hpfi hydraulic support system 0700

high pressure fuel injection TM

ECD-0090 10-2001

REV 2

HYDRAULICSUPPORTSYSTEMMANUAL

Contact Information

CONTCONTCONTCONTCONTAAAAACTING ENGINUITYCTING ENGINUITYCTING ENGINUITYCTING ENGINUITYCTING ENGINUITY

For replacement parts and service:

Enginuity LLC2643 Midpoint Dr., Suite AFort Collins, Colorado 80525

Phone: (970) 224-0170Fax: (970) 224-0171

or e-mail us at [email protected]

visit us at www.enginuityinc.com

SPSPSPSPSPARE & REPLARE & REPLARE & REPLARE & REPLARE & REPLAAAAACEMENT PCEMENT PCEMENT PCEMENT PCEMENT PARARARARARTSTSTSTSTS

Enginuity strives to maintain the best quality product available to the consumer. The individual componentsused 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 performanceand/or system failure. If you should have trouble with a component of the system, please see the specificportion of this manual for a description of how to send that component back to Enginuity LLC for repair orreplacement.

In the interest of minimizing downtime on your system Enginuity LLC advises stocking spare parts for thesystem on hand. Please contact Enginuity LLC for a list of recommended spare parts for your system.

Table of Contents

System SpecificSystem SpecificSystem SpecificSystem SpecificSystem Specificaaaaationstionstionstionstions 44444

IntroductionsIntroductionsIntroductionsIntroductionsIntroductions 66666

GenerGenerGenerGenerGeneral Informaal Informaal Informaal Informaal Informationtiontiontiontion 77777

InstInstInstInstInstallaallaallaallaallationtiontiontiontion 99999

Hydraulic Oil Supply Headers 9

Hydraulic Oil Return Headers 9

Gas/Oil Return Headers 9

Branch Hoses 9

Header Support and Mounting 9

Hydraulic Header Bypass Valves 10

Hydarulic Oil 10

Gas/Oil Seperator 10

Visual Gas Leak Indicator 11

Hydraulic System Vent 11

Engine Mounted Hydraulic Skid 12

Hydraulic Oil Lever Sensor 12

Oil Heater 14

Hydraulic Oil Pump 14

Auxiliary Hydraulic Oil Pump 16

System StSystem StSystem StSystem StSystem Stararararart Upt Upt Upt Upt Up 1818181818

Filling the Reservoir 18

Filling the Main Hydraulic Pump 18

Line Flushing and Oil Pre-Filtering 18

Setting System Operating Pressure 19

Filling Visual Leak Indicator with Oil 19

Hydraulic Oil Lever Sensor 20

Cycling HPiV’s 20

Table of Contents

OPEROPEROPEROPEROPERAAAAATION AND MAINTENANCETION AND MAINTENANCETION AND MAINTENANCETION AND MAINTENANCETION AND MAINTENANCE 21

General System 21

Reservoir Oil Level 21

Changing Hydraulic Oil 21

Adjusting the Oil Pressure Control Setting 21

Engine Driven Hydraulic Pump 22

Hydraulic Oil Return Line 22

Gas/Oil Return Line 22

Visual Leak Indicator 22

Identifying Leaking HPiV Gas Seals 23

Gas/Oil Separator 24

Bypass Valves 24

Engine Mounted Hydraulic Skid 25

Hydraulic Return Filter 25

Hydraulic Oil Supply Strainer 28

Auxiliary Hydraulic Pump 28

Oil Return Pressure Relief Valve 28

Oil Return Filter 28

Maintenance ScheduleMaintenance ScheduleMaintenance ScheduleMaintenance ScheduleMaintenance Schedule 3030303030

TTTTTroubleshooting Guideroubleshooting Guideroubleshooting Guideroubleshooting Guideroubleshooting Guide 3131313131

Main Engineering FMain Engineering FMain Engineering FMain Engineering FMain Engineering Figuresiguresiguresiguresigures

Overall System Schematic 6

Hydraulic Infrastructure Schematic 7

Engine Mounted hydraulic Skid Component Identification 13

Main Pump and adapters (Exploded View) 14

Visual Leak Indicator (Exploded View) 23

Engine Mounted Hydraulic Skid Schematic 25

Hydraulic Control Block Port Identification 26

Hydraulic Control Block (Exploded View) 27

System Specifications

GenerGenerGenerGenerGeneral Configural Configural Configural Configural Configuraaaaationtiontiontiontion

Number of Power CylindersSpeed Range

FFFFFuel Gas Ruel Gas Ruel Gas Ruel Gas Ruel Gas Requirementsequirementsequirementsequirementsequirements

Acceptable LHV Range Specific Gravity Operating Temperature Operating Pressure (nominal) Minimum Operating Pressure (<5% duty cycle) Particulate H

2S Tolerance

HydrHydrHydrHydrHydraulic Supporaulic Supporaulic Supporaulic Supporaulic Support Systemt Systemt Systemt Systemt System

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 Case Vent

5-20220-500 rpm

850-1200 BTU/SCF0.55-0.6550°-75°F (10°-24°C)480-520 psig350 psig< 5 micron< 7 grains/BTU

750-850 psig60±5 psigVented to Atmosphere1000 psig

8.5 U.S. GallonsSAE 10W per SAEJ300

40°F (5°C)90°-120°F (32°−50°C)

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 NPT1/4” Female NPT

-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)

System Specifications

ElectricElectricElectricElectricElectricalalalalal EHV Cable Length Size Temperature Insulation

In-Pulse+In-Pulse+In-Pulse+In-Pulse+In-Pulse+™™™™™ Power

Environment Temperature (Storage) Temperature (Operating) Relative Humidity

Analog Input Channels (2)

Analog Output Channel

Serial Communications Ports (2)

Other Communication Ports

Discrete Inputs (2)

Discrete Outputs (2)

Classification

72 inches16 AWG221°F (105°C)PVC

90-140VDC (110VDC Nominal)300 Watts NominalSource capable of providing 17ampsfor 2 milliseconds without droppingbelow 90VDC.

-40° - 185°F (-40 - 85°C)-40° - 158°F (-40 - 70°C)95% Non-condensing

4-20mA @ 250 ohmsor 1-5 VDC @ 10 ohms

4-20mA @ 600 ohms max.or 20-160mA@ 50 ohms max.

RS232, RS422, or RS485

LON Network

21VDC nominal @ 3mA; 75VDCnominal @ 3mA; 110VDC @ 3mA

0.6 amp @115 VAC breaking; 4 amp@ 28 VDC breaking

UL, CSA, Class 1, Division 2, GroupsA, B, C, D

HPFi® is an electronically controlled, high-pressure fuelinjection system that combines proven control compo-nents aimed at meeting stringent operating, performance,and emissions reduction requirements. HPFi® elimi-nates many of the characteristic problems of direct in-jected, large-bore, natural gas-fired engines.

With HPFi®, poor air/fuel mixing and unbalanced fuelmetering between power cylinders are things of the past.HPFi® generates a high degree of air/fuel mixing viathe energy of a high-pressure jet. Add to this energyprecision control of the fuel gas injection event and youget an optimally mixed air/fuel charge that produces com-bustion performance and emission characteristicsequivalent to state-of-the-art IC engines.

The commercial availability of HPFi® is the result ofEnginuity LLC commitment to turn advanced technol-ogy into applied solutions. Enginuity LLC has workedwith key suppliers, including Woodward Industrial Con-trols, to bring to the industrial market a state-of-the-artsystem that provides a cost effective strategy for up-grading existing engines while improving operability and

Introduction

GenerGenerGenerGenerGeneral HPFal HPFal HPFal HPFal HPFi system functional schemai system functional schemai system functional schemai system functional schemai system functional schematic. Grey components are optional andtic. Grey components are optional andtic. Grey components are optional andtic. Grey components are optional andtic. Grey components are optional andnot inclnot inclnot inclnot inclnot include in all systems. Please refer to instude in all systems. Please refer to instude in all systems. Please refer to instude in all systems. Please refer to instude in all systems. Please refer to installaallaallaallaallation specific documenttion specific documenttion specific documenttion specific documenttion specific documenta-a-a-a-a-tion to determine which options hation to determine which options hation to determine which options hation to determine which options hation to determine which options have been instve been instve been instve been instve been installed.alled.alled.alled.alled.

reducing maintenance.

The HPFi® system maximizes the use of existing com-mercially available hardware including the WoodwardInpulse+®, and EHV. These components were devel-oped for OEM applications within the large and medium-bore engine industry. All components used in the HPFi®

system are designed for long life in the pipeline-operat-ing environment throughout a wide range of applications.

HPFi® ® ® ® ® is another example of Technology thatWorks™™™™™.

General Information

Schematic of the HPFi hydraulic infrastructure on a typical 10-cylinder integral compressor engine. Dashed box indicatesthe 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® systemare a hybrid electro-hydraulic valve (EHV). The com-bination of electric and hydraulic actuation provides theflexible, precise control of electronic actuation and thespeed and power of hydraulics. Hydraulic power forHPFi® is provided by an integrated, engine mounted hy-draulic infrastructure. Electro-hydraulic actuation allowsfor the precise control of the fuel injection event withthe large fuel valves used in industrial engines. Thisprecise control gives HPFi® its outstanding performancecharacteristics.

The INPULSE+® electronic fuel injection driver and theinjection valves perform the governing function, therebyallowing for the removal of the traditional governor.

