair the cooling and conditioning system be intimately familiar with
the entire EHC hydraulic system, electrical control system and hydraulic equipment
in general. A thorough understanding of proper fluid power maintenance procedure is
necessary for safe and successful completion of all installation, troubleshooting and
repair scenarios.
4. WARNING! The cooling and conditioning system is designed to operate using
phosphate ester, fire resistant, ISO 46 hydraulic fluid. This fluid may pose a health
risk to personnel in direct contact. It is mandatory that the user read and understand
the Material Safety Data Sheet for the specific hydraulic fluid used in the system.
5. CAUTION! Observe proper pump rotation upon start up. Correct if necessary.
6. WARNING! Only properly qualified electricians should carry out electrical wiring and
maintenance tasks.
7. CAUTION! Read and understand all procedures completely before undertaking any
task outlined in this manual.
8. WARNING! If any procedure outlined in this manual is not fully understood, STOP
and DO NOT proceed. Ask for assistance or consult GE Energy.
General Considerations for Maintenance

Cleanliness
By far, the most common reason for failure of hydraulic components is contamination of
the hydraulic fluid. Both particulates and water can be considered as contaminates.
Every precaution should be taken to ensure the cooling and conditioning systems and all
associated components remain free of contaminates and moisture at all times. This
precaution also applies to spare components sitting on the shelf.
Maintenance events present an opportunity for contaminates and moisture to enter the
system. At no time should any part of the system be left open to the atmosphere. All
ports and lines opened or removed during installation, inspection or during repair events
must be plugged and or capped.
Seals and O-rings

The cooling and conditioning system assembly is designed to operate using phosphate
ester, fire resistant, ISO 46 hydraulic fluid. Phosphate ester hydraulic fluid requires the
use of special seal compounds. All hydraulic components that make up this assembly
utilize fluoroelastomer seal materials compatible with phosphate ester hydraulic fluid.
Compatible seal materials include: FKM, FPM, Fluorocarbon and Viton.
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Seal Material Definitions

x Fluoroelastomer seal material is designated FKM by the American Society for
Testing and Materials (ASTM).
x Fluoroelastomer seal material is designated FPM by the International Standards
Organization (ISO).
x Viton is a trademark of the DuPont Corporation.
IMPORTANT! Ensure that all piping connections utilize fluoroelastomer seals and that
all hydraulic hoses are compatible with phosphate ester type fluids.
On-line Repairable Components

Refer to Airline Hydraulics schematic and assembly drawing located in Appendix A.
Cooling Circuit:
Heat Exchangers: On some versions of the cooling and conditioning system a redundant
arrangement of heat exchangers is provided for the HCCM circuit.
x All versions of the water cooled HCCM circuit incorporate redundant shell and tube
design heat exchangers.
x The air cooled version of the HCCM circuit is available with either single or
redundant heat exchangers.
Cooling and conditioning systems that incorporate redundant heat exchangers will
include oil and water side cooler isolation valves that allow for on-line removal and
servicing of the heat exchangers.
Conditioning Circuit:
The TAFM circuit does not incorporate any on-line repairable components. The TAFM
system must be shutdown, locked out and tagged out before undertaking maintenance
on any component in the system.
Desiccant Air Breather:
The desiccant air breather is serviceable while the power unit is in operation. The
cartridge should be replaced when indicated by a color change of the desiccant media.
No special precautions need be taken other than ensuring the safety seal O-ring and
shipping cap are removed prior to installation. The breather should be removed and reinstalled as quickly as possible. Never leave the breather port open for an extended
period.
Note: This EHC hydraulic system is equipped with a Stealth ABS (Active Breather
System). The purpose of this system is to remove moisture from the air that circulates
into the reservoir. Air enters the breather and then moves through the desiccant to admit
filtered dry air into the air space above the fluid in the EHC reservoir. Air exhausts
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through the breather outlets returning to the open atmosphere. The reservoir should
remain airtight to ensure that the breather and system function as intended.
CAUTION! Do not remove the breather unless it is being serviced. Do not obstruct or
plug the breather while the power unit is operational.
Pump Relief Valves:
Refer to Airline Hydraulics schematic and assembly drawing, located in Appendix A.
In order to simplify the system and eliminate potential failure points, factory-set fixed
setting relief valves have been used. These valves protect the two pump circuits from
overpressure.
CAUTION! The pump relief valves, RV-60 (Item 310) and RV-59 (Item 100) have fixed
settings. Both relief valves are factory set. Do not adjust or attempt to adjust these
valves.
x
RV-60 (Item 310), cooling pump relief, set at 250 PSI cracking pressure
RV-59 (Item 100), conditioning pump relief, set at 200 PSI cracking pressure
It is not possible to set the pump relief valves at the user level. If the set pressures are
changed at the user level, it will not be possible to return the valves to the proper setting.
Note: In an emergency, the valves can be returned to an approximate setting by the
following method:
Cooling Pump Relief Valve (RV 60):
x
Shut down the cooling pump.
Lockout and tagout the cooling pump.
Loosen the relief valve adjustment locknut and turn the adjustment stem fully
counterclockwise.
Turn relief valve adjustment stem clockwise 2-1/2 turns.
Tighten the locknut.
Remove locks and tags.
Energize the cooling pump. The system should now be operational.
Note: This is a temporary and approximate method of getting the system up and running
when a relief valve setting has been changed at the user level. This method will allow
the system to operate, but will most likely result in the valve being set at a higher set
point than desired. As soon as possible, the user should obtain and install a factory set
valve. All settings are specified as cracking pressure.
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Conditioning Pump Relief Valve (RV 59):

x
Shut down the conditioning pump.
Lockout and tagout the conditioning pump.
Loosen the relief valve adjustment locknut and turn the adjustment stem fully
counterclockwise.
Turn relief valve adjustment stem clockwise 3 full turns.
Tighten the locknut.
Remove all locks and tags.
Energize the conditioning pump. The system should now be operational.
Note: This is a temporary and approximate method of getting the system running after a
valve setting has been changed at the user level. This method will allow the system to
operate, but will most likely result in the valve being set to a higher set point than
desired. As soon as possible, the user should obtain and install a factory set valve. All
settings are specified as cracking pressures.
Introduction
The cooling and conditioning system is comprised of two independent low pressure
hydraulic circuits:
x High flow HCCM (cooling) circuit: 31 GPM (117.3 LPM)
x Low flow TAFM (conditioning) circuit: 0. 5 GPM (1.9 LPM)
Take the time to trace the fluid flow path using a colored highlighter on the hydraulic
schematic. This will help contribute to a better understanding of the components related
to each system.
The HCCM (cooling) hydraulic circuit includes the cooling and conditioning pumps,
particulate filter and heat exchanger(s). This circuit provides filtering and cooling for the
hydraulic fluid in the EHC reservoir. The operation of the cooling pump is controlled by
the plants Mark 6 control system in response to a temperature switch mounted on the
EHC reservoir. The control system cycles the cooling pump on and off in order to
maintain the hydraulic fluid at an operating temperature of between 105F (40.6C) and
115F (46.1C). The HCCM circuit is intended to operate continuously.
A cooling filtration loop circuit has been provided for continual filtering and temperature
control of the reservoir fluid from the central section of the reservoir.
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Water-cooled cooling and conditioning systems incorporating plate heat exchangers also
include a water regulating valve as an additional method of regulating oil temperature.
The water regulating valve is set to maintain the oil temperature at 115F (46.1C).
Air-cooled cooling and conditioning systems incorporating one or two (see BOM or
schematic diagram) air to oil heat exchangers with 5 HP motors to provide the necessary
cooling.
An integrated manifold controls the following functions.
a) Oil warming by pumping oil through a resistive load of a relief valve RV-60 (item
310). Directional valve PY521X (item 250) (optional, see BOM or hydraulic
schematic) to be energized.
b) Oil cooling by pumping oil through heat exchanger(s).
c) Fluid filtration to 3 Micron Absolute with local pop-up and provision for remote
differential pressure monitoring.
d) Reservoir filling
The TAFM (conditioning) hydraulic circuit includes the following components:
x
Conditioning pump
3-way suction ball valve
Preliminary (optional) and Post-conditioning particulate filters
Fluid conditioning filter
The conditioning filter serves to maintain the optimum condition of the EHC hydraulic
fluid by removing acids and metal soaps. See section below titled IXE Conditioning
Element Resin Mixture. The conditioning filter elements cannot be cleaned or reused.
The TAFM circuit is intended to operate continuously, but can be shutdown in order to
perform regular maintenance such as changing filter elements. The TAFM circuit can
also be utilized to fill and empty the hydraulic reservoir.
The cooling and conditioning system consists of the following major components:
x
Central manifold assembly.
Particulate filters in both the cooling and conditioning circuits.
Conditioning filter.
Heat exchanger(s).
Cooling and conditioning pump/motor assembly (HCCM and TAFM pump).
The central manifold assembly and the heat exchanger(s) are all fixed to a 1/2 thick
mounting plate. The mounting plate has been designed to mount directly to the top of the
EHC reservoir in a flange-style arrangement.
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The HCCM/TAFM (cooling and conditioning) pumps, 3-way suction ball valve and
suction strainer could be supplied loose, to be installed by skid builder. The pumps
discharge connection to be connected to CCP2 and AFP ports of the manifold.
The suction line of the pumps incorporates a magnetic suction strainer. In normal
circumstances, this device does not require inspection or maintenance. The strainer
should be checked if a maintenance event occurs within the hydraulic circuit which has
allowed ferrous metal particles to enter the system.
The 3-way suction ball valve can be aligned so that suction can be taken from the
reservoir for normal operation or from a drum for filling the reservoir.
The conditioning circuit can also be utilized to empty the EHC reservoir by way of a
dedicated connection (HF014) located on the side of the skid.
All particulate and conditioning filter housings are mounted on the top surface of the
central manifold assembly. One particulate filter serves the cooling system while the
other (one or two) particulate filter(s) and the conditioning filter serve the conditioning
system.
All two (or three) particulate filters incorporate differential pressure switches that indicate
when the filter element has collected the maximum amount of contamination. The
switches measure the true pressure differential across the filter element and have a fixed
non-adjustable setting of 72 PSID (5 BAR). The switch electrical connectors incorporate
a light which illuminates when the switch is indicating an abnormal (dirty) condition.
When the switch indicates that the filter particulate element is dirty, the filter element(s)
should be changed without delay. The particulate filter elements are not cleanable or
reusable.
For water cooled systems, two plate type heat exchangers are provided. These heat
exchangers are mounted vertically and are served by water piping that includes a water
regulating valve. The water regulating valves sensing bulb and bulb well are mounted in
a header manifold located in the heat exchangers common oil piping. The oil flow
through the plate type heat exchangers is from bottom to top. This ensures that the heat
exchangers are full of oil at all times. The water regulating valve should be set in the field
to maintain a reservoir temperature of approximately 115F (46.1C).
For air cooled systems, one or two air to oil heat exchangers are provided.
A desiccant air breather is provided to allow the air that moves from the atmosphere to
the inside of the fluid reservoir, and vice versa, to be dried. In normal operation, this
device acts as an exit point for air admitted into the fluid reservoir by the Stealth ABS
gas blanketing system.
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IXE Conditioning Element Resin Mixture

