Owner’s Manual with Photos

For
180K NITROGEN UNIT With
NITROGEN TANK
Job #12328
 PUBLISHED BY

HYDRA RIG
A VARCO COMPANY
FORT WORTH, TEXAS, USA

PREPARED BY
TECHNICAL COMMUNICATIONS DEPARTMENT

REVIEWED BY
SERVICE DEPARTMENT

CONFIDENTIAL/PROPRIETARY NOTICE
This manual contains confidential and proprietary information of Hydra Rig. It is provided to customers of
Hydra Rig, in confidence, with the understanding that it is not to be copied or reproduced without the
expressed, written consent from Hydra Rig. Copies of this manual may be obtained through Hydra Rig
Sales Department. All copyrights and patent rights are reserved.

© Copyright Varco International, Inc. 2001

 HYDRA-RIG TABLE OF CONTENTS

HYDRA RIG 180K NITROGEN UNIT (HEAT PUMP)

PAGE
FOREWORD ..................................................................................................................... INTRO 1
WARRANTIES OF QUALITY AND TITLE ................................................................... INTRO 2
GENERAL WARNING INFORMATION ........................................................................ INTRO 5
SAFETY AND HEALTH.................................................................................................. INTRO 6
NITROGEN SAFETY ..................................................................................................... INTRO 11
TEST PROCEDURES ...............................................................................................................TP-1
LUBRICANTS.............................................................................................................................L-1
SPECIFICATIONS
Weights ................................................................................................................................1
Dimensions ..........................................................................................................................1
Engine (Caterpillar C-15D)..................................................................................................1
Controls..........................................................................................................................1
Engine Fluid...................................................................................................................1
Pumps...................................................................................................................................2
Triplex Pump Lube Oil ........................................................................................................2
Filters And Strainers ............................................................................................................3
Capacities.............................................................................................................................3
HYDRAULIC OIL...........................................................................................................................4
NITROGEN SYSTEM ....................................................................................................................5
VAPORIZER SYSTEM ..................................................................................................................5
OPERATION ...................................................................................................................................7
Diesel Engine .......................................................................................................................7

Heat Pumps .........................................................................................................................7

Centrifugal Charge Pump (Boost Pump) .............................................................................7

Triplex Pump .......................................................................................................................7

Coolant Loop Circuit ...........................................................................................................8

Heat Exchanger ....................................................................................................................8

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LN2 Vaporizer ......................................................................................................................8

Hydraulic Cooling System ...................................................................................................8

Engine Cooling System........................................................................................................9

CONTROLS AND INDICATORS..................................................................................................9
Nitrogen Discharge ..............................................................................................................9

Nitrogen Controls...............................................................................................................11

LN2 Charge Pump ..............................................................................................................12

Engine Controls And Indicators.........................................................................................12

Lube Oil .............................................................................................................................13

Coolant...............................................................................................................................14
COOLANT CIRCUIT....................................................................................................................14
VALVE DEFINITIONS.................................................................................................................15
SUMMARY OF OPERATION .....................................................................................................16
UNIT PRE START CHECK .........................................................................................................17
Control Panel .....................................................................................................................17
System Controls .................................................................................................................18
SYSTEM START PROCEDURE .................................................................................................18
COOLDOWN PROCEDURES .....................................................................................................19
Normal Cooldown .............................................................................................................19
Rapid Cooldown ...............................................................................................................19
Normal Cooldown Procedure ............................................................................................20
Boost Pump Priming ..........................................................................................................21
Rapid Cooldown Procedure ...............................................................................................22
Pumping Procedure For Low Pressure Operation..............................................................23
Pumping Procedure For High Pressure Operation .............................................................24
Shutdown Procedure ..........................................................................................................26

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 HYDRA-RIG TABLE OF CONTENTS

PARTS BREAKDOWN ...............................................................................................................27

Maintenance Parts List.......................................................................................................27
How To Use The Parts Breakdown....................................................................................27
Symbols And Abbreviations ..............................................................................................28
FIGURES
Schematics
Fig. 1.1, 180K N2 Hydraulic Schematic (NE090201A).....................................................29

Fig. 1.2, 180K SCFH Nitrogen Schematic (ND090202) ...................................................32

Fig. 1.3, 180K SCFH Coolant Schematic (ND090204).....................................................34

Fig. 1.4, Pneumatic Schematic (NC090203)......................................................................36

Fig. 1.5, Nitrogen Tank Plumbing Schematic (NC090208) ..............................................38

Fig. 1.6, Electrical Schematic (NE090209) .......................................................................41

Assemblies

Fig. 2.1, 180K Nitrogen Unit Final Assembly (NE000548) ..............................................44

Fig. 2.2, Nitrogen Unit Trailer Assembly (NE000546) .....................................................46

Fig. 2.3, Hose Kit NPS 180K Cat (NA090206).................................................................48

Fig. 2.4, Nitrogen Pumping Systems Fluid Specification (A00079C)...............................52

Fig. 2.5, Control Panel W/Chart Assembly (ND020261) ..................................................54

Fig. 2.6, Relief Valve Assembly (NB050079)...................................................................57

Fig. 2.7, Trailer Specification (NA020228).......................................................................59

Fig. 2.8, 200HP Direct Drive Pump Assembly (NE050119C) ..........................................62

Fig. 2.9, Recirculation Plumbing Assembly (ND150055A) ..............................................65

Fig. 2.10, Cat Engine Specification (NA010072)..............................................................67

Fig. 2.11, Hydraulic Tank Assembly (ND066075C) .........................................................70

Fig. 2.12, 180K Control Panel Hose Kit (NA090207).......................................................73

Fig. 2.13, Pressure Building Coil Assembly (ND150056).................................................76

Fig. 2.14, Vaporizer Assembly (ND057428B) ..................................................................78

Fig. 2.15, Cold End Assembly (NA005877)......................................................................80

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Fig. 2.16, High Pressure Manifold Controls Specification (NA000465B) ........................81

Fig. 2.17, High Pressure Manifold Triplex Controls Specification (NA000467C) ...........82

Installations

Fig. 3.1, 180K N2 Power Unit Installation (NE010074A) .................................................84

Fig. 3.2, Triplex Installation (NE056094C).......................................................................87

Fig. 3.3, Hydraulic/Fuel/Air Tanks Installation (ND030082)............................................89

Fig. 3.4, Tank Plumbing Installation (NE150051).............................................................91