HPFi® makes use of the available governor drive pad byinstalling a low volume hydraulic pump in place of thetraditional mechanical governor. The pump provides hy-draulic fluid, at the necessary pressure and flow, to theinjection valve actuators. The hydraulic system is com-prised of two major sections, the Engine Mounted Hy-draulic Skid which controls the overall hydraulic systemoperation and the hydraulic distribution system whichdistributes hydraulic oil to each HPiV™.

Engine Mounted HydrEngine Mounted HydrEngine Mounted HydrEngine Mounted HydrEngine Mounted Hydraulic Skidaulic Skidaulic Skidaulic Skidaulic Skid

The engine mounted hydraulic system is supported withan engine mounted hydraulic skid designed specificallyfor the HPFi®®®®® system.

The Engine Mounted Hydraulic Skid provides multiplefunctions 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 head-

ers and pump.• Hydraulic Maintenance Pump• Hydraulic oil heating (optional)

HydrHydrHydrHydrHydraulic Distributionaulic Distributionaulic Distributionaulic Distributionaulic Distribution

Hydraulic fluid is distributed to each of the injectionvalves via stainless steel headers routed such that rou-tine engine maintenance is not impeded.

General Information

Three hydraulic headers are used in the hydraulic sup-port system:

Hydraulic oil supply headerHydraulic oil return headerGas/ Oil return line

The hydraulic oil supply header carries oil at a nominal800 psig to the individual HPiV™ where it providesthe force required to actuate the valve. The hydraulicoil return header carries oil back to the hydraulic res-ervoir at a nominal 60 psig.

A gas/oil return line is attached to the EHV adapterplate on each HPiV™. This line carries small amountsof hydraulic oil, and any fuel gas that has migrated pastthe internal valve seals, to the gas/oil separator. Theseparator returns the hydraulic oil to the reservoir anddirects the fuel gas through the visual leak indicatorand into an appropriate vent system. This feature ofthe HPiV™ eliminates fuel gas leakage at the HPiV™and prevents hydraulic oil from entering the combus-tion chamber.

Purging HydrPurging HydrPurging HydrPurging HydrPurging Hydraulic Linesaulic Linesaulic Linesaulic Linesaulic Lines

Purge valves are installed between the oil supply andreturn headers at points farthest from the oil pump.These valves are kept closed normal operation, but canbe used to temporarily short circuit the oil supply andreturn lines. This is helpful before engine starting, inremoving contamination and air entrapped in the sup-ply and return lines after system service. The auxiliaryoil pump can be operated for a period of time when thepurge valves are opened, but the purge valves need tobe closed prior to and during engine operation.

Oil HeaOil HeaOil HeaOil HeaOil Heater (Optional)ter (Optional)ter (Optional)ter (Optional)ter (Optional)

In cold weather and/or exposed applications circulatingand heating the hydraulic oil before attempting to startthe engine is recommended when the hydraulic oil tem-perature is below 40°F (5°C) . Oil temperature above40° F is satisfactory of engine starting, but oil operatingtemperature of 90° to 120° F (32° C) is recommended toachieve optimal performance of the HPFi® system. Asubmersible heater sized specifically for use in theHPFi®system is available from Enginuity and can be ret-rofitted to the system at any time.

FFFFFuel Gas Luel Gas Luel Gas Luel Gas Luel Gas Leak Indiceak Indiceak Indiceak Indiceak Indicaaaaationtiontiontiontion

A visual gas leak indicator is incorporated into the HPFi®

hydraulic system to provide a visual indication of fuelgas leakage from the HPiV™. The visual gas leak indi-cator is installed vertically in close proximity to the en-gine and within sight of the operating floor. The visualleak indicator is designed for service specifically in theHPFi®system without fouling from oil residue present inthe vent stream.

HydrHydrHydrHydrHydraulic Faulic Faulic Faulic Faulic Filililililtrtrtrtrtraaaaationtiontiontiontion

The HPFi® hydraulic support system is equipped withseveral levels of filtration to ensure trouble free opera-tion of the system. Hydraulic oil is filtered to 10 micronto ensure that debris, moisture, and sediment are re-moved continuously during operation. A 140 micronstrainer is located on the discharge of the hydraulic pumpsto prevent debris from entering the system in the eventof a catastrophic pump failure.

Installation

NOTE...NOTE...NOTE...NOTE...NOTE...Enginuity LLC provides a specifi-Enginuity LLC provides a specifi-Enginuity LLC provides a specifi-Enginuity LLC provides a specifi-Enginuity LLC provides a specifi-cccccaaaaation for insttion for insttion for insttion for insttion for installaallaallaallaallation of HPFtion of HPFtion of HPFtion of HPFtion of HPFiiiiiand it’s asand it’s asand it’s asand it’s asand it’s associasociasociasociasociated supported supported supported supported support infrt infrt infrt infrt infra-a-a-a-a-structure (HPFstructure (HPFstructure (HPFstructure (HPFstructure (HPFi-100). All insti-100). All insti-100). All insti-100). All insti-100). All instal-al-al-al-al-lalalalalations, and component replace-tions, and component replace-tions, and component replace-tions, and component replace-tions, and component replace-ment shall be performed in ac-ment shall be performed in ac-ment shall be performed in ac-ment shall be performed in ac-ment shall be performed in ac-cordance with the most recentcordance with the most recentcordance with the most recentcordance with the most recentcordance with the most recentrevision of this specificrevision of this specificrevision of this specificrevision of this specificrevision of this specificaaaaationtiontiontiontion

WWWWWARNING!ARNING!ARNING!ARNING!ARNING!!The HydrThe HydrThe HydrThe HydrThe Hydraulic Supporaulic Supporaulic Supporaulic Supporaulic Support Headerst Headerst Headerst Headerst Headersare equipped with different sizeare equipped with different sizeare equipped with different sizeare equipped with different sizeare equipped with different sizeAN/JIC fitAN/JIC fitAN/JIC fitAN/JIC fitAN/JIC fittings on the oil suppltings on the oil suppltings on the oil suppltings on the oil suppltings on the oil supply,y,y,y,y,return and greturn and greturn and greturn and greturn and gas/oil return poras/oil return poras/oil return poras/oil return poras/oil return portstststststo minimize the chance of revers-to minimize the chance of revers-to minimize the chance of revers-to minimize the chance of revers-to minimize the chance of revers-ing the flow of hydring the flow of hydring the flow of hydring the flow of hydring the flow of hydraulic flaulic flaulic flaulic flaulic fluiduiduiduiduiddue to erroneous connection ofdue to erroneous connection ofdue to erroneous connection ofdue to erroneous connection ofdue to erroneous connection ofthe hoses. Reversal of the hy-the hoses. Reversal of the hy-the hoses. Reversal of the hy-the hoses. Reversal of the hy-the hoses. Reversal of the hy-drdrdrdrdraulic flow resulaulic flow resulaulic flow resulaulic flow resulaulic flow results in uncon-ts in uncon-ts in uncon-ts in uncon-ts in uncon-trolled actutrolled actutrolled actutrolled actutrolled actuaaaaation of the fueltion of the fueltion of the fueltion of the fueltion of the fuelvvvvvalalalalalve which cve which cve which cve which cve which can resulan resulan resulan resulan result in severet in severet in severet in severet in severepersonal injurpersonal injurpersonal injurpersonal injurpersonal injury or deay or deay or deay or deay or death.th.th.th.th.

SYSTEM INFRSYSTEM INFRSYSTEM INFRSYSTEM INFRSYSTEM INFRAAAAASTRUCTURESTRUCTURESTRUCTURESTRUCTURESTRUCTURE

HydrHydrHydrHydrHydraulic Oil Supplaulic Oil Supplaulic Oil Supplaulic Oil Supplaulic Oil Supply Headersy Headersy Headersy Headersy Headers

The HPiV™ oil supply header, specified by Enginuity Tech-nologies to be ½” O.D x 0.083” wall 304/316 stainless steeltubing, rout hydraulic oil from the hydraulic pump to eachindividual HPiV™. Branch hose connections on the oil sup-ply header are 3/4”-16 SAE/JIC (-8) male fittings to which the1/2” oil supply branch hoses are connected. The branch hosesconnect directly to the male SAE/JIC -8 male inlet fitting on theEHV.

HydrHydrHydrHydrHydraulic Oil Raulic Oil Raulic Oil Raulic Oil Raulic Oil Return Headerseturn Headerseturn Headerseturn Headerseturn Headers

The HPiV™ oil return header, specified by Enginuity Tech-nologies to be ½” O.D x 0.083” wall 304/316 stainless steeltubing, connects each individual HPiV™ to the return port onthe hydraulic oil reservoir. Branch hose connections on the oilreturn header are 9/16”-18 SAE/JIC (–6) male fittings to whichthe 1/2” branch hoses are connected. The branch hoses con-nect directly to the male SAE/JIC –6 male inlet fitting on theEHV.

Gas/Oil Return HeadersGas/Oil Return HeadersGas/Oil Return HeadersGas/Oil Return HeadersGas/Oil Return Headers

The HPiV™ gas/oil return headers, specified by EnginuityTechnologies to be 3/8” O.D x 0.065” wall 304/316 stainlesssteel tubing, connects each individual HPiV™ to the gas/oilseparator located in close proximity to the engine (see installa-tion drawings for specific location). Branch hose connectionson the gas/oil return header are 7/16”-20 SAE/JIC (–4) malefittings to which the 1/4” branch hoses are connected. Thebranch hoses connect to SAE/JIC –4 port located in the EHVmounting block.