The standard media used in the IXE 200 type conditioning filter elements which are
supplied with the cooling and conditioning system comprises a mix of 70% weak base
anionic resin and 30% cationic resin. This mixture has been proven to work well with
new installations using brand new oil and almost all field retrofits. However, in some
cases where the existing EHC hydraulic fluid is severely degraded, a different resin
mixture may be more appropriate in order to return the fluid to optimum condition.
In cases where the EHC hydraulic fluid is not brand new, or has been in service for an
extended period of time, it is recommended that the user consult GE Energy for
recommendations relative to Hydac IXE element media mixtures that may be more
appropriate for use in the system. Once the fluid has been returned to optimum
condition, it is recommended that the standard IXE 200 type elements be utilized from
that point forward.
Note: Prior to contacting GE Energy, the user should have the fluid analyzed by a
laboratory where a report of the fluid condition is available for evaluation.
Theory of Operation
HCCM Cooling Circuit

Function: This 31 GPM (117.3 LPM) circuit circulates hydraulic fluid through particulate
filter and heat exchanger. The circuit provides for EHC system hydraulic oil cooling and
filtration.
The cooling pump draws fluid from the EHC reservoir through a magnetic suction
strainer. The pump (Item 170) discharges to the central manifold assembly (Item 10)
which includes the cooling circuit relief valve (Item 310), directional control valve
PY521X (item 250)(optional), pressure gauge CCFI (Item 140), 3 micron particulate filter
F223 (Item 40), de-pressurization and drain valve FV61 (Item 120: See note below) and
the connection ports for the tubing runs to and from the heat exchanger(s). The fluid is
discharged from the central manifold assembly to the heat exchanger(s) (Item 290). On
installations with redundant heat exchangers, 3-way isolation valves (Item 340) (or two
ball valves) allow operation of one heat exchanger while the other heat exchanger is in
stand-by or available for service. From the heat exchanger(s), the fluid flows back to the
EHC reservoir through check valve (item 350)(optional) and the return drop tube.
Cooling circuit particulate filtration:
x
F223 Cooling circuit, 3um rating, replaceable element
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TAFM Conditioning Circuit

Function: This 0.5 GPM (1.9 LPM) circuit circulates hydraulic fluid through conditioning
filter as well as pre and post-filtration on either side of the conditioning filter. The circuit
provides acid control and captures free water.
The conditioning pump (Item 230) draws fluid from either of two points by way of a threeway valve on the suction side of the pump. The three-way valve can be aligned to allow
the pump to take suction from the EHC system reservoir or the external fill connection.
The external connection allows the reservoir to be filled, or topped up from a drum.
During normal operation, the three-way suction valve is aligned so that the pump takes
suction from the fluid reservoir.
The pump discharges to the central manifold assembly (Item 10) which includes the
conditioning circuit relief valve (Item 100), pressure gauge AFPG (Item 140), 3 micron
particulate pre-filter F221(item 40)(optional), conditioning filter IX-01 (iten 20) with ion
exchange (IXE) element (item 25), 3 micron particulate post-filter F222 (Item 60) and depressurization and drain valvesFV52 (optional), FV53 and FV54 (Item 110: See note
below). The circuit also includes check valves CV52 (optional),CV53, CV54 and CV55
(Item 90) (optional)) before and after each filter.
The hydraulic fluid flows in series through the pre-conditioning particulate filter (optional),
through the conditioning (acid control) filter and then on to the post-conditioning and
water removal filter. Upon entering the conditioning filter the fluid is exposed to the
conditioning media and reacts chemically with the resin. This chemical action removes
acids and metal soaps from the hydraulic fluid. The fluid then flows to the postconditioning and water removal filter which serves to remove any particulates not
captured previously any free water in the fluid. From the post-conditioning particulate
filter, the fluid is directed back to the EHC reservoir by way of the central manifold and
the return drop tube.
Manifold connection HF014 can be used to allow the hydraulic fluid to be discharged to
the lube skids external emptying connection and thereby into a suitable container or
drum (ball valve FV55 (item 110) must be closed).
Conditioning circuit, particulate filtration:
x
F221 Conditioning circuit and pre-conditioning, 3um rating, replaceable

element (optional).
F222 Conditioning circuit and post-conditioning, 3um rating, replaceable

element.
x
Conditioning circuit, conditioning filter:
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IX-01 Conditioning filter, IXE (Acid control) element, replaceable element.
Note: The main function of the de-pressurization and drain valve(s) is to allow the
operator to de-pressurize the associated filter housing and render it safe for service.
While it is possible to drain the filter housing using this feature, it is not necessary or
even desirable to completely drain the filter housing while changing the filter element(s).
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Storage and Preservation

The cooling and conditioning system assembly is a vital part of the EHC hydraulic
system and should be stored indoors in a clean and dry area protected from moisture,
dirt and falling objects.
IMPORTANT! Under no circumstance should the assembly be stored exposed to the
weather.
The assembly should be stored with all factory supplied protective caps and plugs
installed and tight.
Residual hydraulic oil will remain within the assembly as a result of factory testing. This
residual oil should not be drained as it will serve to protect the internal parts from
corrosion.
Maximum length of storage will be governed by GE Energy guidelines.
Installation Instructions
The cooling and conditioning system is delivered to the skid builder with the following
items shipped loose:
x
Manifold return tubes (drop tubes).
Cooling and conditioning pump suction line parts.
Ion Exchange unit and filters elements with assembly components
Manifold return tubes (drop tubes) and pumps suction line parts must be installed by the
skid builder prior to final assembly of the cooling and conditioning system onto the lube
skid.
Installing the Ship Loose Components

The return tube ports and the pump suction port are protected by temporary plugs
screwed into the underside of the manifold and a shipping plate installed on the pumps
four-bolt suction port. These protective items are painted yellow for identification. The
shipping plate and plugs can be discarded after they are removed.
CAUTION! It is vital that all ship loose components and all open ports are protected from
contamination ingress during the assembly process.
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Manifold Return Tubes (Drop tubes):