Fig. 3.5, Coolant Plumbing Installation (NE070762) ........................................................93

Fig. 3.6, Low Pressure Plumbing Installation (NE050215A) ............................................95

Fig. 3.7, High Pressure Plumbing Installation (ND050216A) ...........................................98

Fig. 3.8, Lube Plumbing Installation (ND030083) ..........................................................101

Fig. 3.9, Return Manifold Installation (ND036106B)......................................................103

Fig. 3.10, Triplex Shutdown Valve Installation (ND022010B).......................................105

Fig. 3.11, Nitrogen Tank Installation (ND160014)..........................................................107

Fig. 3.12, Recirculating and Tempering Valve Installation (NC051875D) .....................109

MAINTENANCE AND TROUBLESHOOTING
Inspection .........................................................................................................................112
Daily.................................................................................................................................113
Weekly .............................................................................................................................114
Bi-Weekly ........................................................................................................................114
Monthly............................................................................................................................115
Annually...........................................................................................................................115
Cleaning ...........................................................................................................................116
TROUBLESHOOTING...............................................................................................................117
SERVICE LITERATURE
Cold End ..........................................................................................................................126
Air Dryer (AAD00002)....................................................................................................130
Cryogenic Centrifugal Pump (CPC00081) ......................................................................138
Accumulator (HAB00018)...............................................................................................150
Accumulator (HAB00036)...............................................................................................168
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Piston Motor (HMP00116) ..............................................................................................176

Fixed Displacement Gear Pump (HPG00072).................................................................194
Gear Pump (HPG00085)..................................................................................................200
Piston Pump (HPP00134 / HPP00135)............................................................................214
Debooster (IPP00001)......................................................................................................240
Cat Engine Electronic System
MDDM Gauge (ICX00035)
MLA Gauge (ITE00088 & IPE00027)
Gear Pump (HPG00099).........................................................To be provided at a later date
NITROGEN TANK MANUAL (Refer to Hard Copy of this Manual)
PARTS ORDER FORM

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 HYDRA RIG NITROGEN UNIT INTRODUCTION

FOREWORD
Hydra Rig's equipment was engineered for simple operation and maintenance. This equipment manual
provides the operator with the information necessary to learn the fundamentals of successful operation.
Study this manual carefully before making any attempt to operate this equipment. Special attention
should be given to the WARNINGS outlined in the safety summary. DURING OPERATION OR
MAINTENANCE OF THIS EQUIPMENT, PERSONNEL SAFETY SHOULD ALWAYS BE OF
UTMOST IMPORTANCE.

This equipment was designed and all components were specified to provide maximum performance.
Maintenance procedures outlined in this manual should be considered as minimum requirements to
maintain satisfactory performance. Maintenance schedules should be followed as closely as possible.

In the event of equipment failure or performance decrease, maintenance personnel will find valuable
troubleshooting, circuit analysis, and component information in this manual.

It is impossible to include all situations that may occur to cause substandard equipment performance or
failure. The abilities of operators or maintenance personnel to understand and utilize the system
schematics is vital when troubleshooting this equipment. Before operating, adjusting, or replacing any
components, be certain that ramifications and consequences of those actions are clearly understood.
Ensure that appropriate precautions are then taken.

If problems cannot be readily resolved, it is strongly recommended that you contact a Hydra Rig Service
Technician for assistance. A Service Technician is on call 24 hours a day. Hydra Rig, Incorporated
stands behind all equipment and is willing and able to provide replacement parts and field service upon
request.

HYDRA RIG, INCORPORATED

6000 East Berry Street

Fort Worth, Texas 76119

Phone: (817) 457-3825

Fax: (817) 457-3897

(817) 457-1472 (Customer Service)

24-Hour Service Phone: (817) 457-1521

Visit our Web Page at www.hydrarig.com

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 HYDRA RIG NITROGEN UNIT INTRODUCTION

WARRANTIES OF QUALITY AND TITLE

A. Hydra Rig warrants that on the date of delivery and for six (6) months thereafter, the Goods shall be
free from defects in Hydra Rig's materials and workmanship and shall meet the additional express
written statement of quality, if any, made by Hydra Rig in connection with the Sale of Goods and
signed by an officer of Hydra Rig. This Limited Express Warranty of quality set forth in the
immediate preceding sentence shall apply ONLY in favor of the Buyer and shall be subject to the
following limitations:

1. The Limited Express Warranty of quality shall apply only if:

a. The Goods have been exposed to normal use and service, have been reasonably maintained,
and otherwise used in accordance with Hydra Rig's instructions,

b. The Goods are returned to Hydra Rig's factory in Fort Worth, Texas (or such other place
closer to the location of the equipment, goods or parts as may be designated by Hydra Rig)
within ten (10) days after Buyer first discovers a claimed defect with transportation costs
prepaid by Buyer; and

c. Hydra Rig's examination upon the return of such Goods satisfies Hydra Rig that such are in
fact defective.

2. The Limited Express Warranty of quality shall not apply

a. To Goods that have been used or rebuilt (whether by Hydra Rig or by any other entity).

b. To Goods not manufactured entirely by Hydra Rig (however, Hydra Rig shall assign to
Buyer, to the extent the same assignable, whatever warranty Hydra Rig has received from the
manufacturer of such Goods).

c. To Goods that have been altered by any person or entity other than Hydra Rig in any way so
as in Hydra Rig's judgment to affect the stability, reliability, or performance of the Goods.

d. To Goods that have not been used in the service and within the range for which they were
manufactured.

e. To Goods which have been misused or which have been damaged due to the unreasonable
use, negligence, or accident of Buyer or any other entity, or

f. To Goods that have been unreasonably used by Buyer or any other entity after Buyer or such
entity knew or should have known of the defect in the Goods. Any advisory services and/or
recommendations provided by Hydra Rig with respect to the Goods and their uses are not
warranted. Any reference by Hydra Rig to Buyer's specifications and similar requirements
are made only to describe the Goods in general, and no warranties or other terms therein
shall have any force or effect. Catalogs, circulars, or similar pamphlets are for general
information purposes only and shall not be deemed to constitute express written statements
of quality.

B. Other than the express written statements of quality made in paragraph one (1) above, all express
warranties that might arise from representations of Hydra Rig with respect to the sale of goods or
from engineering drawings, samples, models, or actions of Hydra Rig are expressly disclaimed and
negated.