BrBrBrBrBranch Hosesanch Hosesanch Hosesanch Hosesanch Hoses

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

Header SupporHeader SupporHeader SupporHeader SupporHeader Support and Mountingt and Mountingt and Mountingt and Mountingt and Mounting

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

Installation

NOTE...NOTE...NOTE...NOTE...NOTE...When the engine driven HPFWhen the engine driven HPFWhen the engine driven HPFWhen the engine driven HPFWhen the engine driven HPFi hy-i hy-i hy-i hy-i hy-drdrdrdrdraulic paulic paulic paulic paulic pump is first instump is first instump is first instump is first instump is first installed oralled oralled oralled oralled orserserserserserviced, it is adviced, it is adviced, it is adviced, it is adviced, it is advisvisvisvisvisable to primeable to primeable to primeable to primeable to primethe pthe pthe pthe pthe pump and pump and pump and pump and pump and purge entrurge entrurge entrurge entrurge entrapped airapped airapped airapped airapped airfrom the oil lines bfrom the oil lines bfrom the oil lines bfrom the oil lines bfrom the oil lines by cry cry cry cry cranking theanking theanking theanking theanking theengine with the bengine with the bengine with the bengine with the bengine with the by py py py py pasasasasassvsvsvsvsvalalalalalvesvesvesvesvesopen. While this is not an essen-open. While this is not an essen-open. While this is not an essen-open. While this is not an essen-open. While this is not an essen-tial requirement, it will make thetial requirement, it will make thetial requirement, it will make thetial requirement, it will make thetial requirement, it will make thesubsubsubsubsubsequent engine stsequent engine stsequent engine stsequent engine stsequent engine stararararartttttsmoother bsmoother bsmoother bsmoother bsmoother by removng air en-y removng air en-y removng air en-y removng air en-y removng air en-trtrtrtrtrapped in the EHVs.apped in the EHVs.apped in the EHVs.apped in the EHVs.apped in the EHVs.

Correct Oil Level

2-4”

HydrHydrHydrHydrHydraulic Header Bypaulic Header Bypaulic Header Bypaulic Header Bypaulic Header Bypasasasasass Vs Vs Vs Vs Valalalalalvesvesvesvesves

Half-inch, quarter-turn ball valves are installed betweenthe oil supply and return headers on each bank at thefarthest point from the hydraulic oil pump. These by-pass valves, closed during normal operation, are usedto temporarily bypass the HPiVs™ following systemmaintenance. Bypassing the HPiVs™ allows quickremoval of air trapped in the supply lines after installa-tion or service. The bypass valves are to be closedprior to and during engine operation.

HydrHydrHydrHydrHydraulic Oilaulic Oilaulic Oilaulic Oilaulic Oil

The recommended oil to be used in the HPFi®®®®® hydrau-lic system is a high quality, petroleum based, low vis-cosity, hydraulic oil, having a rated viscosity below 35centistokes at 104°F (40°C). Hydraulic oils are formu-lated with desirable additive packages that deal withmoisture, air, foam, corrosion, oxidation, etc., and arenecessary to maximize pump and EHV life. Hydraulicoils 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 SepGas/Oil SepGas/Oil SepGas/Oil SepGas/Oil Separararararaaaaatortortortortor

The gas/oil separator vessel must be positioned so thatoil in the HPFi®®®®® hydraulic reservoir seeks its own levelby way of the interconnecting tubing, resulting in properoil level within the gas/oil separator. When the visualoil level indicator in the hydraulic reservoir is at the“full” mark, the proper separator oil level is 2-4 inchesbelow the gas/oil inlet port.

The oil line connecting the separator and the reservoirshould drop to nearly floor level. The recommendedlocation for a convenient hydraulic system drain valveis at the lowest point of the oil line. This drop in lineheight 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 gaswill enter the reservoir as a result of back pressure inthe gas vent line.

Installation

FRONT

Oil Level

Fill Port

1” NPT Outlet

FL

OW

If the clear housing of the indica-If the clear housing of the indica-If the clear housing of the indica-If the clear housing of the indica-If the clear housing of the indica-tor needs to be cleaned use ator needs to be cleaned use ator needs to be cleaned use ator needs to be cleaned use ator needs to be cleaned use amild, non-abrmild, non-abrmild, non-abrmild, non-abrmild, non-abrasive soap solasive soap solasive soap solasive soap solasive soap solutionutionutionutionutionto clean the clear housing of theto clean the clear housing of theto clean the clear housing of theto clean the clear housing of theto clean the clear housing of thevisuvisuvisuvisuvisual leak indical leak indical leak indical leak indical leak indicaaaaator. Soltor. Soltor. Soltor. Soltor. Solventsventsventsventsventswill degrwill degrwill degrwill degrwill degrade the polade the polade the polade the polade the polymer resulymer resulymer resulymer resulymer result-t-t-t-t-ing in clouding and/oring in clouding and/oring in clouding and/oring in clouding and/oring in clouding and/orfffffailailailailailure.ure.ure.ure.ure.

! cccccaution!aution!aution!aution!aution!The open end of the vent lineThe open end of the vent lineThe open end of the vent lineThe open end of the vent lineThe open end of the vent lineshould be adequshould be adequshould be adequshould be adequshould be adequaaaaatelteltelteltely protected toy protected toy protected toy protected toy protected toprevent it from being plugged inprevent it from being plugged inprevent it from being plugged inprevent it from being plugged inprevent it from being plugged inany waany waany waany waany way by by by by by way way way way water, ice, contter, ice, contter, ice, contter, ice, contter, ice, contamina-amina-amina-amina-amina-tion, or btion, or btion, or btion, or btion, or by bird, rodent,y bird, rodent,y bird, rodent,y bird, rodent,y bird, rodent,animal, or insect actions.animal, or insect actions.animal, or insect actions.animal, or insect actions.animal, or insect actions.

! cccccaution!aution!aution!aution!aution!

The 3/8-inch diameter gas/oil line, interconnecting theengine gas/oil headers and the separator gas/oil inlet,can follow any convenient route. It is not important ifthis line rises above or falls below the reservoir oil levelbecause oil & gas pressure in the HPiV™ will causethe gas & oil leakage to flow to the separator.

The gas/oil separator gas outlet port is to be connectedto the visual gas leak indicator described in the nextsection.

VVVVVisuisuisuisuisual Gas Lal Gas Lal Gas Lal Gas Lal Gas Leak Indiceak Indiceak Indiceak Indiceak Indicaaaaatortortortortor

A visual gas leak indicator is installed in the HPFi®®®®® hy-draulic system to provide a visual indication of gas leak-age from the HPiV™. The visual gas leak indicator mustbe installed vertically so that its outlet port is at the top(marked on upper flange). As described above, a linemust connect the gas outlet port of the gas/oil separatorto the inlet port of the visual gas leak indicator. This linediameter at 1 inch. Like the gas vent line discussed be-low, it should be as direct and as short as possible tominimize back pressure in the event of excessive gasflow through the indicator.

To ease maintenance it is recommended that the indi-cator be mounted at least 3 inches above the gas/oilseparator. Removal of the indicator can be facilitatedthrough the use of a 1 inch union be installed directlyabove the indicator or alternatively, between the indica-tor and the gas/oil separator. The indicator should belocated such that it is easily viewed by the operator ona regular basis.

Once the indicator is installed it should be filled with theproper oil as described in the System Start-Up sectionof this manual.

HydrHydrHydrHydrHydraulic System Vaulic System Vaulic System Vaulic System Vaulic System Vententententent

A 1 inch vent line is connected to the outlet of the visualgas leak indicator. This vent line carries gas leakage toan acceptable disposal location outside the building. Itis important that a 1 inch diameter gas vent line (speci-fied the HPFi® ® ® ® ® Installation Specification HPFI-100) isused to minimize back pressure resulting from poten-tial gas flow. The amount of back pressure the gas ventline creates must not overcome the “isolation head” ofoil in the line interconnecting the separator and the res-ervoir. If gas vent line back pressure overcomes this oilhead, gas will pass through the gas/oil separator directlyinto the reservoir and into the atmosphere near the en-

Installation

< 24”

! cccccaution!aution!aution!aution!aution!FFFFFailailailailailure to position the hydrure to position the hydrure to position the hydrure to position the hydrure to position the hydraulicaulicaulicaulicaulicreserreserreserreserreservoir/engine mounted hydrvoir/engine mounted hydrvoir/engine mounted hydrvoir/engine mounted hydrvoir/engine mounted hydrau-au-au-au-au-lic skid within the specified 24”lic skid within the specified 24”lic skid within the specified 24”lic skid within the specified 24”lic skid within the specified 24”verververververtictictictictical distal distal distal distal distance from the suc-ance from the suc-ance from the suc-ance from the suc-ance from the suc-tion portion portion portion portion port of the hydrt of the hydrt of the hydrt of the hydrt of the hydraulic paulic paulic paulic paulic pumpumpumpumpumpwill resulwill resulwill resulwill resulwill result in sever dt in sever dt in sever dt in sever dt in sever damage to theamage to theamage to theamage to theamage to thepppppump. rendering it inoperump. rendering it inoperump. rendering it inoperump. rendering it inoperump. rendering it inoperableableableableable

L2

L1

Engine Mounted HydrEngine Mounted HydrEngine Mounted HydrEngine Mounted HydrEngine Mounted Hydraulic Skidaulic Skidaulic Skidaulic Skidaulic Skid

The HPFi®®®®® hydraulic oil reservoir, contained in theengine mounted hydraulic skid (Figure10) must be in-stalled close to the engine driven HPFiä oil pump to

minimize pump suction pressure depression. In no in-stance should the bottom surface of the hydraulic res-ervoir bottom be below the pump inlet by more than 24inches. When establishing the reservoir location, thegas/oil separator must be located at the same elevationas the reservoir.