Each of the four (4) drop tubes is a different size. The drop tubes are shipped with
adapters attached to the tubes. Assemble each drop tube assembly as follows:
1. Remove any protective wrapping and/or caps on the tube assembly.
2. Loosen the tube nut and remove the adapter from the end of the tubing
assembly. Ensure that the tube nut does not fall off the tube.
3. Remove the yellow protective shipping plug from the return port on the underside
of the manifold.
4. Install the adapter into the port on the manifold.
5. Install the tubing assembly onto the adapter.
6. Repeat this process for all drop tube assemblies.
IMPORTANT! Ensure that all fittings and tube nuts are properly torqued as these items
will be inaccessible once the cooling and conditioning system is installed.
Cooling and Conditioning System Installation on Lube Skid

Note: Lifting eyes are provided on the heat exchanger supports in order to facilitate a
vertical lift of the assembly onto the lube skid.
The cooling and conditioning system mounting plate is designed to interface with a
corresponding flange located on the top of the lube skid EHC hydraulic reservoir. The
flanged interface should be sealed in a manner that ensures that the entire joint is
airtight and watertight.
IMPORTANT! Install the cooling and conditioning system onto the lube skid only after
the return drop tubes and pump suction line assy have been installed on the underside
of the mounting plate.
1. Lift the cooling and conditioning system assembly and position it onto the lube
skid flange. Secure the assembly with appropriate hardware.
2. Connect and wire the cooling, conditioning pump and heat exchanger electric
motor.
Note: Do not check rotation of the pump motor until the hydraulic reservoir has
been filled with fluid.
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3. In case of water cooled heat exchangers, connect the heat exchanger water
supply and drain lines. The water connections are 1-1/4 NPT (female).
Maximum permissible water flow is 56 GPM (212 LPM)
4. Connect and wire the cooling, conditioning pump and heat exchanger (in case of
air cooled heat exchangers) electric motor.
Note: Do not check rotation of the pump motor until the hydraulic reservoir has
been filled with fluid.
5. Connect and wire the following sensors (See note below):
a. PDS 223 - Differential pressure indicator for filter housing F223.
b. PDS 221 - Differential pressure indicator for filter housing F221 (optional).
c. PDS 222 - Differential pressure indicator for filter housing F222.
IMPORTANT! The differential pressure indicators for filter housings F221 and
F222 are located on the base of the respective filter housings. The differential
pressure indicator for filter housing F223 is located on the side of the central
manifold assembly facing the heat exchangers and is identified by the engraving
on the manifold face: F223 DPS.
6. Connect the lube skids EHC fluid emptying line to the central manifold port
marked HF014. This port is located on the side of the central manifold assembly
facing the heat exchangers. The port on the manifold is SAE-6 (9/16-18 UNF
2B), according to SAE J1926-1 (ISO 11926-1).
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Field Commissioning the Conditioning System:

The following tasks are to be completed in the field once the lube skid had been
permanently installed and electrical power is available.
Prior to commissioning the conditioning system the following tasks must be completed:
x
The conditioning filter (IXE element) must be installed.
The desiccant breather safety o-ring must be removed.
Initial Conditioning Filter and Associated Parts Installation

Refer to manufacturers data sheets located in Appendix C and Airline Hydraulics
schematic and assembly drawing, located in Appendix A.
The following conditioning filter parts are shipped loose (in a box strapped to the cooling
and conditioning system) to the skid builder. These parts need to be installed prior to
commissioning the conditioning system for the first time:
x
Conditioning filter (IXE) element (Hydac P/N 03553650) (See note below).
Upper element adapter (Hydac P/N 02093036)
Spring for upper element adapter (Hydac P/N 02058779)
IMPORTANT! The conditioning filter element should not be removed from the protective
bag or installed in the conditioning filter housing until the skid is being commissioned at
the power station.
As long as the conditioning filter element remains sealed in the factory supplied plastic
bag and is stored at normal temperature conditions, the shelf life is unlimited.
IMPORTANT! The exterior of the conditioning filter element is smooth and solid except
for a series of perforated holes at the top of the element. The fluid enters the element
through these holes and it is critical that the element is installed correctly; with the
perforated holes at the top.
Procedure:
1. Ensure that the conditioning system is shutdown, tagged out and locked out.
2. Open filter housing drain valve FV53.
3.
De-pressurize the conditioning filter housing using the air bleed connection at
the top of the housing. Ensure that the housing is completely de-pressurized.
4.
Remove the top cover of the conditioning filter housing.
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5.
Place the conditioning element (perforated holes toward the top) onto the lower
element adapter inside the housing.
6.
Place the upper element adapter onto the top of the conditioning element.
7.
Place the upper element adapter spring into the machined cavity in the upper
element adapter.
8.
Place the top cover onto the housing and twist the cover counterclockwise to
engage the bolts.
Note: Wipe the cover O-ring and the O-ring seating surface clean prior to
installing the cover.
9.
Tighten the cover bolts securely.
10. Close the filter housing drain valve FV53.

11. Close the housing air bleed connection.
12. Remove locks and tagouts.
13. When the conditioning system is put into service, ensure that air is bled from the
housing using the air bleed connection on the cover. Due to the low flow rate,
this may take some time. Be patient.
Removing the Safety O-ring on the Breather

Refer to manufacturers data sheet located in Appendix C.
Once the desiccant breather has been installed, the safety o-ring must be removed in
order to allow air to move freely in and out of the breather.
Procedure:
1. Locate the pull tab for the o-ring and pull it down to remove the O-ring.
2. Discard the O-ring.
Preparing Cooling and Conditioning System for Operation

1. Fill the EHC Hydraulic reservoir to the recommended level.
2. Check pump rotation:
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a. Ensure electrical power is available to the cooling pump motor and the
conditioning pump motor.
b. Check rotation of the cooling pump and the conditioning pump. Check
rotation by quickly bumping the electric motor(s) on and then off. Follow
pump rotation guidelines shown below. Correct if necessary.
Cooling Pump (HCCM Circuit):
Observe rotation by looking at the cooling pump electric motor fan. Quickly
bump the electric motor on then off. Rotation should be right hand (clockwise)
rotation. If the rotation is not correct, interchange two of the phase wires.
Rotation of the pump is considered right hand (clockwise) as viewed looking
straight at the pumps drive shaft (or looking down at the fan end of the
electric motor). Proper pump rotation is also shown by way of an arrow
sticker on the pump/motor adapter, or on the electric motor.
Conditioning Pump (TAFM Circuit):
Observe rotation by looking at the conditioning pump electric motor fan.
Quickly bump the electric motor on then off. Rotation should be right hand
(clockwise) rotation. If the rotation is not correct, interchange leads A and C.
Rotation of the pump is considered right hand (clockwise) as viewed looking
straight at the pumps drive shaft (or looking at the fan end of the electric
motor). Proper pump rotation is also shown by way of an arrow sticker on the
pump/motor adapter, or on the electric motor.
WARNING! Only properly qualified electricians should carry out electrical
wiring and maintenance tasks on the motors.
3. (Water cooled heat exchanger) Line up heat exchanger oil supply/return valves
and cooling water inlet/outlet valves as follows:
a. Select one heat exchanger for operation.
Note: It is not possible to operate more than one heat exchanger at a time.
See caution note below.
b. Line up the 3-way oil supply valve (located toward the bottom of the heat
exchanger red handle) for the heat exchanger selected so that the arrows
on the valves label designate flow from the supply line (manifold port CCO)
to the heat exchanger.
c. Line up the 3-way oil return valve (located toward the top of the heat
exchanger red handle) for the heat exchanger selected so that the arrows
on the valves label designate flow from the heat exchanger to the return line
(manifold port CCT).
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d. Open the water inlet isolation ball valve (located on top of the heat exchanger
yellow handle) for the heat exchanger selected. This valve is located on the
line coming from the water regulating valve.
e. Open the water outlet isolation ball valve (located on top of the heat
exchanger yellow handle) for the heat exchanger selected.
f.
Ensure that the water inlet and outlet valves for the non-selected heat
exchanger are closed.
Note: Maximum permissible water flow is 56 GPM (212 LPM).
4. Position the valves on the central manifold as follows:

Refer to the Airline Hydraulics schematic and assembly drawing which is located
in Appendix A.
IMPORTANT! Do not force any valves.
Ensure that the heat exchanger oil and water side isolation valves are lined up to
the selected heat exchanger (as described above).
Note: All valve designations are engraved on the central manifold.
x
FV63 OPEN (turn adjustment stem fully counterclockwise, then tighten lock
nut)
FV61 CLOSED (turn adjustment stem fully clockwise, then tighten lock nut)
nut)
nut)
nut)
Commissioning the Cooling (HCCM) Circuit