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 HYDRA RIG NITROGEN UNIT INTRODUCTION

C. All implied warranties existing under the law with respect to the sale of goods' hereunder are hereby
expressly disclaimed and negated. In particular, Hydra Rig hereby negates and disclaims the implied
warranty of merchantability and the implied warranty of fitness for a particular purpose.

D. In addition, all other liability that may arise with respect to the sale of goods, either in contract or tort,
statutory or otherwise, including without limitation, strict liability and liability based upon the
negligence of Hydra Rig, are expressly disclaimed and negated.

E. No representative of Hydra Rig, other than an officer of Hydra Rig, has authority to alter or increase
this Limited Express Warranty in any manner whatsoever, and no attempt to repair or promise to
repair, replace, or improve the Goods covered by this Limited Express Warranty by representative of
Hydra Rig shall waive, change, or extend this Limited Warranty in any manner whatsoever, unless
such action, promise or other representation is in writing and signed by an officer of Hydra Rig.

F. Buyer warrants through the purchase of the Goods that Buyer is familiar with same and the proper use
thereof. Before using the Goods hereunder, Buyer shall give the Goods reasonable and prudent
examination and/or tests to determine the suitability of said Goods for Buyer's intended use.

G. After acceptance of the Goods, Buyer's sole remedy and Hydra Rig's sole liability for any failure of the
Goods to conform with the Limited Express Warranty of quality or for any breach by Hydra Rig for
any obligation pertaining to the quality of the Goods (even if such nonconformity results from the
negligence of Hydra Rig), shall be limited to one of the following at Hydra Rig's option:

1. Repairing or replacing (whichever Hydra Rig shall elect) at Hydra Rig's factory in Fort Worth,
Texas (or such other place closer to the location of the Goods as may be designated by Hydra Rig)
the Goods whereby they comply with the Limited Express Warranty of quality, or

2. Paying Buyer an amount equal to the cost (to Buyer at the original time of sale) of the part of the
Goods that does not comply with the Limited Express Warranty of quality.

In no event shall Hydra Rig be required to repair, replace or reimburse Buyer for more than the part of the
Goods that is found to be not in compliance with the Limited Express Warranty of quality. Any Goods or
parts thereof that are repaired or replaced by Hydra Rig pursuant to this Paragraph shall be arranged as of
their date of delivery in accordance with the terms and conditions of this Agreement.

H. The remedies provided herein shall be the sole and exclusive remedy of buyer for Hydra Rig's breach
of warranties or for any breach of any contractual or legal duty or obligation arising out of the sale of
the goods by Hydra Rig to buyer. Hydra Rig shall not under any circumstances be responsible or
liable to buyer or to any user or to any third party for any economic loss or physical harm, incidental,
consequential punitive, or special damages (including without limitation downtime, loss of profits
and/or loss of business opportunities) arising from any defect in the goods or services or any failure of
the goods or services to conform with the warranties made herein or any failure of Hydra Rig to meet
any obligation or duty existing and applicable under the law with respect to the sale of the goods
whether such defect in goods or failure of the goods to conform with the warranty or failure of Hydra
Rig to meet its obligations or duties result in damage or harm only to the goods or to other property.

I. Except to the extent such obligation is inconsistent with Hydra Rig's obligation to Buyer under the
terms of the Limited Express Warranty stated above in Paragraph 11, Buyer agrees to defend,
indemnify, and hold Hydra Rig harmless from and against any and all claims, liabilities, loss, costs
(including without limitation, the cost of litigation and attorney's fees), and expense made against or
incurred by Hydra Rig on account of death or bodily injury to persons or injury to property or loss,
damage or expense (including without limitation, subsurface damage, subsurface trespassing, or
damage to the well or reservoir), which relates to or results from, or is in any way attributable to the
sale, handling, use or operation of the Goods or any device, material, or thing which the Goods are
made a part or to which the Goods are attached or within which the Goods are enclosed (while in
Buyer's possession or subsequent to any transfer of possession to any other entity) or which related to

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 HYDRA RIG NITROGEN UNIT INTRODUCTION

or results from, or in any way attributable to, the Goods or services provided by Hydra Rig to buyer
hereunder.

J. Buyer's obligations to defend and indemnify and hold Hydra Rig harmless shall apply and be fully
enforceable, irrespective of whether such death or bodily injury to persons or injury to property or
loss, damage or expenses is caused by or results from the sole or concurrent negligence or other fault
of Hydra Rig or any agent or employee of Hydra Rig or any independent contractor who is directly
responsible to Hydra Rig.

K. Due to a policy of continuous product improvement, Hydra Rig reserves the right to change designs,
materials, or specifications and to discontinue product without notice.

L. To help defray the cost of restocking, there will be a charge of twenty percent (20%) on items
returned for credit with a minimum charge of Ten and No/100's ($10.00) Dollars. No credit will be
given on items returned without prior approval and written instructions accompanying the items
stating the reasons for return and the name of Hydra Rig's representative who authorized the return.
Only the Officers of Hydra Rig may authorize return of items for credit. Hydra Rig cannot be
responsible for holding or accounting for items returned without prior approval and proper written
instructions being shipped with the returned items. If freight is not prepaid on the items returned for
credit, the cost of freight will be deducted from the credit issued. Non-standard items that are
manufactured at the request of Buyer cannot be returned for credit. Hydra Rig cannot be responsible
for items that are shipped to Hydra Rig without the above information.

M. An action for breach of any provision herein contained must be commenced within one year after the
cause of action has accrued or such cause is forever barred.

N. All terms contained herein are separable and the invalidity of any part hereof shall not affect the
validity of any other part.

O. The rights and remedies herein reserved to Hydra Rig shall be cumulative and in addition to other
rights and remedies provided by law. The failure of Hydra Rig to insist upon strict performance
hereof in any one instance shall not constitute a release of its right to require such performance in the
future with respect to such incidence or with respect to any later breach of the Agreement by Buyer.

Buyer's rights and obligations under this Agreement may not be assigned or transferred without
the express written consent of Hydra Rig.

