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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 ........................................................................
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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.
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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
Loosen the relief valve adjustment locknut and turn the adjustment stem fully
counterclockwise.
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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Loosen the relief valve adjustment locknut and turn the adjustment stem fully
counterclockwise.
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
Refer to Airline Hydraulics schematic and assembly drawing, located in Appendix A.
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
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
Conditioning filter.
Heat exchanger(s).
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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Theory of Operation
Refer to Airline Hydraulics schematic and assembly drawing, located in Appendix A.
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x
Conditioning circuit, conditioning filter:
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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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Installation Instructions
Refer to Airline Hydraulics schematic and assembly drawing, located in Appendix A.
The cooling and conditioning system is delivered to the skid builder with the following
items shipped loose:
x
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.
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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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Conditioning filter (IXE) element (Hydac P/N 03553650) (See note below).
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.
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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.
Procedure:
1. Locate the pull tab for the o-ring and pull it down to remove the O-ring.
2. Discard the O-ring.
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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).
FV63 OPEN (turn adjustment stem fully counterclockwise, then tighten lock
nut)
FV61 CLOSED (turn adjustment stem fully clockwise, then tighten lock nut)
FV64 OPEN (turn adjustment stem fully counterclockwise, then tighten lock
nut)
FV65 OPEN (turn adjustment stem fully counterclockwise, then tighten lock
nut)
FV52 CLOSED (turn adjustment stem fully clockwise, then tighten lock nut)
FV53 CLOSED (turn adjustment stem fully clockwise, then tighten lock nut)
FV54 CLOSED (turn adjustment stem fully clockwise, then tighten lock nut)
FV55 OPEN (turn adjustment stem fully counterclockwise, then tighten lock
nut)
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Procedure:
1.
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.
8.
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.
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.
IMPORTANT! It is the responsibility of the user to determine the maximum length of time
that the conditioning circuit can be shut down for regular maintenance (Example:
particulate or conditioning filter element changes).
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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.
2.
Remove the hard cap on the external connection HF014 on the side of the lube
skid.
3.
4.
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.
9.
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.
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.
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 Hydac model code: BD 800 X 2 W 0.0, P/N 02075158.
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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.
2.
3.
4.
5.
Observe pressure at gauge point CCFI. The reading should be 0 PSI (0 BAR).
6.
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.
9.
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.
Rev. None
27
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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
conditioning circuit pump and then fully opening de-pressurization and drain valve FV52.
IMPORTANT! It is the responsibility of the user to determine the maximum length of time
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.
2.
3.
4.
5.
Observe pressure at gauge point AFPG. The reading should be 0 PSI (0 BAR).
6.
7.
Ensure that filter housing F221 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.
Note: It is not necessary to completely drain the filter housing.
8.
9.
Once it is determined that the housing has been de-pressurized, the bleed plug
on the top cap should be tightened securely.
10. Remove the filter housing top cap. Set the cap aside on a clean surface. Protect
the cap from contamination.
Rev. None
28
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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 cap is removed. This is normally
not a problem but the user should be aware that it could happen.
11. Remove the spring. Set the spring aside on a clean surface. Protect the spring
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
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 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.
15. Install the grommet cap.
16. 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.
17. 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.
18. Remove tags and locks on the conditioning circuit pump.
19. Start the conditioning circuit pump.
20. Bleed air from the filter housing using the bleed plug located at the top of the
filter housing.
Rev. None
29
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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.
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.
Rev. None
30
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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.
Ensure that filter housing F222 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.
Note: It is not necessary to completely drain the filter housing.
8.
9.
Once it is determined that the housing has been de-pressurized, the bleed plug
on the top cap should be tightened securely.
10. 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 cap is removed. This is normally
not a problem but the user should be aware that it could happen.
11. Remove the spring. Set the spring aside on a clean surface. Protect the spring
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
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. Remove the lower 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.
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.
Rev. None
31
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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.
19. Install the grommet cap.
20. 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.
21. 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.
22. Remove tags and locks on the conditioning circuit pump.
23. Start the conditioning circuit pump.
24. 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.
Rev. None
32
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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
conditioning circuit pump and then fully opening de-pressurization and drain valve FV53.
CAUTION! The conditioning filter element has a distinct top and bottom. The element
should be installed with the perforated holes at the top.
IMPORTANT! It is the responsibility of the user to determine the maximum length of time
that the conditioning circuit can be shutdown for maintenance.
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.
Rev. None
33
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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.
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!
11. Remove the spring. Set the spring aside on a clean surface. Protect the spring
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.
Rev. None
34
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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.