Refer to the Airline Hydraulics schematic and assembly drawing which is located in
Appendix A.
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Procedure:
1.
Ensure that cooling pump rotation has been verified.
2.
Ensure that (optional) air cooled heat exchanger motor(s) rotation has been
verified.
3.
Open ball valve of the heat exchanger which will be operating and close ball
valve of the heat exchanger which will not be operated.
4.
Start the cooling pump and air cooled heat exchanger motor.
5.
Observe the pressure at gauge CCFI. The gauge should read between 150 PSI
(10.3 BAR) and 200 PSI (13.8 BAR).
6.
Bleed air from filter housing F223 using the bleed plug located at the top of the
filter housing.
WARNING! There is a possibility that EHC hydraulic fluid will leave the filter
housing during this procedure. Ensure that personnel performing this procedure
are equipped with appropriate PPE (Personal Protective Equipment). Ensure
rags and oil absorbent material are at hand in order to wipe up / soak up any oil
that leaves the filter housing during the air bleed procedure.
Note: It is not necessary to bleed every last bit of air from the filter housings.
Bleeding the majority of the air is sufficient.
7.
Operate the cooling circuit for a period of at least 15 minutes.
8.
Shut down the cooling pump.
9.
Line up the 3-way isolation valve (for water cooled heat exchanger) to the other
oil cooler.
10. Change status of ball valves to operate other (optional) air heat exchanger.
11. Line up the water side isolation valves to the other oil cooler (water cooled heat
exchanger option). Ensure that the water side isolation valves serving the cooler
that was on line previously are closed.
12. Start the cooling pump.
13. Operate the cooling circuit for a period of at least 15 minutes.
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CAUTION! It is vital that both heat exchangers are filled with oil during the
commissioning process. Operate each heat exchanger for a period of 10-15 minutes in
order to ensure that the coolers are full of oil and all air has been circulated to the
reservoir. Oil will remain in the shell side of the heat exchanger(s) and will serve to
prevent a bubble of air from entering the reservoir when the standby heat exchanger is
put on line during EHC system operation.
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Additional Tasks:
Once both water cooled heat exchangers have been filled with oil and if operational
circumstances permit, the water regulating valve on the heat exchanger water supply
line should be set. This task will take some time as the reaction time of the entire oil
volume to temperature change can be very slow. The water regulating valve should be
set to maintain the oil in the EHC reservoir at a temperature of 1150F (460C).
Once the water regulating valve has been set, automatic operation (by way of the Mark 6
control system) of the cooling pump/motor should be verified.
The cooling circuit can now remain operating, or it can be shut down depending on plant
requirements.
Commissioning the Conditioning (TAFM) Circuit

Procedure:
1. Ensure that conditioning pump rotation has been verified.
2. Start the conditioning pump.
3. Observe the pressure at gauge AFPG. The gauge should read between 45 PSI
(3.1 BAR) and 60 PSI (4.1 BAR).
4. Bleed air from filter housing F221 (if supplied) using the bleed plug located at the
top of the filter housing.
WARNING! There is a possibility that EHC hydraulic fluid will leave the filter
housing during this procedure. Ensure that personnel performing this procedure
are equipped with appropriate PPE (Personal Protective Equipment). Ensure
rags and oil absorbent material are at hand in order to wipe up / soak up any oil
that leaves the filter housing during the air bleed procedure.
Note: It is not necessary to bleed every last bit of air from the filter housings.
Bleeding the majority of the air is sufficient.
5. Bleed air from the ion exchange filter housing (IX-01) using the test point located
at the top of the filter housing.
Note: The test point interfaces with industry standard 1620 type Microbore test
hoses. The end of the hose should be directed into a bucket. Follow precautions
noted above.
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6. Bleed air from filter housing F222 using the bleed plug located at the top of the
filter housing. Follow precautions noted above.
7. Operate the conditioning circuit for a period of at least 30 minutes. During this
period, periodically bleed air from the top of the filter housings.
The conditioning circuit can now remain operating, or it can be shut down depending on
plant requirements.
Normal Operation
Cooling Circuit:
As long as cooling water is available, the water cooling circuit can continue to operate
without the need for operator attention.
During sustained operation, the particulate filter in the cooling circuit will be doing its job
which is collecting contaminates. Over time, as the filter collects contaminates, the
differential pressure across the element will increase causing a corresponding rise in
cooling circuit operating pressure. The operating pressure (gauge point CCFI) will rise
very slowly, by approximately 72 PSI (5 BAR) over a period of months. This is the point
at which the differential pressure indicator, PDS223 will trip to indicate it is necessary to
change the filter element. The control system will alert the operator(s) when the indicator
trips. The cooling circuit should then be shutdown, locked out, tagged out and the
particulate filter element should be changed. After the filter element has been replaced,
the circuit can be returned to normal operation.
It is important to understand that the differential pressure indicator reacts to the
difference in pressure across the filter element, not to overall cooling circuit operating
pressure.
Note: There is also a light on the differential indicators electrical connector that will
illuminate when the indicator is in the trip state.
CAUTION! Immediately replace the filter element when the differential pressure indicator
trips. DO NOT DELAY. Always have spare filter elements on hand.
CAUTION! The HCCM cooling circuit must be shutdown, de-pressurized, locked out and
tagged out when servicing filter F223. Refer to the section in this manual titled Servicing
Filter Elements / Changing Cooling Filter Element.
IMPORTANT! It is the responsibility of the user to determine the maximum length of time
that the cooling circuit can be shut down for regular maintenance (example: particulate
filter element changes). Knowledge of local ambient conditions and normal operating oil
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temperature will help to determine how long the cooling circuit can be shutdown before
the oil temperature rises to an unacceptable level.
Conditioning Circuit
The conditioning circuit can continue to operate without the need for operator attention.
During sustained operation the particulate filters in the conditioning circuit will be doing
their job which is collecting contaminates. Over time, as the particulate filters in the
conditioning circuit collect contaminates, the differential pressure across the elements
will increase up and the circuit operating pressure (gauge point AFPG and gauge point
AFXG) will rise very slowly. Under normal circumstances, this should take many months.
When either of the particulate filter elements in the conditioning circuit (PDS221, or
PDS222) reach the indicator trip point of 72 PSI (5 BAR) the associated indicator will trip
to indicate it is necessary to change the filter element. The control system will alert the
operator(s) when the indicators trip. The conditioning circuit should then be shutdown,
locked out, tagged out and the filter element associated with the indicator that tripped
should be changed. After the filter element has been replaced, the circuit can be
returned to normal operation.
It is important to understand that the differential pressure indicators react to the
difference in pressure across the filter element, not to overall conditioning circuit
operating pressure.
Note: There is also a light on the differential indicators electrical connector that will
illuminate when the indicator is in the trip state.
The conditioning filter does not utilize a differential pressure indicator to indicate when
the element requires replacement. Instead, conditioning filter element replacement is
indicated by chemical analysis of the hydraulic fluid. This will be discussed later in this
document in the section titled when to change the ion exchange filter element.
CAUTION! Immediately replace the filter element when the differential pressure indicator
trips. DO NOT DELAY. Always have spare filter elements on hand.
CAUTION! The TAFM conditioning circuit must be shutdown, de-pressurized, locked out
and tagged out when servicing filters F221, F222 and the ion exchange conditioning
filter, IX-01. Refer to the section in this manual titled Servicing Filter Elements /
Changing Cooling Filter Element.
that the conditioning circuit can be shut down for regular maintenance (Example:
particulate or conditioning filter element changes).
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TAFM System Set-up for Filling and Emptying Reservoir

The cooling and conditioning system is designed to allow the EHC reservoir to be filled
and emptied by way of the TAFM sub system. Whenever the TAFM system is being
used to fill of empty the reservoir, the oil will flow through all the filters associated with
the system and will be filtered and conditioned.
The lube skid is provided with external connections and a dedicated transfer hose that
will allow the conditioning pump to take suction from, or discharge to, drums or totes.
The function of the external connections is as follows:
x
Filling. Connects to the three-way valve (item 510) on the conditioning pump
suction line. Use the skid builder supplied transfer hose to take suction from a
drum or tote. Ensure that the hose being used is compatible with the EHC
hydraulic fluid.
HF014: Emptying. Connects by way of the lube skid piping to the discharge port
on the central manifold labeled HF014. Use the skid builder supplied transfer
hose to discharge to a drum or tote. Ensure that the hose being used is
compatible with the EHC hydraulic fluid.
Filling:
1. Shut down the conditioning pump.
2. Ensure that the external discharge connection HF014 is blocked off.
3. Ensure that the transfer hose is inserted into the fluid container so it will not draw
air (See caution note below).
4. Attach the transfer hose onto the external connection of the three-way valve
(item 510).
5. Change the position of the three-way valve on the conditioning pump suction line
to allow suction to be taken from the external connection.
6. Start conditioning pump.
7. Monitor the fluid level in the reservoir and the external fluid container. Ensure that
air is not drawn into the system.
8. When the EHC reservoir is filled to the appropriate level, shut down the
conditioning pump.
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9.
Change the position of the three-way valve on the conditioning pump suction
line to allow suction to be taken from the fluid reservoir. This is the normal
operating position. It is recommended that the valve be locked or tagged in this
position.
10. Remove the transfer hose connected to external connection of the three-way
valve.
11. Install the hard cap securely on external connection of the three-way valve. This
step is extremely important. If the cap has become lost, obtain a new one.
12. The conditioning system can now be operated in normal mode.
CAUTION! If the EHC system is operational during the filling process, it is vital for the
technician to monitor the level in the fluid container to ensure that air is not drawn into
the system.
Emptying:
1.
Shut down the conditioning pump.
2.
Remove the hard cap on the external connection HF014 on the side of the lube
skid.
3.
Attach the transfer hose to connection HF014.
4.
Close valve FV55
5.
Start the conditioning pump. Fluid will begin to flow through the transfer hose
into the external fluid container.
6.
Monitor the fluid level in the reservoir and the external fluid container.
7.
When the EHC reservoir is emptied to the appropriate level, shut down the
conditioning pump.
8.
Open valve FV55
9.
Remove the transfer hose connected to external connection HF014.
10. Install the hard cap securely on external connection HF014. This step is
extremely important. If the cap has become lost, obtain a new one.
11. Ensure that the EHC system is not energized with a low fluid level.
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IMPORTANT! The transfer hose supplied by the skid builder should be marked FOR
EHC FLUID TRANSFER ONLY. Do not use the hose for other purposes. The
connections on the hose should be plugged or capped to prevent dirt ingress during
storage.
CAUTION! Ensure that the hard caps on both external connections HF013 and HF014
are installed and secure at all times except during EHC fluid filing or emptying events.
Service, Troubleshooting and Repair