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 HYDRA RIG NITROGEN UNIT INTRODUCTION

General Warning Information

This manual contains various WARNINGS, CAUTIONS, and NOTES, which must be carefully
observed in order to safely rig up, operate, rig down, and service this unit. The manufacturer recommends
that overall good safety practices be adhered to at all times when personnel are near said unit. It is the
owner's and operator's responsibility to establish good safety practices, train personnel, and enforce
observance of those safety standards. It is also important to understand that these WARNINGS,
CAUTIONS, and NOTES are defined as follows:

WARNING

A COMMENT PERTAINING TO:

AN OPERATION OR MAINTENANCE ACTION, PROCEDURE PRACTICE

CONDITION, OR STATEMENT THAT, IF NOT STRICTLY OBSERVED, WILL
RESULT IN INJURY OR DEATH TO PERSONNEL AND/OR DAMAGE TO
EQUIPMENT .

CAUTION

A COMMENT PERTAINING TO:

AN OPERATION OR MAINTENANCE PROCEDURE, PRACTICE, OR CONDITION, WHICH, IF

NOT OBSERVED, CAN RESULT IN PERSONNEL INJURY AND/OR DAMAGE TO EQUIPMENT

NOTE: An essential comment pertaining to:

The highlighting of a specification, procedure, practice, or condition
that aids in the maintenance or operation of the equipment function
involved or described.

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 HYDRA RIG NITROGEN UNIT INTRODUCTION

Safety And Health

The following are general safety precautions. Personnel must understand and apply these precautions
during all phases of operation and maintenance of this equipment. Specific precautions will be included
in the text for certain potentially hazardous operations in the form of WARNING or CAUTION
statements. Some of the warnings appear in the text of this publication but are presented here for
emphasis.

Qualified Personnel
Only qualified personnel should be authorized to operate and perform maintenance on this equipment.

Protective Equipment
Personnel operating and performing maintenance on this equipment should wear suitable protective
clothing and equipment.

Safety Practices
Overall good safety practices should be adhered to at all times when setting up, operating, shutting down
and maintaining this equipment. It is the equipment owner’s/operator’s responsibility to ensure that good
safety practices, personnel training programs, and safety practices are maintained.

Unauthorized Personnel
Keep unauthorized personnel away from the unit when operating, servicing, or performing maintenance.

High Pressures
Ensure pressure in piping connected to the unit has been bled to zero (0) before attempting to disconnect
any equipment.

Unauthorized Maintenance
Do not attempt unauthorized disassembly or maintenance of components. Some components, such as
accumulators, store fluids under pressure. Contact your Hydra Rig representative for further information.

Lifting
Equipment used in lifting and moving the unit must be of sufficient rating to handle the weight involved.

Use Of Solvents Or Paints

Ensure that a current Material Safety Data Sheet (MSDS) for each chemical being used is available and
has been reviewed by all personnel. Keep cleaning solvents or paints in approved safety containers and in
minimum quantities. Some solvents or paints may be toxic to skin, eyes, and respiratory tract. Observe
manufacturer’s WARNING labels and safety directives. Use solvents, paints, and other volatile/aromatic
chemicals in well-ventilated and authorized areas. Discard rags that have been soiled with chemicals in
approved disposal containers.

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 HYDRA RIG NITROGEN UNIT INTRODUCTION

Compressed Air Usage

Use of compressed air can create an environment of propelled foreign particles. Air pressure used for
cleaning should be reduced to less that 30 psi and used with effective chip guarding and personal
protective equipment. Never direct compressed air toward other personnel.

Moving Parts
Keep hands, hair, clothing, jewelry, rags, and tools away from moving parts.

Visibility
Do not attempt to operate equipment with obstructed visibility. Never operate equipment between sunset
and sunrise without suitable lighting.

Pre-Start
Before starting the unit ensure that all operating controls are in the proper STARTUP position.

Work Areas
Keep work areas clean and clear of obstructions, hand tools, and other objects when operating the unit.

Transporting The Unit

Ensure that all components are secured before transporting the unit to another location.

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 HYDRA RIG NITROGEN UNIT INTRODUCTION

Lubricants Safety And Health

Fire Hazards
Many petroleum products are highly volatile and flammable and must be handled with extreme caution to
prevent fire or explosion. These include propane, kerosene, diesel fuel, and many solvents. The federal
Occupational Safety and Health Administration (OSHA) have classified products with flash points below
37.8°C (100°F) as “flammable," and products with flash points at or above 37.8°C and below 93°C
(200°F) “combustible."

Petroleum products should not be stored or handled near sources of ignition, such as heat, sparks, open
flame, or any sources of static electricity, nor near strong oxidants as chlorine (including swimming pool
chemicals) and concentrated oxygen. Gasoline should be used as a motor fuel only. It should never be
used as a cleaning solvent or thinner or for any other non-motor fuel use.

WARNING

EMPTY CONTAINERS RETAIN RESIDUE (LIQUID AND/OR VAPOR) AND

CAN BE DANGEROUS. DO NOT PRESSURIZE, CUT, WELD, BRAZE,
SOLDER, DRILL, GRIND OR EXPOSE SUCH CONTAINERS TO HEAT,
FLAME, SPARKS, STATIC ELECTRICITY, AND OTHER SOURCES OF
IGNITION; THEY MAY EXPLODE AND CAUSE INJURY OR DEATH. DO NOT
ATTEMPT TO CLEAN SINCE RESIDUE IS DIFFICULT TO REMOVE, AND
EVEN A TRACE OF REMAINING MATERIAL CONSTITUTES AN EXPLOSIVE
HAZARD. EMPTY DRUMS SHOULD BE COMPLETELY DRAINED,
PROPERLY BUNGED, AND RETURNED TO A DRUM RECONDITIONER.
ALL OTHER CONTAINERS SHOULD BE DISPOSED OF IN AN
ENVIRONMENTALLY SAFE MANNER AND IN ACCORDANCE WITH
GOVERNMENTAL REGULATIONS.

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 HYDRA RIG NITROGEN UNIT INTRODUCTION

Health Hazards
Health studies have shown that many petroleum hydrocarbons pose potential human health risks that may
vary from person to person. As a precaution, exposure to liquids, vapors, and mists of petroleum products
should be minimized.

Inhalation

Health specialists have established maximum concentration levels for hydrocarbon vapors in air to which
nearly all workers may be exposed. Where applicable, the levels established for oil and grease products
are indicated in Material Safety Data Sheets (MSDS). Prolonged breathing of hydrocarbon vapor
concentrations somewhat in excess of prescribed limits may result in light-headedness, dizziness, and
nausea. Inhalation of higher vapor concentrations may produce dizziness, headache, respiratory tract
irritation, and unconsciousness. One or two breaths of high concentrations, such as may occur close to
tank openings of volatile products, can cause immediate unconsciousness. If a person is overcome by
vapor, remove the individual from the exposure at once and call a physician. If breathing is irregular or
has stopped, start resuscitation and administer oxygen, (if available).