18. Remove tags and locks on the conditioning circuit pump.
19. Start the conditioning circuit pump.
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.
CAUTION! Dispose of the used filter element in accordance with all local and company
environmental guidelines.
Rev. None
35
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Rev. None
36
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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
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Bill of Material
ITEM
QTY
VENDOR
DESCRIPTION
PART NUMBER
10
Daman
DAM-E28215 REVO
20
Hydac
HYC-02095296
25
Hydac
30
MARTIN FLUID
POWER
MIS-OR37175 (OR371BV75)
40
Hydac
HYCHF4P09PXXA1.1/VSO20
0HE
45
Hydac
50
HYDAC
HYC-VD5D0VL110
02062198
60
Hydac
HYCHF4P18PXXA1.1/VB6SO
200HG
60A
Hydac
80
HYDAC
TEST POINT
06007029
90
Hydac
HYC-RV08A01CV05
03010153
91
Parker
Cavity Plug
8P5ON-S
100
Hydac
HYC-DB08A01CV050V
03010141
110
SUN
NFDCLAV
Rev. None
38
AHC-SM00251
AHC-SM00250
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111
SUN
SUN-991034
120
SUN
SUN-NFFDLIV
121
SUN
SUN-991034
130
Hydac
HYC-06007030
140
Noshok
NOS25500SST300PSI/BAR
150
SUN
Needle Valve
SUN-NFABKXV
ITM367791
5KFS112XAA1027
160
GE
170
IMO
AA3G/NVPSCA143SJ
3535/034
180
BSF
C-FACE ADAPTER
46532-882
190
MAGNALOY
COUPLING HALF 28 MM x 8 MM
KEYWAY
M100M2808
200
MAGNALOY
M10002406
210
MAGNALOY
HYTREL INSERT
M170H5
GE
ITM367791
5KFS112XAA1027
220
Rev. None
39
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230
VIKING
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
M10001604
252
MAGNALOY
INSERT, HYTREL
M170H5
270
APPOLO
76F-147-01A
280
THERMAL
TRANSFER
65253
281
THERMAL
TRANSFER
67438
282
DAMAN
D31832, R0
290
THERMAL
TRANSFER
SSC-836-217204
300
PARKER
PAR-16P5ONS
310
SUN
SUN-RDHALEV
320
SUN
SUN-XIOA-XXV
340
DMIC
BV3L-1500-SA-4323
Rev. None
40
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350
APOLLO
62-107-01
360
SUN
XDCA-XXV
380
DAMAN
D32966, R1
390
Hydac
RESERVOIR BREATHER
HYC-BD800X2W0.0
02075158
400
MAGNOM
MAG-PM11003SU2NPT
555103014
410
MAGNOM
MAGPM07603SU3/4NPT
555103002
420
DMIC
DMIC
BV3LZ0500SA4323ZZZO
Rev. None
41
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MANUFACTURER
Hydac
Conditioning Filter
Element
(Used w/ Item 20)
Hydac
AHC-SM00251
Hydac
Water Absorbing/
Particulate Filter Element
(Used w/ Item 60)
AHC-SM00250
Hydac
Desiccant Breather
Element (Item 390)
Hydac
RDHA-LEN
Hydac
DB08A-1-C-V-050-V
IMO
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
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
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Appendix A
Airline Hydraulics Drawings
Assembly drawing A1057-04M000 and hydraulic schematic, AHC Drawing No: A1057-04H000
Rev. None
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2
REV
A
42.58
38.17
21.80
18.05
C
D
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
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
DT-
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.
18.38
GE SIGNATURES
GE DRAWING NUMBER
DATE
288D2342
ISSUED:
A-1057-4
ENGLISH
3.38
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
TITLE:
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
Fluid Related:
Operating pressure
Relief valve set pressure
Particulate filter maximum differential
Flow rate
Hydraulic fluid
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
Rev. None
0.75kW (1HP)
400 VAC
50 Hz / 3 Phase
1430 RPM (nominal)
1.6 AMPS at 100% rated load
www.airlinehyd.com
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
POST-FILTER (F222)
INLET GAUGE
POST-FILTER GAUGE
Rev. None
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RESERVOIR BREATHER
CONDITIONING MANIFOLD
Rev. None
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HEAT
EXCHANGERS (2)
(ITEMS 290)
Rev. None
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Appendix D
Manufacturers Data Sheets
x
Magnaloy Couplings
Magnom Pumpmate
HYDAC RV08A-01
HYDAC DB08A-01
DMIC BV3L/BV3LZ
IMO Pumps
VIKING Pumps
GE MOTOR 3.7 KW
GE MOTOR 0.75 KW
Rev. None
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