Other than contamination related failure, there is little that will go wrong with the cooling
and conditioning assembly during the life of the EHC system.
Normal Service (Filter Elements)

Filter and Breather Part Numbers
Particulate Filter Element Part Numbers:
x
Particulate Filter Elements for Filter Housings (F221 and F223) Filter
element part number: SM00251. Quantity required per housing, per change: 1
pc.
Particulate Filter Elements for Filter Housing (F222) Combination filter and
water absorbing element part number: SM00250. Quantity required per housing,
per change: 1 pc.
Conditioning Element Part Number:

x
Ion Exchange Filter Element for Filter Housing (IX-01) - Hydac model code:
IXE-200/-GE, P/N 03553650. Quantity required per housing per change: 1 ea.
Desiccant Air Breather Element Part Number:

x
Desiccant Air Breather Hydac model code: BD 800 X 2 W 0.0, P/N 02075158.
Changing Cooling Circuit Particulate Filter Element (F223)

WARNING! De-pressurize filter housing before removing the housing cover. The filter
housing can be de-pressurized by shutting down, locking out and tagging out the cooling
circuit pump and then fully opening de-pressurization and drain valve FV61.
that the cooling circuit can be shutdown for maintenance.
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IMPORTANT! The particulate filter element is secured in the filter housing by a spring.
The purpose of the spring is to ensure that the rubber grommet on the bottom of the
element stays firmly engaged with the spigot at the bottom of the housing. The upper
portion of the spring seats into a recessed cavity on the underside of the top cap. The
lower portion of the spring seats in a device called a grommet cap which fits snugly into
a rubber grommet on the top of the filter element. The rubber grommet is a permanent
part of the filter element, but the grommet cap is not. The user should remove and retain
the grommet cap during the element change procedure.
Procedure:
1.
Obtain a spare cooling circuit particulate filter element, SM00251. Quantity

required per housing, per change: 1 pc.
2.
Obtain lint-free rags.
3.
Shutdown the cooling circuit pump.
4.
Tag out and lock out the cooling circuit pump.
5.
Observe pressure at gauge point CCFI. The reading should be 0 PSI (0 BAR).
6.
OPEN valve FV61.
7.
Ensure that filter housing F223 is de-pressurized by cracking the bleed plug on
the top cap of the filter housing. Wait approximately 5 minutes. This will allow
the level in the housing to decrease by a small amount.
8.
Note: It is not necessary to completely drain the filter housing.
9.
Close valve FV61.
10. Once it is determined that the housing has been de-pressurized, the bleed plug
on the top cap should be tightened securely.
11. Remove the filter housing top cap. Set the cap aside on a clean surface. Protect
the cap from contamination.
CAUTION! Although the filter housing tube is fixed to the filter housing base
with thread locking compound, it may be necessary to utilize a strap wrench to
prevent the housing tube from turning while the top cap is removed. This is
normally not a problem but the user should be aware that it could happen.
12. Remove the spring. Set the spring aside on a clean surface. Protect the spring
from contamination.
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13. Remove the grommet cap from the top of the filter element. Set the grommet
cap aside on a clean surface. Protect the grommet cap from contamination.
14. Remove the filter element. Immediately put the used element in a clean
container compatible with the hydraulic fluid used in the EHC system. This step
is important to ensure that the element is ready for examination should it
become necessary.
15. Install the new filter element. The element can be installed in either direction.
Make sure that the rubber grommet on the bottom of the filter element is fully
seated on the spigot at the bottom of the filter housing.
16. Install the grommet cap.
17. Install the spring into the grommet cap.
Hint: In order to minimize the amount of time it takes to bleed air from the
housing upon start up, the housing can be topped up with CLEAN fluid prior to
installing the top cap.
IMPORTANT! Only take this shortcut if CLEAN fluid is available. If the user
cannot ensure that clean fluid is available, skip this step.
18. Install and tighten the filter housing top cap. Ensure that the O-ring and O-ring
sealing surfaces have been wiped clean and re-lubricated with CLEAN oil prior
to installing the cap.
Note: Ensure the spring engages the recessed cavity in the top cap.
19. Remove tags and locks on the cooling circuit pump.
20. Start the cooling circuit pump.
21. Bleed air from the filter housing using the bleed plug located at the top of the
filter housing.
CAUTION! Dispose of the used filter element in accordance with all local and
company environmental guidelines.
Changing Optional Conditioning Circuit Particulate Filter Element

(F221)
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housing can be de-pressurized by shutting down, locking out and tagging out the
conditioning circuit pump and then fully opening de-pressurization and drain valve FV52.
that the conditioning circuit can be shutdown for maintenance.
IMPORTANT! The particulate filter element is secured in the filter housing by a spring.
The purpose of the spring is to ensure that the rubber grommet on the bottom of the
element stays firmly engaged with the spigot at the bottom of the housing. The upper
portion of the spring seats into a recessed cavity on the underside of the top cap. The
lower portion of the spring seats in a device called a grommet cap which fits snugly into
a rubber grommet on the top of the filter element. The rubber grommet is a permanent
part of the filter element, but the grommet cap is not. It is vital that the user remove and
retain the grommet cap during the element change procedure.
Procedure:
1.
Obtain a spare conditioning circuit particulate filter element, SM00251. Quantity

required per housing per change: 1 ea.
2.
Obtain lint-free rags.
3.
Shutdown the conditioning-circuit pump.
4.
Tagout and lockout the conditioning-circuit pump.
5.
Observe pressure at gauge point AFPG. The reading should be 0 PSI (0 BAR).
6.
OPEN valve FV52.
7.
8.
Close valve FV52.
9.
Once it is determined that the housing has been de-pressurized, the bleed plug
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prevent the housing tube from turning while the cap is removed. This is normally
not a problem but the user should be aware that it could happen.
from contamination.
12. Remove the grommet cap from the top of the filter element. Set the grommet
cap aside on a clean surface. Protect the grommet cap from contamination.
13. Remove the filter element. Immediately put the used element in a clean
become necessary.
14. Install the new filter element. The element can be installed in either direction.
Make sure that the rubber grommet on the bottom of the filter element is fully
seated on the spigot at the bottom of the filter housing.
18. Remove tags and locks on the conditioning circuit pump.
19. Start the conditioning circuit pump.
filter housing.
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21. Check for air carry over by bleeding the conditioning filter housing (IX-01) and
filter housing F222.
CAUTION! Dispose of the used filter element in accordance with all local and company
environmental guidelines.
Changing Conditioning Circuit Particulate and Water Absorbing