To avoid inhalation of excessive concentrations of hydrocarbons, store and handle highly volatile
petroleum products such as gasoline, solvents, and solvent-cutback products only in open well-ventilated
areas. In special case of indoor handling, such as, laboratory's products should always be handled under
vented hoods powered with explosion-proof motors.

Under certain circumstances, sulfur compounds in hot asphalt and heavy, or residual, fuels may form the
toxic gas hydrogen sulfide (H2S). Prolonged breathing of 50 to 100 ppm of H2S may produce eye and
respiratory tract irritation, headache, nervousness, and nausea. At higher concentrations of H2S (700 to
1000 ppm) only a few breaths of the gas may lead to unconsciousness and could be fatal. To avoid
breathing excessive concentrations of H2S, personnel should stand upwind of tank and bulk transport
compartments containing asphalt or heavy fuel, insure that personnel are at least two feet from
compartment openings, and avoid breathing vapors when opening hatches and dome covers. Use
respirator equipment where necessary.

Ingestion

As a precaution, if petroleum products are ingested, keep the person calm. DO NOT induce vomiting.
Call the Poison Control center (1-800-764-7661) or a physician immediately, identifying the product and
approximate amount swallowed. While petroleum products are generally not highly toxic, fuels, solvent,
and light oils with viscosity’s below 20.5 Centistokes (100 SUS) at 37.8°C (100°F) pose a distinct hazard
of being aspirated into the lungs and causing chemical pneumonia. This is a delayed effect that may not
occur for a week to ten days. Because of the risk of swallowing, petroleum products should never be
siphoned by mouth.

Skin Contact

Prolonged or repeated contact of petroleum oils, grease, solvents, or fuels with the skin can cause skin
irritation and dermatitis. In case of skin contact, wash skin thoroughly with soap and warm water. A
waterless hand cleaner and a soft skin brush can also be used to help remove oils and greases. Promptly
remove and launder petroleum-soaked clothing before re-use. If a petroleum product contacts the eyes,
flush the eyes with fresh water until the irritation subsides; if irritation persists, call a physician. Avoid
prolonged contact with petroleum products, wear chemical-resistant gloves, apron, splash goggles, and
other protective clothing.

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 HYDRA RIG NITROGEN UNIT INTRODUCTION

High-pressure injection of grease through the skin (a grease gun injury) can cause serious delayed damage
to soft tissues. Hydraulic oil under high pressure can cause similar injury. Regardless of the size or
appearance of the wound, a physician should be contacted immediately

Chronic Health Effects

Studies with laboratory animals have shown that prolonged exposure to certain petroleum products can
cause cancer and other chronic health effects. Some petroleum oils have caused skin cancer in mice
following skin-painting tests over the animals’ lifetime. In similar tests, used motor oil also has caused
skin cancer. Prolonged and repeated inhalation of concentrated gasoline vapors have caused kidney
damage and kidney cancer in rats and liver cancer in mice. Inhalations of the vapors of kerosene, diesel
fuel, and most non-aromatic solvents are known to cause kidney damage in male rats. The normal hexane
(n-hexane) component of hexane solvent is known to cause a form of motor nerve damage called
peripheral polyneuropathy in humans.
You can protect yourself from petroleum-related hazards by exercising care and common sense in the
handling of petroleum products. Appropriate engineering controls, work practices, and personal
protection should be used to minimize skin contact and to keep exposure by inhalation as far below the
recommended occupational exposure limit as is reasonably practical.

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 HYDRA RIG NITROGEN UNIT INTRODUCTION

NITROGEN SAFETY
General Information
Strict compliance with proper safety and handling practices is necessary when using a Horizontal Liquid
Transport Vessel. We recommend that all our customers re-emphasize safety and safe handling practices
to all their employees and customers. While every possible safety feature has been designed into the unit
and safe operations are anticipated, it is essential that the user of the Horizontal Liquid Transport Vessel
carefully read all WARNINGS and CAUTION notes listed in this safety summary and enumerated below.
Also, read the information provided in the Safety Bulletin for Oxygen and Inert Gases following this
Safety Summary. Periodic review of the Safety Summary is recommended.

In an oxygen-enriched atmosphere, flammable items burn vigorously and could explode. Excess
accumulation of oxygen creates an oxygen-enriched atmosphere (defined by the Compressed Gas
Association as an oxygen concentration above 23%). Certain items considered non-combustible in air
might burn rapidly in such an environment. Keep all organic materials and other flammable substances
away from possible contact with oxygen; particularly oil, grease, kerosene, cloth, wood, paint, tar, coal,
dust, and dirt that may contain oil or grease. Do not permit smoking or open flame in any area where
oxygen is stored, handled, or used. Failure to comply with this warning may result in serious personal
injury.

Nitrogen and argon vapors in air may dilute the concentration of oxygen necessary to support or
sustain life. Exposure to such an oxygen deficient atmosphere can lead to unconsciousness and serious
injury, including death.

Before removing any parts or loosening fittings empty a cryogenic container of liquid contents and
release any vapor pressure in a safe manner. External valves and fittings can become extremely cold
and may cause painful burns to personnel unless properly protected. Personnel must wear protective
gloves and eye protection whenever removing parts or loosening fittings. Failure to do so may result in
personal injury due to the extreme cold and pressure in the tank.

Accidental contact of liquid gases with skin or eyes may cause a freezing injury similar to a burn.
Handle liquid so that it will not splash or spill. Protect your eyes and cover skin where the possibility of
contact with liquid, cold pipes and cold equipment, or cold gas exists. Safety goggles or a face shield
should be worn if liquid ejection or splashing may occur or cold gas may issue forcefully from equipment.
Clean, insulated gloves that can easily be removed and long sleeves are recommended for arm protection
cuff-less trousers should be worn over the shoes to shed spilled liquid.

If clothing should be splashed with liquid oxygen it will become highly flammable and easily ignited
while concentrated oxygen remains. Such clothing must be aired out immediately, removing the clothing
if possible, and should not be considered safe for at least 30 minutes.

Use only replacement parts that are compatible with liquid oxygen and have been cleaned for oxygen use.
Do not use regulators, fittings, hoses, etc., which have been previously used in a compressed air
environment. Similarly, do not use oxygen equipment for compressed air. Failure to comply with these
instructions may result in serious damage to the container.