The engine mounted hydraulic skid is designed withmounting flanges on the flanks of its base. Using steelangle (1.5” to 2”) results in the oil drain of the reservoirbottom being accessible when the hydraulic skid is setin place. The mounting frame can be mounted on alevel 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 outletand return port locations to enhance air, moisture, andcontaminant separation. Extra return oil ports have beenprovided to ease piping in restricted locations, but thetwo return ports that are on the same side of the reser-voir as the outlet ports are the preferred return oil portlocations.

When connecting the gas/oil separator to the reservoirconsider making the interconnection to the reservoir atit’s bottom drain port, if a drain valve is being installedat the bottom of the “U tube” (as recommended). Do-ing so will result in a convenient means to fully drainthe oil reservoir using the floor level “U tube” drainvalve. If a drain valve is not installed in the “U tube”,the reservoir bottom drain port should be left acces-sible for reservoir draining in addition to a capped teelocated in the lowest section of the“U tube”. (See Figure11 on pg. 14)

HydrHydrHydrHydrHydraulic Oil Laulic Oil Laulic Oil Laulic Oil Laulic Oil Level Sensorevel Sensorevel Sensorevel Sensorevel Sensor

An oil level sensor is installed in the 2” NPT port pro-vided in the top of the oil reservoir. The dual level set-tings of the GEMS Model LS-800 unit are factory setfor use with the HPFi®®®®®hydraulic reservoir. This levelsensor unit is CSA listed for hazardous locations (ClassI, Div 1, Group D) and has an explosion proof wiringconduit enclosure containing a terminal strip. The twoindependent level switches are SPST type and do notshare a common lead.

The level switch designated L2 is a “low oil warning”switch that is closed at normal oil levels, but opens whenthe oil level drops to approximately 3 gallons below the“full” level. The level switch designated L1 is a “low oilshut down” switch that is closed at normal oil levels,but opens when the oil level drops to approximately 6gallons below the “full” level. These switch contacts

Installation

Engine Mounted HydrEngine Mounted HydrEngine Mounted HydrEngine Mounted HydrEngine Mounted Hydraulic Skidaulic Skidaulic Skidaulic Skidaulic SkidComponent IdentificComponent IdentificComponent IdentificComponent IdentificComponent Identificaaaaationtiontiontiontion

Installation

NOTE...NOTE...NOTE...NOTE...NOTE...iiiiin cold climan cold climan cold climan cold climan cold climates the hydrtes the hydrtes the hydrtes the hydrtes the hydraulic res-aulic res-aulic res-aulic res-aulic res-ererererervoir oil should be heavoir oil should be heavoir oil should be heavoir oil should be heavoir oil should be heated andted andted andted andted andthe warm oil circulathe warm oil circulathe warm oil circulathe warm oil circulathe warm oil circulated throughted throughted throughted throughted throughthe HPFthe HPFthe HPFthe HPFthe HPFiiiii oil lines before a oil lines before a oil lines before a oil lines before a oil lines before attttttempt-tempt-tempt-tempt-tempt-ing a cold engine sting a cold engine sting a cold engine sting a cold engine sting a cold engine stararararart. Enginuityt. Enginuityt. Enginuityt. Enginuityt. EnginuityLLC provides a specificLLC provides a specificLLC provides a specificLLC provides a specificLLC provides a specificaaaaation fortion fortion fortion fortion foroil heaoil heaoil heaoil heaoil heaters thaters thaters thaters thaters that hat hat hat hat have the physicve the physicve the physicve the physicve the physicalalalalalsize and performance charsize and performance charsize and performance charsize and performance charsize and performance character-acter-acter-acter-acter-istics suitistics suitistics suitistics suitistics suitable Fable Fable Fable Fable For this applicor this applicor this applicor this applicor this applicaaaaation.tion.tion.tion.tion.

should be connected with the main engine control toprovide 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 downthe HPFi®®®®® equipped engine, before the hydraulic pumpbegins ingesting air.

Oil HeaOil HeaOil HeaOil HeaOil Heater (ter (ter (ter (ter (OptionalOptionalOptionalOptionalOptional)))))

An optional electrically powered oil heater can be in-stalled in the pre-existing 2” NPT port provided in theside of the HPFi®®®®® reservoir. This heater is necessaryin cold climate locations where the HPFi®®®®® hydraulic oiltemperature may fall below 40°F (5°C). In installa-tions prone to this condition, it is recommended that theheater be employed to raise the oil temperature priorto issuance of the engine start command.

The Chromolox® heater specified by Enginuity is spe-cifically sized for the HPFi®®®®® reservoir and is UL andCSA listed for hazardous location use. The heater isavailable for use with several input voltages so pleasespecify the desired input voltage when ordering theheater from Enginuity LLC..

The integral thermostat should be set to provide an oiltemperature of about 90°F (32°C). In all but extremelycold environments, the hydraulic oil will remain at ac-ceptably warm temperatures due to pump induced workand radiant heat from warm engine components.

HydrHydrHydrHydrHydraulic Oil Pumpsaulic Oil Pumpsaulic Oil Pumpsaulic Oil Pumpsaulic Oil Pumps

The main engine-driven hydraulic pump for the HPFi®®®®®

system is a Vickers model PVQ32 (Figure10), whichis a variable displacement, pressure compensated unit.

The pump is typically installed on the vacant governordrive pad of HPFi®®®®® equipped engines. Installation re-quires using a specially designed adapter plate, an SAEadapter flange, and a specially designed shaft couplingmanufactured by Enginuity LLC..

The adapter plate is first installed on the engine drivepad. The adapter flange is piloted on the drive pad toaccurately align the pump shaft with the governor driveshaft in the engine. Next the mating splines of the pumpdrive shaft and the engine drive shaft should be coatedwith high quality petroleum base grease. The SAEadapter flange and the shaft coupling, which adaptsthe straight, keyed pump shaft with the splined gover-nor drive shaft in the engine, should now be installedon the pump.

FFFFFigure 11igure 11igure 11igure 11igure 11 - Main engine driven hydraulicpump and governor drive adapters (ex-ploded view with both styles of cou

Vicker s PVQ32 Main Hydraulic Pump

UG8 Adapter Flange ( Enginuity P/N 10050)

Clar k TCV Pump Coupler

Cooper-Bessemer GMW Pump Coupler ( Enginuity P/N 10051)

Installation

! cccccaution!aution!aution!aution!aution!

WWWWWARNING!ARNING!ARNING!ARNING!ARNING!!Care should be tCare should be tCare should be tCare should be tCare should be taken in adjust-aken in adjust-aken in adjust-aken in adjust-aken in adjust-ing the PVQ32 presing the PVQ32 presing the PVQ32 presing the PVQ32 presing the PVQ32 pressure setsure setsure setsure setsure setting.ting.ting.ting.ting.If the adjusting screw is turnedIf the adjusting screw is turnedIf the adjusting screw is turnedIf the adjusting screw is turnedIf the adjusting screw is turnedout too fout too fout too fout too fout too far, it will be expelled bar, it will be expelled bar, it will be expelled bar, it will be expelled bar, it will be expelled byyyyyoil presoil presoil presoil presoil pressure potentiallsure potentiallsure potentiallsure potentiallsure potentially resuly resuly resuly resuly result-t-t-t-t-ing in severe personal injuring in severe personal injuring in severe personal injuring in severe personal injuring in severe personal injuryyyyy.....

FFFFFailailailailailure to position the hydrure to position the hydrure to position the hydrure to position the hydrure to position the hydraulicaulicaulicaulicaulicreserreserreserreserreservoir/engine mounted hydrvoir/engine mounted hydrvoir/engine mounted hydrvoir/engine mounted hydrvoir/engine mounted hydrau-au-au-au-au-lic skid within the specified 24”lic skid within the specified 24”lic skid within the specified 24”lic skid within the specified 24”lic skid within the specified 24”verververververtictictictictical distal distal distal distal distance from the suctionance from the suctionance from the suctionance from the suctionance from the suctionporporporporport of the hydrt of the hydrt of the hydrt of the hydrt of the hydraulic paulic paulic paulic paulic pump willump willump willump willump willresulresulresulresulresult in severe dt in severe dt in severe dt in severe dt in severe damage to theamage to theamage to theamage to theamage to thepppppump. rendering it inoperump. rendering it inoperump. rendering it inoperump. rendering it inoperump. rendering it inoperable.able.able.able.able.

Discharge pressure adjustment

In engine applications where the shaft is not splinedthe mating shafts should be coated with high qualitypetroleum base grease and assemble before insertingthe tapered retaining pin.

The pump, flange adapter assembly, and shaft cou-pling can now be attached to the adapter plate. Whenthe pump/coupling/flange adapter assembly is installedon the engine, the coupling must “float” on the splinedshaft and not be “bottomed” (axially compressed) asthe pump is installed.