Filter Elements (F222)
IMPORTANT! There are two (2) combination particulate filter and water absorbing
elements in the F222 filter housing. The two elements are stacked one on top of the
other. Located between the two elements is a device called an element connector. The
element connector fits snuggly into the rubber grommets between the two elements. The
user should remove and retain the element connector during the element change
procedure.
IMPORTANT! The two particulate filter elements are secured in the filter housing by a
spring. The purpose of the spring is to ensure that the rubber grommet on the bottom of
the lower element stays firmly engaged with the spigot at the bottom of the housing. The
upper portion of the spring seats into a recessed cavity on the underside of the top cap.
The lower portion of the spring seats in a device called a grommet cap which fits snugly
into a rubber grommet on the top of the upper filter element. The rubber grommet is a
permanent part of the filter element, but the grommet cap is not. The user should
remove and retain the grommet cap during the element change procedure.
Procedure:
1. Obtain a spare conditioning circuit particulate and water absorbing filter element,
SM00250. Quantity required per housing per change: (1 ea.)
2. Obtain lint-free rags.
3. Shutdown the conditioning-circuit pump.
4. Tag out and lock out the conditioning-circuit pump.
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5. Observe pressure at gauge points AFPG and AFXG. The reading on both
gauges should be 0 PSI (0 BAR).
6. OPEN valve FV54.
7.
8.
Close valve FV54.
9.
Once it is determined that the housing has been de-pressurized, the bleed plug
prevent the housing tube from turning while the cap is removed. This is normally
not a problem but the user should be aware that it could happen.
from contamination.
12. Remove the grommet cap from the top of the upper filter element. Set the
grommet cap aside on a clean surface. Protect the grommet cap from
contamination.
13. Remove the upper filter element. Immediately put the used element in a clean
become necessary.
14. Remove the lower filter element. Immediately put the used element in a clean
become necessary.
IMPORTANT! The element connector located between the upper and lower
filter elements should be removed and re-used. A new element connector does
not come with the new filter elements.
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15. Remove the element connector. Set the element connector aside on a clean
surface. Protect the element connector from contamination.
16. Install a new lower filter element. The element can be installed in either
direction. Make sure that the rubber grommet on the bottom of the filter element
is fully seated on the spigot at the bottom of the filter housing.
17. Install the element connector into the rubber grommet on the top of the lower
filter element.
18. Install a new upper filter element. The element can be installed in either
direction. Make sure that the rubber grommet on the bottom of the filter element
is fully seated on the element connector.
filter housing.
Changing Conditioning Filter Elements (Housing IX-01)

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CAUTION! The conditioning filter element has a distinct top and bottom. The element
should be installed with the perforated holes at the top.
IMPORTANT! The conditioning filter element is secured in the filter housing by a spring.
The purpose of the spring is to ensure that the rubber gasket on the bottom of the
element stays firmly seated onto the element adapter (lower) at the bottom of the
housing. The upper portion of the spring seats into a recessed cavity on the underside of
the top cap. The lower portion of the spring seats into a recessed cavity machined into a
device called an element adapter (upper) which in turn seats onto a rubber gasket on the
top of the filter element. The rubber gasket is a permanent part of the filter element, but
the element adapter is not. It is vital that the user remove and retain the element adapter
during the element change procedure.
Procedure:
1. Obtain a spare conditioning circuit ion exchange filter element, Hydac model
code: IXE-200/-GE, Hydac part number 03553650. Quantity required per
housing, per change: (1 ea.)
2. Obtain lint-free rags.
3. Obtain approximately 3-4 gallons of CLEAN EHC hydraulic fluid in a clean
covered container. Ensure that the cover is installed to prevent the clean fluid
from being contaminated with dirt, or water. This fluid will be used to fill the
conditioning filter housing prior to the installation of the top cover.
4. Shutdown the conditioning circuit pump.
5. Tag out and lock out the conditioning circuit pump.
6. Observe pressure at gauge point AFPG and AFXG. The reading on both gauges
should be 0 PSI (0 BAR).
7. OPEN valve FV53.
8.
Ensure that filter housing IX-01 is de-pressurized by installing an industry

standard 1620 type test hose onto the test point at the top cap of the filter
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housing. Wait approximately 1 minute. This will allow the level in the housing to
decrease by a small amount.
Note: It is not advisable or necessary to completely drain the filter housing.
9.
Close valve FV53.
10. Remove the filter housing top cover by loosening the four bolts that hold on the
cover and rotating the cover so that the notches in the cover clear the bolts. The
bolts do not need to be removed. Set the cover aside on a clean surface.
Protect the cover from contamination.
Note: Do not damage or misplace the O-ring for the cover!
from contamination.
12. Remove the element adapter from the top of the filter element. Set the element
adapter aside on a clean surface. Protect the element adapter from
contamination.
13. Remove the conditioning filter element. Immediately put the used element in a
clean container compatible with the hydraulic fluid used in the EHC system. This
step is important to ensure that the element is ready for examination should it
become necessary.
14. Install the new conditioning filter element.
Note: Install the element with the perforated holes at the top.
IMPORTANT! In order to minimize the amount of air carried over from the
conditioning filter housing to the next filter (and possibly to the reservoir) upon
start up, the housing should be topped-up with CLEAN EHC hydraulic fluid prior
to installing the top cover.
Pour the clean fluid into the housing in order to fill (as much is practical), the
housing and the air space in the top of the element. Pour fluid into the hollow
center of the element. Fill the housing just shy of the rim. Once the housing and
the element have been filled with hydraulic fluid, proceed to the next step.
15. Install the element adapter.
16. Install the spring into the machined cavity in the element adapter.
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17. Install the top cover and rotate the cover so that the sides of the notches in the
cover contact the shank of the bolts. Tighten the four bolts evenly.
Note: Ensure that the O-ring and O-ring sealing surfaces have been wiped
clean and re-lubricated with CLEAN oil prior to installing the cap. When installing
the top cover, ensure the spring engages the underside of the top cover
properly.
20. Bleed the remaining air from the conditioning filter housing using the industry
standard 1620 type test hose that is still installed onto the test point on the top
cover of the filter housing.
21. Once all air has been expelled, remove the test hose and install the protective
cap onto the test point.
22. Check for air carry over by bleeding filter housing F222.
Important Information Related to Conditioning Filter Elements

When to Change the Ion Exchange Filter Element
The point at which the user should change the ion exchange conditioning element is
dictated by an increase in the hydraulic fluids TAN number (Total Acid Number), not by
differential pressure. Unlike the particulate filters, the differential pressure across the ion
exchange filter assembly will not substantially increase while the element is in service,
therefore the conditioning filter assembly does not include a differential pressure
indicator.
The TAN number of the hydraulic fluid is determined by laboratory fluid analysis. Ideally,
the user will have a fluid sampling and test program in place whereby a sample of EHC
fluid is sent out for analysis once each month. The maximum allowable TAN number is
dictated by GE Energy in combination with results trending of the EHC system fluid
analysis reports.
Generally speaking, the ion exchange element should be changed when fluid analysis
reports indicate a two month increasing trend in the TAN number.
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Ion Exchange Element Water Content

The media in the ion exchange filter element is activated by water. When new, the media
contains approximately 5% water by weight. The water in the media will leave the filter
element and migrate downstream when the element is first put into service. The TAFM
conditioning system has been designed so that the water leaving the conditioning
element is captured and retained before it has a chance to enter the EHC reservoir. The
water leaves the ion exchange element very soon after the new element is first put into
service. Action on the part of the user is required to ensure that the water is successfully
retained and removed.
Immediately downstream of the conditioning element (IX-01) is a special dual purpose
water removal and particulate filter assembly (F222). The main purpose of this filter is to
capture and retain the free water that leaves the ion exchange element. The F222 filter
assembly contains two filter elements (referred to as the BN/AM elements) that not only
capture contaminates, but also capture free water. As the BN/AM elements capture
more and more water, the differential pressure across the elements will go up.
Eventually, when the elements have collected all the water they can hold, the differential
pressure indicator will trip at 72 PSID (5 BAR). This indicates that the elements need to
be changed.
Each time that the ion exchange element is changed, the user should be aware that the
BN/AM elements in filter assembly F222 may need to be replaced. It will be necessary to
have two (2) spare BN/AM elements standing by, ready for use, during all conditioning
element change events.
Immediately after new ion exchange element has been put onto service, the existing set
of BN/AM elements will collect the water that originates from the new ion exchange
element. At this point, the F222 differential indicator may indicate that the BN/AM
elements need to be changed. If the differential pressure indicator does trip, shutdown
the system and replace the BN/AM elements immediately. After the new BN/AM
elements are put into service, the system can continue to operate until the next ion
exchange element change is indicated.
IMPORTANT! Replacement of the dual purpose BN/AM filter elements is not specifically
dictated by ion exchange element maintenance events. The dual purpose BN/AM
elements may reach maximum pressure differential due to other causes, such as the
collection of additional contaminates. If this is the case, the elements should be changed
irrespective of the ion exchange filter condition.
Changing Desiccant Air Breather Cartridge