Before locating oxygen equipment, become familiar with the National Fire Protection Association (NFPA)
standard No. 50, "Bulk Oxygen Systems at Customer Sites," and with all local safety codes. The NFPA
standard covers general principles recommended for installing bulk oxygen systems on industrial and
institutional consumer premises.

INTRO 11
 HYDRA RIG NITROGEN UNIT INTRODUCTION

Safety Bulletin
Hydra Rig liquid transport units are safely designed with the following features:

1. A vacuum maintenance system specifically designed to provide long life and all possible safety
provisions.

2. Safety relief devices to protect the pressure vessel and vacuum casing, sized and selected according to
ASME standards to include a pressure control valve and rupture disc to protect the pressure vessel
and a reverse buckling rupture disc or lift plate to protect the vacuum casing from over pressure.
While Hydra Rig equipment is designed and built to the most rigid standards, no piece of mechanical
equipment can ever be 100% foolproof.

Portions of the following information have been extracted from Safety Bulletin SB-2, from the
Compressed Gas Association, Inc. Additional information on nitrogen and argon and liquid cylinders is
available in CGA Pamphlet P-9. Write to the Compressed Gas Association, Inc., 1235 Jefferson Davis
Highway, Arlington, VA 22202.

Safety Bulletin From CGA

Cryogenic containers, stationary or portable are from time-to time subjected to assorted environmental
conditions of an unforeseen nature. This safety bulletin is intended to call attention to the fact that
whenever a cryogenic container is involved in any incident whereby the container or its safety devices are
damaged, good safety practices must be followed. The same holds true whenever the integrity or function
of a container is suspected of abnormal operation.

Good safety practices dictate that the contents of a damaged or suspect container be carefully emptied soon
as possible. Under no circumstances should a damaged container be left with product in it for an extended
time. A damaged or suspect container should not be refilled unless the unit has been repaired and
rectified.

Incidents that require that such practices be followed include highway accidents, immersion in water,
exposure to extreme heat or fire, and exposure to most adverse weather (earthquakes, tornadoes, etc.).
Whenever a container is suspected of abnormal operation, or has sustained actual damage, good safety
practices must be followed.

If there a known or suspected container vacuum problems (even if an extraordinary circumstance such as
those noted above has not occurred), do not continue to use the unit. Continued uses of a cryogenic
container that has a vacuum problem can lead to embrittlement and cracking. Further, the carbon steel
jacket could possibly rupture if the unit is exposed to inordinate stress conditions caused by an internal
liquid leak.

Before reusing a damaged container, the unit must be tested, evaluated, and repaired as necessary. It is
highly recommended that any damaged container be returned to Hydra Rig for repair and rectification.

The remainder of this safety bulletin addresses those adverse environments that may be met with when a
cryogenic container has been severely damaged. These are oxygen deficient atmospheres, oxygen-
enriched atmospheres, and exposure to inert gases.

Oxygen Deficient Atmospheres

The normal oxygen content of air is approximately 21%. Depletion of oxygen content in air, either by
combustion or by displacement with inert gas, is a potential hazard and users should exercise suitable
precautions.

INTRO 12
 HYDRA RIG NITROGEN UNIT INTRODUCTION

One aspect of this possible hazard is the response of humans when exposed to an atmosphere containing
only 8 to 12% oxygen. In this environment, unconsciousness can be immediate with virtually no warning.

When the oxygen content of air is reduced to about 15 or 16%, the flame of ordinary combustible
materials, including those commonly used as fuel for heat or light, may be extinguished. Somewhat below
this concentration, an individual breathing the air is mentally incapable of diagnosing the situation
because the onset of symptoms such as sleepiness, fatigue, lassitude, loss of coordination, errors in
judgment and confusion can be masked by a state of “euphoria,” leaving the victim with a false sense of
security and well being. Human exposure to atmosphere containing 12% or less oxygen leads to rapid
unconsciousness. Unconsciousness can occur so rapidly that the user is rendered essentially helpless.
This can occur if the condition is reached by immediate change of environment, or through the gradual
depletion of oxygen.

Most individuals working in or around oxygen deficient atmospheres rely on the “buddy system” for
protection - obviously, the “buddy” is equally susceptible to asphyxiation if he or she enters the area to
assist an unconscious partner unless equipped with a portable air supply. Best protection is obtainable by
equipping all individuals with a portable supply of respirable air. Lifelines are acceptable only if the area
is essentially free of obstructions and individuals can assist one another without constraint. If oxygen
deficient atmosphere is suspected or known to exist:

• Use the “buddy system”. Use more than one “buddy” if necessary to move a fellow worker in an
emergency.

• The worker and “buddy” should be equipped with self-contained or airline breathing
equipment.

Oxygen Enriched Atmospheres

An oxygen-enriched atmosphere occurs whenever the normal oxygen content of air is allowed to rise
above 23%. While oxygen is non-flammable, ignition of combustible materials can occur more readily in
an oxygen-rich atmosphere than in air; and combustion continues at a faster rate although no more total
heat is released. It is important to locate an oxygen system in a well-ventilated location, since oxygen-rich
atmospheres may collect temporarily in confined areas during the functioning of a safety relief device or
leakage from the system.

Oxygen system components, including but not limited to, containers, valves, valve seats, lubricants,
fittings, gaskets and interconnecting equipment including hoses, shall have adequate compatibility with
oxygen under the conditions of temperature and pressure to which the components may be exposed in the
containment and use of oxygen. Easily ignitable materials shall be avoided unless they are parts of
equipment or systems that are approved, listed, or proved suitable by tests or by experience.

Compatibility involves both combustibility and ease of ignition. Materials that burn in air may burn
violently in pure oxygen at normal pressure, and explosively in pressurized oxygen. In addition, many
materials that do not burn in air may do so in pure oxygen, particularly when under pressure. Metals for
containers and piping must be carefully selected, depending on service conditions. The various steels are
acceptable for many applications, but some service conditions may call for other materials (usually copper
or its alloys) because of their greater resistance to ignition and lower rate of combustion.

Similarly, materials that can be ignited in air have lower ignition energies in oxygen. Many such
materials may be ignited by friction at a valve seat or stem packing, or by adiabatic compression produced
when oxygen at high pressure is rapidly introduced into a system initially at low pressure.