The Vickers PVQ32 pump is designed to have its casedrain port connected to the hydraulic reservoir via acase drain line. Hydraulic oil that passes through clear-ances in the pump is returned to the hydraulic reser-voir via this line. The case drain line should not bepressurized or blocked, and should be connected toone of the return line ports on the hydraulic reservoir.

The bottom surface of the hydraulic reservoir mustnot be positioned more than 24 inches below thePVQ32 pump inlet. When establishing the reservoirlocation keep in mind that the gas/oil separator mustbe located such that the oil level is maintained at alocation 2-4 inches below the gas/oil return line inlet.It is recommended that the pump suction port be be-low the oil outlet on the reservoir where possible.

The PVQ32 pump is factory set to control output pres-sure at 800 ±50 psig. If the outlet pressure is out ofcompliance, adjust the pressure compensator on thepump housing while the engine is running. Care shouldbe taken in adjusting the PVQ32 pump pressure set-ting. If this adjustment is turned outward too far, it willbe expelled by oil pressure.

It is important to note that the main engine drivenPVQ32 oil pump does not control the HPFi®®®®® systemoil pressure when the auxiliary HPFi®®®®® oil pump is op-erating. When the auxiliary oil pump is operating(whether the main pump is or is not operating), theHPFi®®®®® system pressure is controlled by the in-line pres-sure relief valve which is factory set at approximately1000 psig. The auxiliary pump must not be operatingwhen the main pump pressure setting is being adjusted.

Installation

FFFFFigure 13igure 13igure 13igure 13igure 13


NOTE...NOTE...NOTE...NOTE...NOTE...FFFFFailailailailailure to isolaure to isolaure to isolaure to isolaure to isolate the main hy-te the main hy-te the main hy-te the main hy-te the main hy-drdrdrdrdraulic paulic paulic paulic paulic pump (PVQ32) with flex-ump (PVQ32) with flex-ump (PVQ32) with flex-ump (PVQ32) with flex-ump (PVQ32) with flex-ible hoses cible hoses cible hoses cible hoses cible hoses can resulan resulan resulan resulan result in ft in ft in ft in ft in failailailailailureureureureureof connections, fitof connections, fitof connections, fitof connections, fitof connections, fittings, and thetings, and thetings, and thetings, and thetings, and thepppppump cump cump cump cump casing due to vibrasing due to vibrasing due to vibrasing due to vibrasing due to vibraaaaation in-tion in-tion in-tion in-tion in-duced stress.duced stress.duced stress.duced stress.duced stress.


Connection PointsConnection PointsConnection PointsConnection PointsConnection Points

Once the engine mounted hydraulic skid, main hydraulicpump and distribution headers are mounted on the en-gine the individual components can be connected. Themain hydraulic pump is connected to the hydraulic skidusing flexible hoses rated for hydraulic duty.

The discharge of the PVQ32 pump (Figure13) is identi-fied on the pump casing and is connected to the –8 Male37° SAE/JIC fitting located on the lower right hand cor-ner of the hydraulic skid.

The suction side of the PVQ32 pump (Figure 13) is con-nected to the 1” Female NPT tee fitting on the righthand side of the hydraulic skid.

Like the hydraulic pump supply and return headers (Fig-ure 14) are connected to the hydraulic control block lo-cated on the hydraulic skid using flexible hydraulic hoses.The supply header is connected to port A3 on the hy-draulic control block. The return header is connected toport A5 which is slightly above and to the right wherethe 140 micron filter connects to the block. Both theports (A3 and A5) are female –12 SAE O-Ring (1 1/16-12 UNC).

AAAAAuxiliaruxiliaruxiliaruxiliaruxiliary Pumpy Pumpy Pumpy Pumpy Pump

An auxiliary hydraulic pump is included in the enginemounted hydraulic skid to allow purging of the oil linesand servicing of the HPFi® ® ® ® ® system while the engine isstopped. The auxiliary pump is placed in parallel withthe engine driven pump and is powered by compressedair. The auxiliary pump is not necessary to support en-gine starting. When the auxiliary oil pump is operating,the HPFi® ® ® ® ® system oil pressure will be controlled by thepressure relief valve in the oil supply line as discussed inthe preceding paragraph.

The auxiliary hydraulic pump is driven with 90 psig, dryshop air. The shop air is connected to the 1/4” NPT portlocated on the end of the auxiliary pump on the far leftside of the hydraulic skid (Figure15). A manual 1/4”quarter-turn ball valve should be installed at the inlet toallow the auxiliary pump to be turned on and off withoutdisconnecting the shop air hose.

Installation Notes

System Start Up

Oil Full Level



FFFFFilling the Rilling the Rilling the Rilling the Rilling the Reseresereseresereservoirvoirvoirvoirvoir

During storage and handling, oil containers must betightly sealed to exclude moisture and other contami-nation. All containers and oil transfer equipment mustbe free of contamination.

The reservoir is equipped with a screened oil filler portdesigned to trap coarse contaminates. Despite thescreened filler port, all oil should be filtered prior tobeing introduced to the system. While not a require-ment, it is recommended that a commonly available fil-tering/pumping unit specifically designed for oil trans-fer and filtering be utilized.

The oil should be circulated through the system usingthe auxiliary pump while monitoring the oil level in thereservoir (Figure16). Additional oil should be addeduntil a constant level is maintained in the sight glass.

The specific oil to be used in the hydraulic system willbe agreed upon by Enginuity LLC and the client. Thisoil shall be high-quality, petroleum-based, lubricating oilas specified in the HPFi Installation Specificationand in the System Specifications section of this manual.

FFFFFilling the Main Hydrilling the Main Hydrilling the Main Hydrilling the Main Hydrilling the Main Hydraulic Pumpaulic Pumpaulic Pumpaulic Pumpaulic Pump

Before the main hydraulic pump (PVQ-32) is turnedover for the first time it should be filled with oil. Thepump can be filled by disconnecting both the inlet andoutlet hoses and filling the housing with the same oilapproved for the application. Once filled, reconnectand properly tighten the flexible hoses connecting thepump to the hydraulic skid.

Line FlLine FlLine FlLine FlLine Flushing and Oil Pre-Fushing and Oil Pre-Fushing and Oil Pre-Fushing and Oil Pre-Fushing and Oil Pre-Filililililter-ter-ter-ter-ter-inginginginging

The greatest risk of incurring damage due to oil con-tamination occurs during the initial start-up of the hy-draulic system due to the presence debris and fluidsfrom the installation process. The increased potentialto damage system components at this time warrantsthat special precautions be implemented.

Prior to making the final connections to the HPiVs thehydraulic system must be flushed and the oil pre-fil-tered. This can be easily accomplished by jumperingthe supply and return hoses together at each cylinder(Figure 17). Use the fittings called out in the instal-lation section for this purpose.

System Start Up

Care should be tCare should be tCare should be tCare should be tCare should be taken in adjustingaken in adjustingaken in adjustingaken in adjustingaken in adjustingthe pthe pthe pthe pthe pump outlet presump outlet presump outlet presump outlet presump outlet pressure setsure setsure setsure setsure setting.ting.ting.ting.ting.If the adjustment screw is turnedIf the adjustment screw is turnedIf the adjustment screw is turnedIf the adjustment screw is turnedIf the adjustment screw is turnedtoo ftoo ftoo ftoo ftoo far outward it will be expelledar outward it will be expelledar outward it will be expelledar outward it will be expelledar outward it will be expelledbbbbby oil presy oil presy oil presy oil presy oil pressure possure possure possure possure possiblsiblsiblsiblsibly resuly resuly resuly resuly resultingtingtingtingtingin personal injurin personal injurin personal injurin personal injurin personal injury.y.y.y.y.



WWWWWARNING!ARNING!ARNING!ARNING!ARNING!!

This circulates oil through each branch line and throughthe supply and return headers. Operating the system inthis configuration for 10 minutes is sufficient for re-moving fabrication related debris and pre-filtering thesystem. To maintain sufficient oil velocities required toclean the system, jumper the headers in pairs only.Repeat this procedure in pairs until all of the system hasbeen cleaned.

When flushing is complete, connect the HPiVs and thesystem can be started with a reduced risk of damagedue to contamination.

The gas/oil return header(s) should simply be blown outwith compressed shop air. Each branch connectionshould likewise be blown out prior to connection to theHPiV.

SetSetSetSetSetting System Operting System Operting System Operting System Operting System Operaaaaating Pres-ting Pres-ting Pres-ting Pres-ting Pres-suresuresuresuresure

The main engine driven hydraulic pump is factory set to800 psig. Adjustment of this setting is not required un-der normal installation conditions. Likewise, the fac-tory set pressure relief valve located in the hydraulicdistribution block controls the outlet pressure of theauxiliary maintenance pump and should not be adjusted.

Once the system is operating the hydraulic supply pres-sure should be verified to be 800+/- 50 psig using thehydraulic supply pressure gauge.

If necessary, the supply pressure can be adjusted usingthe pressure adjusting screw located on the engine drivenpump (consult the pump technical manual provided sepa-rately). The system supply pressure should be closelymonitored while the adjustment is being made.

FFFFFilling Villing Villing Villing Villing Visuisuisuisuisual Lal Lal Lal Lal Leak Indiceak Indiceak Indiceak Indiceak Indicaaaaator withtor withtor withtor withtor withOilOilOilOilOil

Once the visual gas leak indicator is installed in theHPFi hydraulic system a small quantity of low viscosity,translucent oil such as SAE 10W engine oil can be addedthrough the 1/4” filler plug in the top flange of the indi-cator. The indicator has an oil level indicator line on itsinner wall, visible through the transparent outer hous-ing. The oil level should be at this level line when nogas is flowing through the visual gas leak indicator.