The desiccant air breather cartridge should be replaced when the color of the silica gel
media turns from gold to green. A color indicator label is provided on the side of the
cartridge to assist in determining when to replacement is required. The desiccant air
breather is not reusable.
Rev. None
36
www.airlinehyd.com
The desiccant air breather cartridge includes a 2.00 NPT male connection. The
cartridge is screwed into a plastic coupling which is a permanent part of the cooling and
conditioning system assembly and should not be removed.
The breather should be changed as quickly as possible. The system should never
operate for any length of time with the breather removed.
IMPORTANT! The Hydac desiccant breather is protected from moisture ingression
during storage by a safety seal o-ring and a shipping cap. These protective devices
should be removed prior to installing the breather.
Procedure:
1. Obtain a spare desiccant air breather cartridge, Hydac model code: BD 800 X 2
W 0.0, P/N 02075158. Quantity required per change: (1 ea.)
2. Remove the protective plastic cap installed on the 2 MNPT connection.
3. Remove the existing desiccant air breather cartridge. Grasp the plastic coupling
with one hand and unscrew the cartridge with the other hand.
4. Install the replacement desiccant air breather. Grasp the plastic coupling with
one hand and screw on the new cartridge with the other hand. Tighten securely
by hand.
5. Remove the protective safety o-ring.
Rev. None
37
www.airlinehyd.com
Bill of Material
ITEM
QTY
VENDOR
DESCRIPTION
PART NUMBER
10
Daman
Manifold assembly, IXU, without filters

or hardware
DAM-E28215 REVO
20
Hydac
HYDAC ION EXCHANGE UNIT WITH

NO ELEMENT
HYC-02095296
25
Hydac
30
MARTIN FLUID
POWER
BROWN VITON O-RING
MIS-OR37175 (OR371BV75)
40
Hydac
Filter assembly, HF, manifold mount,

NO ELEMENT(2096842)
HYCHF4P09PXXA1.1/VSO20
0HE
45
Hydac
50
HYDAC
DIFFERENTIAL PRESSURE SWITCH

FOR FILTER 02062198
HYC-VD5D0VL110
02062198
60
Hydac
Recirculation Filter 18" Housing, no

element
HYCHF4P18PXXA1.1/VB6SO
200HG
60A
Hydac
Water Absorbing/ Particulate Filter

Element (Ships loose as part of 658-7
Startup Kit, Item 3)
80
HYDAC
TEST POINT
06007029
90
Hydac
Cartridge Type Check Valve 03010153
HYC-RV08A01CV05
03010153
91
Parker
Cavity Plug
8P5ON-S
100
Hydac
Cartridge Type Relief Valve - 55 to 500

psi 03010141
HYC-DB08A01CV050V
03010141
110
SUN
Cartridge Type Needle Valve
NFDCLAV
Rev. None
Conditioning Filter Element

(Ships loose as part of 658-7 Startup
Kit, Item 2)
Particulate Filter Element

(Ships loose as [art of 658-7 Startup
Kit, Item 1)
38
IXE 200/-GE (03553650)
AHC-SM00251
AHC-SM00250
www.airlinehyd.com
111
SUN
Tri Grip Knob Kit
SUN-991034
120
SUN
Cartridge Type Needle Valve (T-18A)
SUN-NFFDLIV
121
SUN
Tri Grip Knob Kit
SUN-991034
130
Hydac
Test point, M1620 format, SAE-6 male

connection, Viton seals
HYC-06007030
140
Noshok
0 to 300 psi/bar dual scale, liquid filled

pressure gauge
NOS25500SST300PSI/BAR
150
SUN
Needle Valve
SUN-NFABKXV
ITM367791
5KFS112XAA1027
160
GE
5HP/3.7KW, 2925 RPM, 400/3/50,

VAC, 112M FRAME, CAST IRON,
Class 1, Zone 2, AEX NA 11C T3
IECEX CAS .09.0012TEFC, IP55,
Class H Insulation, IEC Design N,V15T
Mount, 65K Temp. Rise, 1.00 S.F.,
Altitude 3300Ft,-40 TO 65*C Ambient,
FT Face, Terminal Box on Top, F1
Mounting, W/feet and Ground Lug on
Motor, Space Heaters, 230VAC, 3 N.C.,
CL F Thermostat Trip, 212E Paint Plan,
Internal Epoxy Paint, Additional
Nameplate w/Directional Arrows.
170
IMO
3 Screw 3G series pump 2" Code 61

Inlet, 1-1/2 code 61 outlet, Viton Seals
AA3G/NVPSCA143SJ
3535/034
180
BSF
C-FACE ADAPTER
46532-882
190
MAGNALOY
COUPLING HALF 28 MM x 8 MM
KEYWAY
M100M2808
200
MAGNALOY
COUPLING HALF 3/4 X 3/16
M10002406
210
MAGNALOY
HYTREL INSERT
M170H5
GE
1HP/0.75KW, 1425 RPM, 400/3/50,

VAC, 90S FRAME, CAST IRON Class
1, Zone 2, AEX NA 11C T3 IECEX CAS
.09.0012., TEFC, IP56, Class H
Insulation, 65K Temp. Rise, 1.00 S.F.,
Altitude 3300Ft, 65*C Ambient
IEC.,Design N, FT Face, F1 Mounting,
W/feet and Ground Lug on Motor, PTC
Winding 170 deg C Thermistors, 212E
ITM367791
5KFS112XAA1027
220
Rev. None
39
www.airlinehyd.com
Paint Plan, Internal Epoxy Paint,

Additional Nameplate w/.
230
VIKING
Pump, gear, 0.067 cu/in rev,
GP0470-A0O P/N
V3G0470-1852015 , 3/8
NPT, W/VITON SEALS &
LIP SEAL, NEEDLE
BEARINGS, LESS
INTERAL RELIEF
VALVE
240
BSF
C-FACE ADAPTER
46532-881
250
MAGNALOY
COUPLING HALF 24 MM X 8 MM
M100M2408
251
MAGNALOY
COUPLING HALF 1/2 x 1/8
M10001604
252
MAGNALOY
INSERT, HYTREL
M170H5
270
APPOLO
BALL VALVES, 3/4 NPT
76F-147-01A
280
THERMAL
TRANSFER
WATER MODULATING VALVE1 1/2

ASME 150 # FLANGES, 75 135
DEG F, BRASS
65253
281
THERMAL
TRANSFER
THERMO WELL, BRASS, 17 1/2
67438
282
DAMAN
HEADER BLOCK, THERMO WELL
D31832, R0
290
THERMAL
TRANSFER
HEAT EXCHANGER, SSC-836-4-4-F

W/ 2 SAE SS ORB PORTS,1 1/2 NPT
WATER, 316SS
SSC-836-217204
300
PARKER
CAVITY PLUG N.O.
PAR-16P5ONS
310
SUN
Relief Valve (T16A)
SUN-RDHALEV
320
SUN
CAVITY PLUG ALL PORTS BLOCKED

T-16A
SUN-XIOA-XXV
340
DMIC
3-WAY BALL VALVE
BV3L-1500-SA-4323
Rev. None
40
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350
APOLLO
1-1/2 NPT CHECK VALVES
62-107-01
360
SUN
CAVITY PLUG, ALL PORTS

PLUGGED, T-5A
XDCA-XXV
380
DAMAN
KF4P COVER PLATE
D32966, R1
390
Hydac
RESERVOIR BREATHER
HYC-BD800X2W0.0
02075158
400
MAGNOM
2 NPT, SUCTION STRAINER
MAG-PM11003SU2NPT
555103014
410
MAGNOM
3/4 NPT, SUCTION STRAINER
MAGPM07603SU3/4NPT
555103002
420
DMIC
3-WAY BALL VALVE 1/2, ZERO LEAK
DMIC
BV3LZ0500SA4323ZZZO
Rev. None
41
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List of Recommended Spare Parts

RECOMMENDED
ON-HAND
QUANTITY
MANUFACTURER
Hydac
Conditioning Filter
Element
(Used w/ Item 20)
IXE 200/-GE (03553650)
Hydac

(Used w/ Item 40)
AHC-SM00251
Hydac
Water Absorbing/
(Used w/ Item 60)
AHC-SM00250
Hydac
Desiccant Breather
Element (Item 390)
BD 800 X 2 W 0.0 (02075158)
Hydac
Cooling Pump Relief

Valve (Item 310)
RDHA-LEN
Hydac
Conditioning Pump Relief

Valve (Item 100)
DB08A-1-C-V-050-V
IMO
3 Screw 3G series pump

2 Code 61 Inlet, 1-1/2
code 61 outlet, Viton
Seals (item 170)
AA3G/NVPSCA143SJ
3535/034
GP0470-A0O P/N V3G04701852015 , 3/8 NPT, W/VITON
SEALS & LIP SEAL, NEEDLE
BEARINGS, LESS INTERAL
RELIEF VALVE
DESCRIPTION
(ITEM NUMBER)
PART NUMBER
VIKING
Pump, gear, 0.067 cu/in

rev, (item 230)
THERMAL
TRANSFER
HEAT EXCHANGER
(item 290)
Hydac
Differential Pressure
Indicator (Item 50)
VD5D.0/VL115 (02062198)
Noshok
Pressure Gauge
(Item 140)
25500SST300PSI/BAR
Rev. None
42
SSC-836217204
www.airlinehyd.com
MAGNALOY
INSERT, HYTREL
M170H5
MAGNALOY
INSERT, HYTREL
M270H5
Contact Information:
Airline Hydraulics Corporation
3557 Progress Drive
Bensalem, PA, 19020
Phone: (215) 638-4700
Rev. None
43
www.airlinehyd.com
Appendix A
Airline Hydraulics Drawings
Assembly drawing A1057-04M000 and hydraulic schematic, AHC Drawing No: A1057-04H000
Rev. None
www.airlinehyd.com
2
REV
A
42.58
38.17
21.80
18.05
C
D
WATER OUTLET CONNECTION