INTRO 13
 HYDRA RIG NITROGEN UNIT INTRODUCTION

Nitrogen And Argon

Nitrogen and argon (inert gases) are simple asphyxiates. Neither gas will support or sustain life and can
produce immediate hazardous conditions through the displacement of oxygen. Under high pressure, these
gases may produce narcosis although an adequate oxygen supply, sufficient for life, is present.

Nitrogen and argon vapors in air dilute the concentration of oxygen necessary to support or sustain life.
Inhalation of high concentrations of these gases can cause anoxia, resulting in dizziness, nausea,
vomiting, or unconsciousness and possibly death. Individuals should be prohibited from entering areas
where the oxygen content is below 19% unless equipped with a self-contained breathing apparatus.
Unconsciousness and death may occur with virtually no warning if the oxygen concentration is below
approximately 8%. Contact with cold nitrogen or argon gas or liquid can cause cryogenic (extreme low
temperature) burns and freeze body tissue.

Persons suffering from lack of oxygen should be immediately moved to areas with normal atmospheres.
SELF CONTAINED BREATHING APPARATUS MAY BE REQUIRED TO PREVENT
ASPHYXIATION OF RESCUE WORKERS. Assisted respiration and supplemental oxygen should be
given if the victim is not breathing. If cryogenic liquid or cold boil-off gas contacts a worker’s skin or
eyes, the affected tissues should be promptly flooded or soaked with tepid water (105-115°; 41-46°C). DO
NOT USE HOT WATER. Cryogenic burns resulting in blistering or deeper tissue freezing and should
be examined promptly by a physician.

INTRO 14
 HYDRA RIG NITROGEN UNIT INTRODUCTION

Safety For Handling And Exposure

Characteristics Of Nitrogen

• Non-toxic and non-flammable

• Colorless

• Odorless

• Tasteless

• Extremely cold

Properties Of Nitrogen

• Normal boiling point - 320 degrees Fahrenheit.

• Density at 70 degrees Fahrenheit, 1.0 Atmospheres - 0.07245 Lb. per cubic foot.

• Vapor at normal boiling point - 0.287 Lb. per cubic foot.

• Liquid at normal boiling point - 50.4 Lb. per cubic foot.

Any contact of liquid or cold gaseous Nitrogen with any bodily part may induce freezing similar to
frostbite. Proper body protection and dress when handling or in and around its use is essential. Handle
liquid Nitrogen (LN2), in a manner to avoid splashing or spillage. Safety goggles and clothing covering
as much of the body as possible is recommended. Avoid providing reservoirs with clothing, such as cuffs
in pants, shirtsleeves or pants tucked inside boots. Gloves that are insulated, easily removed and cleaned
should be preferred to ordinary gloves.

Although bodily protection is importance, a well-ventilated work environment is even more essential.
Nitrogen is odorless, colorless and tasteless. The human senses cannot detect it within the air. Without
proper ventilation, Nitrogen can expand displacing enough oxygen in the working atmosphere to
cause dizziness, unconsciousness or even death when inhaled. Store liquid Nitrogen (LN2) containers
in well-ventilated facilities or outdoors.

To summarize safety using gaseous or liquid Nitrogen, always remember:

Keeps work area well ventilated.

Dress appropriately.

INTRO 15
 HYDRA RIG NITROGEN UNIT INTRODUCTION

The following are general safety precautions. These precautions are not related to any specific procedures
and do not appear repeatedly in this publication. Personnel must understand and apply these precautions
during all phases or operation and maintenance of this equipment. Specific precautions will be included
in the text for certain potentially hazardous operations as a WARNING or CAUTION statements. Some
of the warnings appear in the text of this publication but are presented here for emphasis.

Qualified Personnel

Only qualified personnel should be authorized to operate and perform maintenance on this equipment.

Protective Equipment

Personnel operating and performing maintenance on this equipment should wear suitable protective
clothing and equipment.

Safety Practices

Overall, good safety practices should be adhered to always when setting up, operating, shutdown, and
maintenance of this equipment. It is the equipment owner's/operator's responsibility to establish good
safety practices, personnel training, and enforce observance of safety practices.

Unit Operation

Personnel should not operate the unit unless they are thoroughly familiar with the equipment manual, all
unit operating controls, and functions. Reading the equipment manual does not qualify any individual to
operate this equipment.

Unauthorized Personnel

Keep unauthorized personnel away from the unit when operating, repairing, or performing maintenance.

High Pressures

Ensure pressure in piping connected to the unit has been bled to zero (0) pressure before attempting
to disconnect any component.

Unauthorized Maintenance

Do not attempt unauthorized disassembly or maintenance of components. Some components (such as

accumulators) store fluids under pressure. Contact your Hydra Rig representative for further information.

Lifting

Equipment used in lifting and moving the unit must be of sufficient rating to handle the weight involved.

Use Of Solvents Or Paints

Keep cleaning solvents or paints in approved safety containers and in minimum quantities. Some
solvents/paints may have adverse effect on skin, eyes, and respiratory tract. Observe manufacturer's
WARNING labels and safety directives. Use solvents/paints only in well-ventilated and authorized areas.
Discard rags soiled with solvent/paint in approved disposal containers.

INTRO 16
 HYDRA RIG NITROGEN UNIT INTRODUCTION

Compressed Air Usage

Use of compressed air can create an environment of propelled foreign particles. Air pressure should be
reduced t less than 30 psig and used with effective chip guarding and personal protective equipment.
Never direct compressed air to the body or other personnel.

Moving Parts

Keep hands, hair, clothing, jewelry, rags, and tools away from moving parts when the unit is in operation.

Visibility

Do not attempt to operate equipment with obstructed visibility. This includes before sunrise and after
sunset unless suitable lighting provisions are available.

Pre-Start

Before starting, ensure that all operating controls are in the proper position (for example, Off, On,
Neutral).

Work Areas

Keep work areas clean and clear of obstructions, hand tools, and other objects when operating the unit.

Transporting The Unit

Ensure all components are secured before transporting the unit to another location.

INTRO 17
 HYDRA RIG

Lubricants

Petroleum-Based Oils
For the majority of lubricant applications, petroleum-based oils provide satisfactory service at low cost. For
severe service, very low and very high temperature operations, long-life and some specialty applications,
synthetic lubricants can be the answer to cost-effective lubrication.