System Start Up

When cWhen cWhen cWhen cWhen cyyyyycling the HPivs to pcling the HPivs to pcling the HPivs to pcling the HPivs to pcling the HPivs to purgeurgeurgeurgeurgeany entrany entrany entrany entrany entrapped air from the hy-apped air from the hy-apped air from the hy-apped air from the hy-apped air from the hy-drdrdrdrdraulic system the on-engineaulic system the on-engineaulic system the on-engineaulic system the on-engineaulic system the on-engineheader should be isolaheader should be isolaheader should be isolaheader should be isolaheader should be isolated via theted via theted via theted via theted via themanumanumanumanumanual block val block val block val block val block valalalalalve, locked outve, locked outve, locked outve, locked outve, locked outand the vent open. Fand the vent open. Fand the vent open. Fand the vent open. Fand the vent open. Failailailailailure to venture to venture to venture to venture to ventthe header during this operthe header during this operthe header during this operthe header during this operthe header during this operaaaaationtiontiontiontionwill resulwill resulwill resulwill resulwill result in fuel being injectedt in fuel being injectedt in fuel being injectedt in fuel being injectedt in fuel being injectedinto the power cinto the power cinto the power cinto the power cinto the power cylinders whichylinders whichylinders whichylinders whichylinders whichcccccan resulan resulan resulan resulan result in explosion, ct in explosion, ct in explosion, ct in explosion, ct in explosion, causingausingausingausingausingpersonal injurpersonal injurpersonal injurpersonal injurpersonal injury.y.y.y.y.

WWWWWARNING!ARNING!ARNING!ARNING!ARNING!!HydrHydrHydrHydrHydraulic Oil Laulic Oil Laulic Oil Laulic Oil Laulic Oil Level Sensorevel Sensorevel Sensorevel Sensorevel Sensor

The hydraulic reservoir is equipped with an oil levelsensor with two switches for sensing two oil levels.The switch contacts are monitored by the engine con-troller and serve as warning and shut down alarms. Theoutput signal of the level sensor should be confirmedduring system start up to ensure the correct functional-ity.

CyCyCyCyCycling the EHVscling the EHVscling the EHVscling the EHVscling the EHVs

Once the reservoir, headers and main hydraulic pumpsystem have been filled with hydraulic oil the systemshould be operated on the auxiliary pneumatic pumpwhile the fuel valves are being actuated. Operating thesystem in this manner removes air trapped in the vari-ous system components and the EHVs. Please referto the Enginuity Manual HPFi-102, Inpulse SoftwareManual for directions on how to activate the EHV testmode.

Operation & Maintenance

FFFFFailailailailailure to return the 3-waure to return the 3-waure to return the 3-waure to return the 3-waure to return the 3-wayyyyyselector vselector vselector vselector vselector valalalalalve to the filve to the filve to the filve to the filve to the filteredteredteredteredteredposition immediaposition immediaposition immediaposition immediaposition immediatelteltelteltely followingy followingy followingy followingy followingfilfilfilfilfilter replacement cter replacement cter replacement cter replacement cter replacement can resulan resulan resulan resulan result int int int int inacceleracceleracceleracceleracceleraaaaated wear and pre-mated wear and pre-mated wear and pre-mated wear and pre-mated wear and pre-maturetureturetureturefffffailailailailailure of the EHVs and otherure of the EHVs and otherure of the EHVs and otherure of the EHVs and otherure of the EHVs and otherasasasasassociasociasociasociasociated hydrted hydrted hydrted hydrted hydraulic systemaulic systemaulic systemaulic systemaulic systemcomponents.components.components.components.components.

Oil Full Level


NOTE...NOTE...NOTE...NOTE...NOTE...All filAll filAll filAll filAll filter elements should beter elements should beter elements should beter elements should beter elements should bereplaced and/or cleaned areplaced and/or cleaned areplaced and/or cleaned areplaced and/or cleaned areplaced and/or cleaned at thet thet thet thet thetime thatime thatime thatime thatime that the system oil ist the system oil ist the system oil ist the system oil ist the system oil ischanged.changed.changed.changed.changed.


GENERGENERGENERGENERGENERAL SYSTEMAL SYSTEMAL SYSTEMAL SYSTEMAL SYSTEM

RRRRReseresereseresereservoir Oil Lvoir Oil Lvoir Oil Lvoir Oil Lvoir Oil Levelevelevelevelevel

When the HPFi® system is operating, the oil level inthe HPFi® hydraulic oil reservoir should be maintainedat the “full” mark of the visual oil level indicator, lo-cated on the side of the reservoir (Figure 20).

Changing HydrChanging HydrChanging HydrChanging HydrChanging Hydraulic Oilaulic Oilaulic Oilaulic Oilaulic Oil

It is recommended that the hydraulic oil be routinelyreplaced every 12 months, or every 8,750 hours of op-eration. Oil replacement may be required more fre-quently if contamination or overheating occurs. Thehydraulic system is equipped with a drain port, locatedon the bottom of the reservoir, for convenient removalof the system contents.

The recommended type of oil to be used in the HPFi®

system is a low viscosity hydraulic oil, having a ratedviscosity below 35 centistokes at 104°F (40°C). Hy-draulic oils are formulated with desirable additive pack-ages to deal with moisture, air, foam, corrosion, oxida-tion, etc. that will maximize pump and valve life. Agood quality SAE 10W engine oil (grades SC, SD, SE,SF, SG) will work satisfactorily. Circulating and heat-ing the hydraulic oil before attempting to start the en-gine is recommended if oil temperature is below 40°F(5°C). Oil operating temperatures between 90° and120°F (32°C) is recommended.

In the event of severe oil contamination or oil over-heating, it is advisable to drain the hydraulic oil fromthe distribution headers. This requires removal of thehoses at the engine mounted skid and at each HPiV.

An alternate method of removing the contaminated oilin the lines is to drain the reservoir. Then partially refillthe reservoir with clean oil and operate the hydraulicsystem on the auxiliary pump for a short time. Repeatthis procedure until the system is filled with clean oil.

Operation & MAintenance

RRRRRemember thaemember thaemember thaemember thaemember that when the auxiliart when the auxiliart when the auxiliart when the auxiliart when the auxiliaryyyyyHPFHPFHPFHPFHPFiiiii oil p oil p oil p oil p oil pump is operump is operump is operump is operump is operaaaaating, theting, theting, theting, theting, theHPFHPFHPFHPFHPFiiiii system oil pres system oil pres system oil pres system oil pres system oil pressure will besure will besure will besure will besure will beapproximaapproximaapproximaapproximaapproximatelteltelteltely 1000 psig, and isy 1000 psig, and isy 1000 psig, and isy 1000 psig, and isy 1000 psig, and iscontrolled bcontrolled bcontrolled bcontrolled bcontrolled by the in-line presy the in-line presy the in-line presy the in-line presy the in-line pressuresuresuresuresurerelief vrelief vrelief vrelief vrelief valalalalalve, not bve, not bve, not bve, not bve, not by the main oily the main oily the main oily the main oily the main oilpump pressure control. The mainpump pressure control. The mainpump pressure control. The mainpump pressure control. The mainpump pressure control. The mainoil pump will again control theoil pump will again control theoil pump will again control theoil pump will again control theoil pump will again control thesystem oil pressure when the aux-system oil pressure when the aux-system oil pressure when the aux-system oil pressure when the aux-system oil pressure when the aux-iliariliariliariliariliary py py py py pump is shut offump is shut offump is shut offump is shut offump is shut off.....

RRRRRestricting the hydrestricting the hydrestricting the hydrestricting the hydrestricting the hydraulic oil re-aulic oil re-aulic oil re-aulic oil re-aulic oil re-turn line will cause all of theturn line will cause all of theturn line will cause all of theturn line will cause all of theturn line will cause all of theHPiVs opening simulHPiVs opening simulHPiVs opening simulHPiVs opening simulHPiVs opening simultttttaneouslaneouslaneouslaneouslaneously andy andy andy andy andremain open, flooding the engineremain open, flooding the engineremain open, flooding the engineremain open, flooding the engineremain open, flooding the enginecccccylinders with high presylinders with high presylinders with high presylinders with high presylinders with high pressure fuelsure fuelsure fuelsure fuelsure fuelgggggas which cas which cas which cas which cas which can resulan resulan resulan resulan result in severe me-t in severe me-t in severe me-t in severe me-t in severe me-chanicchanicchanicchanicchanical dal dal dal dal damage, personal injuramage, personal injuramage, personal injuramage, personal injuramage, personal injury,y,y,y,y,or deaor deaor deaor deaor death.th.th.th.th.

NOTE...NOTE...NOTE...NOTE...NOTE...


Adjusting the Oil Pressure Con-Adjusting the Oil Pressure Con-Adjusting the Oil Pressure Con-Adjusting the Oil Pressure Con-Adjusting the Oil Pressure Con-trol Settrol Settrol Settrol Settrol Settingtingtingtingting

When the main engine driven pump is operating thepressure is controlled by the regulator that is integralto the pump. This pressure setting is factory adjustedto be 800 +/- 50 psig, but it should be periodicallychecked by observing the gage installed in the HPFi®

hydraulic system. If this pressure is not correct, whenonly the main engine pump is being operated, adjustthe pressure compensator on the engine driven pumpas discussed in System Start Up.