3/4" FEMALE NPT
1
REVISION HISTORY
DESCRIPTION
ADDED "CENTER OF GRAVITY" CALLOUT
CHANGED CHANNEL TO 6" WIDE UPDATED TUBE RUNS - UPDATED RIGHT
ISO VIEW
UPDATED DIMS TOP VIEW - UPDATED
TUBE RUN TO NEW HEAT EXCHANGER
RELOCATED COOLER SUB-ASSEMBLY
CHANNEL TO 3" FROM PLATE EDGE AND
UPDATED TUBING RUNS TO AS-BUILT.
DATE
BY
1/27/2014 G.S.
2/6/2014
G.S.
3/21/2014 G.S.
4/17/2014 WCP
D
10.03
3.88
P2.00 LIFTING
WATER INLET CONNECTION

3/4" FEMALE NPT
6.12
10.50
.24
D
A
CENTER OF
GRAVITY
B
C
58.86
57.27
61.31
22.48
ALLOW 12" FOR
ELEMENT REMOVAL
(9.26)
2.73
.44
HF014 - JIC-08
RESERVOIR DRAIN
FILL - JIC-08
CUSTOMER FILL
DOWN TUBE LENGTH SUPPLIED
IS 50" AS STANDARD
SPECIFY IF DIFFERENT LENGTH
IS REQUIRED
10.50
20.45
47.50
NOTE:
1. USE SPREADER BAR TO LIFT ASSEMBLY.
2. ESTIMATED WEIGHT: 1250 LBS. (567 kg)
2.50
4.00 TYP
.50
4.00 TYP
.50
23.13
18.00
15.00
GE Power Generation
4.00
3.00
GENERAL ELECTRIC COMPANY

Schenectady, NY
VENDOR SUPPLIED DRAWING
DT-
GE NOT TO REVISE. GE REVISION LEVEL IS AS SHOWN ON THIS APPLIQUE.

THIS DOCUMENT IS FILED UNDER THE GE DRAWING NUMBER
4.00 TYP
9.00
4.00
A
25.00
11.99
16.25
THIS DOCUMENT SHALL BE REVISED IN ITS ENTIRETY. ALL SHEETS OF THIS DOCUMENT ARE
THE SAME REVISION LEVEL AS INDICATED IN THIS VENDOR SUPPLIED DRAWING APPLIQUE.
FIRST MADE FOR:
18.38
GE SIGNATURES
GE DRAWING NUMBER
DATE
288D2342
ISSUED:
TOLERANCES UNLESS SPECIFIED

Interpret Drawing Per ANSI Y14.5-1994
A-1057-4
ENGLISH
3.38
36X P.44 THRU
JOB #:
22.09
4
SHEET 1 of 1
REV.
CHECKED:
25.00
.XX B
XXX B
Angular .X =
Angular .XX=
B
Perpendicularity=
Parallelism=
Concentricity=
Third Angle Projection
METRICS
[.X
B]
[.XX B]
Angular .X =
Angular .XX =
B
Perpendicularity=
Parallelism =
Concentricity=
All Threads to be CLASS 2
Remove Sharp Edges and Burrs
100% Employee Owned Company
3557 Progress Drive,

Bensalem, PA 19020
Phone: (215) 638-4700
Fax: (215) 637-1707
www.airlinehyd.com
TITLE:
GE 298A0046P0003 IXFU COOLING

ASSEMBLY LAYOUT DRAWING
SCALE:
N.T.S.
SIZE:
BY:
DWG. #:
G.Selph
A1057-04M000
DATE:
12/17/13
SHEET:
REV.:
1 of 1
Appendix B
Application-Related Technical Data
Then technical data below is specific to the following cooling and conditioning assembly:
GE Energy part number: 103T4244P0100
General:
Estimated weight of assembly
Installation position
Design standards for fluid field
connections
1500 lbs. (680 KG)

Vertical
SAE standard J1926 for threaded ports
SAE standard J518 for flange ports
Fluid Related:
Operating pressure
Relief valve set pressure
Particulate filter maximum differential
Flow rate
Hydraulic fluid
Cooling: to 180 PSI (12.4 BAR)

Conditioning: to 150 PSI (10.3 BAR)
Cooling: 250 PSI (17.2 BAR)
Conditioning: 200 PSI (13.9 BAR)
Cooling: 72 PSI (5 BAR)
Conditioning: 72 PSI (5 BAR)
Cooling: 31 GPM (117.3 LPM)
Conditioning: 0. 5 GPM (1.9 LPM)
Fyrquel EHC / Phosphate ester
Electrical
Electric Motor (Cooling Pump):
Horsepower
Voltage
Frequency / Phases
Rated Speed
Full Load current
3.7kW (5HP)
400 VAC
50 Hz / 3 Phase
2925 RPM (nominal)
7.1 AMPS at 100% rated load
Electric Motor (Conditioning Pump):

Horsepower (conditioning)
Voltage
Frequency / Phases
Rated Speed (conditioning)
Full Load current
Rev. None
0.75kW (1HP)
400 VAC
50 Hz / 3 Phase
1430 RPM (nominal)
1.6 AMPS at 100% rated load
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Particulate filter differential pressure switches, PDS222 and PDS223:

Switch changeover (trip) point
Voltage (maximum)
Induction free power rating
Contacts
Insulation
72 PSID (5 BAR)
250 VAC (maximum)
5A at 250 VAC (maximum)
3A at 12 VDC or 24 VDC (maximum)
1A at 60 VDC (maximum)
SPDT (pin ID 1, 2 and 3) see below
IP55
In normal operation with differential pressure across the element below the changeover point, contacts 1
(common) and 2 (clean) are made. When the differential pressure across the element reaches the changeover
point of 72 PSID (5 BAR), the switch contacts change state and contacts 1 (common) and 3 (dirty) are made.
The electrical connector on the switch includes a light which will illuminate when the switch senses that the
filter element has reached the switch set point of 72 PSID (5 BAR).
Rev. None
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Appendix C
COOLING-LOOP FILTER (F223)
FLUID CONDITIONING FILTER (IX-01)
AIR BLEED PLUG

(TYPICAL LOCATION)
POST-FILTER (F222)
DIAGRAM 1: Filter arrangement and identification.
COOLING FILTER GAUGE
INLET GAUGE
POST-FILTER GAUGE
DIAGRAM 2: Filter gauge identification.
Rev. None
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RESERVOIR BREATHER
DIAGRAM 3: Reservoir breather location.
3-WAY HEAT EXCHANGER

SELECTION BALL VALVE
(ITEM 340)
CONDITIONING MANIFOLD
DIAGRAM 4: Component location and identification.
Rev. None
www.airlinehyd.com
HEAT
EXCHANGERS (2)
(ITEMS 290)
3-WAY HEAT EXCHANGER

SELECTION BALL VALVE
(ITEM 340)
DIAGRAM 5: Heat exchangers.
NEEDLE VALVE (FV55)
DIAGRAM 6: Valve location on side of manifold.
Rev. None
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Appendix D
Manufacturers Data Sheets
x
Sun Hydraulics NFDD (OPTIONAL)
Sun Hydraulics NFAB
Sun Hydraulics NFFD
Sun Hydraulics NFDC
Sun Hydraulics RDHA
Sun Hydraulics XDCA
Sun Hydraulics XIOA
Sun Hydraulics 991-034 Handknob Control Kit
Magnaloy Couplings
Noshok 400/500 Series Stainless Steel Pressure Gauges
Magnom Pumpmate
HYDAC RV08A-01
HYDAC HF4P Series
HYDAC DB08A-01
HYDAC Clogging Indicators
Hydac Betamicron Filter Element
Hydac Aquamicron Filter Element
Hydac 1620 Series TestPoints
Hydac BD Reservoir Breather
Thermal Transfer - Heat Exchangers
DMIC BV3L/BV3LZ
IMO Pumps
VIKING Pumps
Apollo Valves 77-100 Series & 62 Series
GE MOTOR 3.7 KW
GE MOTOR 0.75 KW
Thermal Transfer Water Modulating Valve
Rev. None
www.airlinehyd.com

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