Main Engine Driven HydrMain Engine Driven HydrMain Engine Driven HydrMain Engine Driven HydrMain Engine Driven HydraulicaulicaulicaulicaulicPumpPumpPumpPumpPump

The pump output pressure setting should be checked,and adjusted if necessary. The PVQ32 pump requiresa case drain line between the pump and the hydraulicreservoir.

Maintenance of the PVQ-32 is to be cared out in ac-cordance with manufacturer’s recommended practicesand procedures.

HydrHydrHydrHydrHydraulic Oil Raulic Oil Raulic Oil Raulic Oil Raulic Oil Return Lineeturn Lineeturn Lineeturn Lineeturn Line

The oil return lines are pressurized to about 60±5 psigby a relief valve installed just upstream of the oil filtra-tion unit. This “back-pressure” is necessary to pre-vent “voiding” in the pulsating return lines and to re-duce cavitation in the EHV.

The hydraulic oil return lines should be inspected regu-larly for signs of damage. Restriction of the hydraulicoil return lines significantly impacts the operation ofthe valve. Damaged portions of the system should beimmediately replaced with new components.

Gas/Oil Return LineGas/Oil Return LineGas/Oil Return LineGas/Oil Return LineGas/Oil Return Line

The gas/oil oil return lines should be inspected regu-larly for signs of damage. Restriction of the gas/oil oilreturn lines will eliminate the ability to detect HPiVseal leakage resulting in a potentially hazardous oper-ating condition. Damaged portions of the system shouldbe immediately replaced with new components.


Use a mild, non-abrUse a mild, non-abrUse a mild, non-abrUse a mild, non-abrUse a mild, non-abrasive soap so-asive soap so-asive soap so-asive soap so-asive soap so-lution to clean the clear hous-lution to clean the clear hous-lution to clean the clear hous-lution to clean the clear hous-lution to clean the clear hous-ing of the visuing of the visuing of the visuing of the visuing of the visual leak indical leak indical leak indical leak indical leak indicaaaaator.tor.tor.tor.tor.SolSolSolSolSolvents will degrvents will degrvents will degrvents will degrvents will degrade the polade the polade the polade the polade the poly-y-y-y-y-mer resulmer resulmer resulmer resulmer resulting in clouding and/orting in clouding and/orting in clouding and/orting in clouding and/orting in clouding and/orfffffailailailailailure.ure.ure.ure.ure.

Top Cap (Eng inuity P/N 10055)

Bottom Cap (Eng inuity P/N 10057)

Si ght Glass (Eng inuity P/N 10056)

Sleeve (Eng inuity P/N 10054)

Upper Si ght Gl ass O-Ring

Lower Si ght Gl ass O-Ring

Sleeve O-Ring

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

Gas/Oil Retur n

VVVVVisuisuisuisuisual Gas Lal Gas Lal Gas Lal Gas Lal Gas Leak Indiceak Indiceak Indiceak Indiceak Indicaaaaatortortortortor

The visual gas leak indicator should need no routineservice unless the oil within it becomes contaminatedor is lost. The oil can be drained using the drain plug inthe bottom flange of the indicator. If the indicator needsto be cleaned to eliminate contamination, the transpar-ent outer tube should be removed and rinsed with de-tergent and water, followed by a thorough drying.

If cleaning becomes necessary, the indicator can bedisassembled by securing the Lower Cap in a vise andunscrewing the Upper Cap. All o-rings should be re-placed following maintenance and prior to re-assem-bly. The o-rings should be lubricated with a light coatof SAE 10W oil to prevent binding during assembly.The assembly should be tightened until snug. Overtightening will result in failure of the polycarbonate sightglass.

If necessary, oil can be added to the indicator using theoil filler plug in the upper flange. The proper oil level ismarked on the indicator’s inner housing.

The gas leak indicator directs gas thru a shallow poolof oil, causing bubbles to form that are visible throughthe transparent housing of the indicator. The relativerate of gas flow can be observed as the level of bubbleactivity in the indicator. Large gas flows force the smallamount of oil into the outer housing until the gas flowrate is reduced and the oil returns to a shallow pool inthe housing where bubbling resumes for small gas flows.

When an HPiV is newly installed, and for many thou-sands of operating hours thereafter, no significant gasleakage is expected. In the event of a gas valve o-ringfailure, or simply a gas valve seal wearing, gas leakagewill become evident in the gas leak indicator and cor-rective measures can be taken.

Identifying Leaking HPiV Gas SealsIdentifying Leaking HPiV Gas SealsIdentifying Leaking HPiV Gas SealsIdentifying Leaking HPiV Gas SealsIdentifying Leaking HPiV Gas Seals

If significant gas flow is observed in the visual gas leakindicator, the following procedure can be used to iden-tify which HPiVs have leaking gas seals.

Each HPiV has a gas/oil drain fitting (-4 Male SAE/JIC 37°) attached to the EHV mounting block. Do notconfuse this line with the larger oil lines connected tothe EHV. This gas/oil drain line carries small amountsof oil and HPiV gas seal leakage (if present) to thegas/oil separator.


If appreciable gas leakage is suspected, it can be veri-fied when the gas/oil drain fitting is loosened and re-moved (while the engine is running). If gas leakage isnot discernible, a closer check can be made in the fol-lowing way. Attach a short length of flexible line to thegas/oil drain fitting on the EHV mounting block. Sub-merge the free end of the hose in a vessel of oil. Gasleakage will be indicated by a continuous stream ofbubbles emitted from the submerged end of the hose.Repeat the procedure on each cylinder until the leakingHPiV is identified.

Gas/Oil SepGas/Oil SepGas/Oil SepGas/Oil SepGas/Oil Separararararaaaaatortortortortor

The HPFi® hydraulic system includes a gas/oil separa-tor to separate oil and fuel gas leakage from HPiV in-ternal seals. The gas/oil separator is a small vessel con-nected to and positioned at the level of the hydraulic oilreservoir.

The bottom of the separator is connected to the reser-voir by a line having a “U tube” configuration that dropsto near floor level and then back up again to the el-evated reservoir. Oil in the reservoir seeks its own levelin both reservoir and separator via the “U tube” inter-connecting line. A hydraulic system oil drain valve isinstalled at the lowest point in the “U tube” portion of

the gas/oil return line to facilitate draining the hydrau-lic system.

Under normal operating conditions the gas/oil separa-tor requires no maintenance but should be visually in-spected on a regular basis for signs of damage.

BypBypBypBypBypasasasasass Vs Vs Vs Vs Valalalalalvesvesvesvesves

Purge valves are installed between the oil supply andreturn headers at points farthest from the oil pump.These valves are normally kept closed but can be usedto temporarily short together the oil supply and returnlines. This is helpful, before engine starting, in remov-ing contamination and air from the supply lines afterinstallation or service, and in warming the hydraulic oilin cold climates. The “purge” valves can be openedand the auxiliary oil pump can be operated for a periodof time. The purge valves are then closed prior to andduring engine operation.


ENGINE MOUNTED HYDRENGINE MOUNTED HYDRENGINE MOUNTED HYDRENGINE MOUNTED HYDRENGINE MOUNTED HYDRAAAAAULICULICULICULICULICSKIDSKIDSKIDSKIDSKID

The engine mounted hydraulic skid used in theHPFi®

hyddraulic support system is manufactured for Eninuityby Motion Industries. Replacement parts for the skidare available directly from Motion Industries or VikersHydraulics as identified in the associated Hydraulic Skidmanual. Please refer to the skid manual for replace-ment part information.

HydrHydrHydrHydrHydraulic Oil Raulic Oil Raulic Oil Raulic Oil Raulic Oil Return Feturn Feturn Feturn Feturn Filililililterterterterter

The oil filter unit installed in the HPFi® hydraulic sys-tem oil return line is a spin-on type filter. Replacementelements are available through the distributors listed inthe back of this manual.

The filter unit’s indicator displays when the filter is dirtyand needs to be replaced. If the filter is not replacedand becomes plugged with contamination, a bypasspressure relief valve in the filter unit will open to pre-vent excessive back pressure. In this instance, the by-passed oil will not be filtered until the dirty filter is re-placed.

The filter element can be easily replaced without shut-ting down the engine or HPFi® system. This is done bytemporarily repositioning the 3-way valve (upstream ofthe filter unit) to the bypass position, and by directingthe returning oil around the filter unit. This method isrecommended, even when changing the filter with theHPFi® system stopped, because the 3-way valve willkeep oil in the lines from running out when the filtercanister is removed. A check valve downstream of thefilter unit prevents oil from back flowing to the filter, sothe filter can be removed with little oil spillage. Theused filter canister can simply be unscrewed and a newcanister screwed on in its place, tightening the new can-ister per instructions accompanying or printed on thenew filter.

Once the new filter is in place, the 3-way valve mustbe returned to the normal (filtering) position to assurethat the return oil passes through the filter element. Asimple observation can be made if it is uncertain whichposition is the normal position on the 3-way valve. Whenthe HPFi® system is operating, the pressure gage read-ing upstream of the filter unit can be observed as the 3-way valve is alternately switched from one position tothe other. The pressure reading will be slightly higherwhen the 3-way valve is in the normal (filtering) posi-tion.

Engine Mounted Hydrauilc Skid Schematic: Valve callouts aredetailed on page 29.


The hydraulic oil return filter is equipped with an inte-gral differential gauge indicator which indicates the needfor maintenance and cleaning. See manufacturers rec-ommendations for optimum performance.

HydrHydrHydrHydrHydraulic Oil Supplaulic Oil Supplaulic Oil Supplaulic Oil Supplaulic Oil Supply Stry Stry Stry Stry Strainerainerainerainerainer

The purpose of the in-line strainers, located in the out-let lines of the two HPFi® oil pumps, is to catch coarseparticulate contamination that passes through or is ex-pelled by the pumps, and prevent it from reaching theHPiV™. Under normal operating conditions, thesestrainers should seldom, if ever, need servicing. How-ever, if the hydraulic oil becomes badly contaminated,or if an oil pump fails, the strainers should be cleanedper manufacturers recommendations.

The supply oil strainer is equipped with an integral dif-ferential pressure indicator which indicates the needfor maintenance and cleaning.

AAAAAuxiliaruxiliaruxiliaruxiliaruxiliary Hydry Hydry Hydry Hydry Hydraulic Pumpaulic Pumpaulic Pumpaulic Pumpaulic Pump

Maintenance of the PVQ-32 is to be cared out in ac-cordance with manufacturer’s recommended practicesand procedures.

Oil ROil ROil ROil ROil Return Preseturn Preseturn Preseturn Preseturn Pressure Rsure Rsure Rsure Rsure Relief Velief Velief Velief Velief Valalalalalveveveveve

The oil returning to the HPFi® system oil reservoir fromthe HPiVs flows through a pressure relief valve, whichcreates a 60±5 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 dam-age.

Oil ROil ROil ROil ROil Return Feturn Feturn Feturn Feturn Filililililterterterterter

The oil returning to the HPFi® hydraulic oil reservoirfrom the HPiVs is directed through a disposable 10-micron oil filter element. The filter unit is piped so thata 3-way, open center, manually operated valve can beused to bypass the filter, in the event that the filter ele-ment needs replacement without shutting down the en-gine. It is very important that this 3-way valve is anopen center type to assure that the HPiV return line isnever blocked during engine operation.

The hydrThe hydrThe hydrThe hydrThe hydraulic straulic straulic straulic straulic strainer cainer cainer cainer cainer can onlan onlan onlan onlan onlyyyyybe serbe serbe serbe serbe serviced when the system isviced when the system isviced when the system isviced when the system isviced when the system isoperoperoperoperoperaaaaating. Opening the strting. Opening the strting. Opening the strting. Opening the strting. Opening the strainerainerainerainerainerduring operduring operduring operduring operduring operaaaaation ction ction ction ction can resulan resulan resulan resulan result int int int int inpersonal injurpersonal injurpersonal injurpersonal injurpersonal injury, or deay, or deay, or deay, or deay, or death.th.th.th.th.


All filAll filAll filAll filAll filter elements should be re-ter elements should be re-ter elements should be re-ter elements should be re-ter elements should be re-placed and/or cleaned aplaced and/or cleaned aplaced and/or cleaned aplaced and/or cleaned aplaced and/or cleaned at the timet the timet the timet the timet the timethathathathathat the system oil is changed.t the system oil is changed.t the system oil is changed.t the system oil is changed.t the system oil is changed.

NOTE...NOTE...NOTE...NOTE...NOTE...


HYDRAULIC CONTROL BLOCK:

PORT IDENTIFICATION

A1 Supply from Pneumatic Auxiliary PumpA2 Supply from PVQ PumpA3 Oil Supply to EngineA4 Oil Supply Return From Pressure ReliefA5 Oil Return from EngineA6 Oil Supply to 10 Micron Hydraulic FilterA7 Oil Return From 10 Micron HydraulicFilterA7 Oil Return to ReservoirA8 Oil Supply From 140 Micron StrainerA9 Oil Supply to 140 Micron Strainer

G1 Supply Pressure GaugeG2 Port for Low Pressure Alarm SwitchG3 Backpressure Gauge Port

INTERNAL CONTROL VALVES1 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)


CV3-10-P-0-40

CV3-10-P-0-10

CV3-10-P-0-3

CV3-10-P-0-3

MRV3-10-D2-03

RV3-10-S-0-18

931-F-08620

111 Z 60000

HYDRAULIC CONTROL BLOCK (Exploded View)

INTERNAL CONTROL VALVES

Tag Part Number Manufacturer1 CV3-10-P-0-40 (Check Valve) Vickers 2

MRV3-10-D2-0 (Manual 3-Way Valve) Vickers4 CV3-10-P-0-10 (Check Valve) Vickers5-1 CV3-10-P-0-3 (Check Valve) Vickers5-2 CV3-10-P-0-3 (Check Valve) Vickers7 RV3-10-S-0-18 (Relief Valve) Vickers

931-F-08620 Wika1 I Z 60000 SPI/Motion Industries

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

Maintenance Schedule

• Hydraulic oil supply pressure (800±50 psig)

• Hydraulic oil return pressure (60±5 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

Daily operator Checks

• Inspect/replace hydraulic branch hoses (note wearmarks and abrasions if not replaced)

• Cycle hydraulic maintenance pump )without PVQ32operating)

• Cycle 3-way diverter valve

Monthly Maintenance

• 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 fordamage

• 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

Annual Maintance

Troubleshooting Guide

The following table is provided to the user to assist in deter-mining the possible causes of unsatisfactory system perfor-mance and to suggest corrective actions to resolve the prob-lem. This information, coupled with engine operating datawill provide a complete picture of the problem being ad-dressed.

This information is provided as a diagnostic tool forthe user. Information contained in this section should not beviewed as a reflection of Enginuity experience with this sys-tem.

PROBLEM PROBABLE CAUSE SOLUTION

Engine will not start Air trapped in hydraulic lines Cycle hydraulic oil with bypassvalves open

Bypass vales open Close bypass valveSystem leak Tighten fitting or replace defective

componentBroke pump drive coupler Replace couplerNo Hydraulic pressure

No hydraulic pressure Bypass valves open Close bypass valvesMain hydraulic pump failure Replace pump

Main hydraulic pump failure Main pump pressure adjustment Readjustscrew backed outDamaged hydraulic pressure relief ReplacevalveExcessive strainer differential Clean strainerExcessive filter differential Replace filterSystem leak Tighten fitting or replace defectivecomponent

Bubbles in Visual Leak Indicator Leaking HPiV stem seal Identify worn HPiV and replacevalve/cartridge

Excessive oil consumption Systemleak Inspect system and repair orreplace defective component(s)

Erratic HPiV operation Insufficient hydraulic supply Increase hydraulic supply pressureInsufficient hydraulic return

Increase hydraulic return pressure pressureAir trapped in hydraulicx lines Cycle hydraulic oil with bypass

valves openPremature gas seal failure Excessive hydraulic supply

pressureHPiV remains open Hydraulic rturn line restricted Inspect system and repair or

replace defective component(s)Seized valve stem Identify damaged HPiV and

replace valve/cartridge

Common Abbreviations

ABLS Applications Block Language SoftwareAO Analog OutputA/D Analog to DigitalATDC Degrees After Top Dead CenterAWG American Wire GageBDC Bottom Dead CenterBHP Break Horsepower RatingBMEP Break Mean Effective PressureBOM Bill of MaterialCPM Continuous Pressure MonitorCPU Central Processor UnitDI Discrete InputDO Discrete OutputDSP Digital Signal ProcessingDUART Dual Universal Asynchronous Receiver TransmitterFOPS Fiber Optic Pressure SensorEFI Electronic Fuel InjectionEGAV Electronic Gas Emission ValveEHV Electro-Hydraulic ValveEMI Electromagnetic InterferenceFPGA Field Programmable Gate ArrayFTIO Fault Tolerant Input/OutputGAP Graphical Applications ProgrammerHHT Hand Held ToolHPFi High-Pressure Fuel InjectionHPiV High Pressure Injection ValveIMEP Indicated Mean Effective PressureI/O Input/OutputJIC Joint Industrial CouncilLED Light Emitting DiodeLPP Location of Peak PressureMAP Engine Manifold Air PressureMGAV Mechanical Gas Admission Valve (OEM)MIL MilitaryMPU Magnetic PickupMUX Multiplexer

Common Abbreviations

NC Normally ClosedNEC National Electric CodeNO Normally OpenOCP Operator Control PanelPC Personal ComputerPCC Pre Combustion ChamberPCB Printed Circuit BoardPCI Personal Computer InterfacePLC Programmable Logic ControllerPP Cylinder Peak PressurePSI Pounds per Square InchPSIA Pounds per Square Inch AbsolutePSIG Pounds per Square Inch GaugePWM Pulse Width ModulationQSPI Queued Serial Peripheral InterfaceQSM Queued Serial ModuleRFI Radio Frequency InterferenceRAM Random Access memoryrpm Revolutions Per MinuteSAE Society of Automotive EngineersSCADA Supervisory Control and Data AcquisitionSCE Signal Conditioning ElectronicsSIO Serial Input/OutputSYSCON Systems ControllerTBD To Be DeterminedTBS To be SuppliedTDC Top Dead CenterTPU Time Processor UnitUL Underwriters LaboratoryUV EPROMS – Ultra-violet Light Erasable Read Only MemoryVAC Volts Alternating CurrentVDC Volts Direct CurrentVI Voltage InputVME Versa Module EurocardXCVR Transceiver Alarm Philosophy

hpfi hydraulic support system 0700

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