Synthetic Lubricant
A properly formulated synthetic lubricant can be very cost-effective, considering unit downtime,
maintenance and the expense of regulatory compliance. In an atmosphere of increasingly stringent
equipment manufacturers' specifications and environmentally driven state, federal and international
regulatory constraints, the role of synthetic lubricants will increase.

One of the main assets of synthetic lubricant use is to extend drain and service intervals. Also, operating
temperature extremes, energy efficiency, and pressure requirements all combine to enhance the value of
using synthetics.

Remember, synthetics generally offer:

• Utility over wide temperatures

• Excellent stability

• Long service life

• Unique performance traits

• Longer equipment life

• Less maintenance cost

Always make certain that synthetic lubricants meet or exceed equipment manufacturers’ recommendations
and warranty requirements.

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 HYDRA RIG

Compressor Oils
There are a variety of petroleum-based and synthetic-based compressor oils available. Consult the
equipment manufacturer’s operating manual for the required specifications, then order the desired product
by specification from a reliable lubricant's supplier.

NOTE: Laboratory Analysis Of Lubricants, Equipment, And Operating Conditions Will

Allow Service Intervals To Be Extended. The Manufacturers’ Equipment
Recommendations Never Should Be Compromised.
Seal Compatibility With Petroleum And Synthetic-Based Products Must Be
Investigated. Most Equipment Manufacturers’ Operating Manuals Cover This
Subject

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 HYDRA RIG

General Product
CATEGORY
LYONDELL EXXON MOBIL SHELL TEXACO
GREASE
General Purpose
Lithium Complex Litholine Complex Unirex EP-2 Mobil grease Retinax LC-2 Starplex 2
NLGI-2 EX-2 HP-2

Lithium Complex Litholine Molyplex Ronex Extra- Mobil grease Retinax AM-2 Starplex Moly
w/3% Moly, NLGI-2 EX-2 Duty Moly-2 CM-P-2 MPGM-2
AUTOMATIC
TRANSMISSION
FLUID
(Dexron III/ Dexron III/Mercon Superflo ATF Multi-Purpose Donax TG Havoline ATF
Mercon) ATF ATF Mercon/
Dexron III
MANUAL
TRANSMISSION
FLUID
(Heavy Duty) Arcofleet S-3 XD-3 SAE 50 Delvac 1250 Rotella T Ursa Super
SAE 50 SAE 50 SAE 50 Plus SAE 50
GEAR OILS
(Extreme Pressure)
SAE 80 Pennant NL 68 Spartan EP68 Mobilgear 626 Omela 68 Meropa 68
SAE 90 Pennant 220 Spartan EP220 Mobilgear 630 Omela 220 Meropa 220
SAE 140 Pennant 460 Spartan EP460 Mobilgear 634 Omela 460 Meropa 460
HYDRAULIC
OILS
(with Anti-Wear)

SAE 10 Duro AW 32 NUTO H32 DTE 24 Tellus 32 Rando HD 32

SAE 20 Pennant 220 Spartan EP220 Mobilgear 630 Omela 220 Meropa 220
SAE 20 Pennant 460 Spartan EP460 Mobilgear 634 Omela 460 Meropa 460
MOTOR OILS
Single-Viscosity Arcofleet S-3 XD-3 Extra Delvac 1230 Rotella T Ursa Super
SAE 30 SAE 50 SAE 30 SAE 30 Plus SAE 30

Arcofleet S-3 XD-3 Extra Delvac 1300 Rotella T Ursa Super

Multi-Viscosity
SAE 10W40 SAE 15w40 Super SAE XLA SAE Plus SAE
15w40 15w40 15w40

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 HYDRA RIG

Synthetic Product
CATEGORY
LYONDELL EXXON MOBIL SHELL TEXACO
GREASE
General Purpose
Synthetic Base Royal On- Starfak 2202
N/A Unirex S-2 Mobilith SHC-220
Lithium-Complex Guard LC-460
NLGI-2
AUTOMATIC
TRANSMISSION Synthetics not recommended for automatic transmission use.
FLUID
MANUAL
TRANSMISSION
FLUID
(Heavy Duty) N/A SGO SAE 50 Mobiltrans Dentax Syn-Star
SHC-SAE 50 S-SAE 50 TL-SAE 50
GEAR OILS
N/A SGO-75w90. Mobilube SHC Spirax S Syn-Star GL
75w/90. 75w90. 75w/90
SGO-80w140 Mobilube SHC Spirax S Syn-Star GL
80w/90 80w/140 80w/140
HYDRAULIC OILS
SAE 10 Univis N 32 Mobil SHC-500- Royco 700-32 Hydra 32
32
N/A
SAE 20 Univis N46 Royco700-46 Hydra 46
Mobil SHC-500-
46
SAE 20 Univis N68 Royco700-68 Syn-Star
DE-68
Mobil SHC-500-
68

MOTOR OILS Synthetics not recommended for Heavy-Duty Motor Oils

L4
 HYDRA RIG

Viscosity Ranges For AGMA Lubricants

Viscosity ranges for AGMA lubricant numbers are identical to those of ASTM system D 2422.

Use extreme pressure (EP) lubricants only when recommended by the gear drive manufacture.

ISO Viscosity grade and range (100° F) is for reference only - not included in AGMA specifications.
Viscosity systems for industrial fluid lubricants ASTM D 2422. Also British Standards Institute B. S. 4231.

METRIC EQUIVALENT
AGMA LUBRICANT ISO VISCOSITY RANGE VISCOSITY RANGE,
R & O GEAR EP GEAR VISCOSITY SUS AT 100°F cSt at 37.8°C (100°F
OILS LUBRICANT GRADE MINIMUM MINIMUM MAXIMUM
MAXIMUM
1 - 46 193 235 41.4 50.6
2 2EP 68 284 347 61.2 74.8
3 3EP 100 417 510 90 110
4 4EP 150 626 765 135 165
5 5EP 220 918 1122 198 242
6 6EP 320 1335 1623 288 352
7 COMP 7EP 460 1919 2346 414 506
8 COMP 8EP 680 2837 3467 612 748
8A COMP - 1000 4171 5090 900 1100

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 HYDRA RIG

ISO Viscosity Classification System

Industrial oils are graded and approved according to the International Standards Organization (ISO)
Viscosity Classification System. The ISO system is based on viscosity at only one temperature, 40°C. ISO
viscosity ranges are summarized in the table below:

ISO MID-POINT VISCOSITY RANGES

VISCOSITY cSt @ cSt @ 40°C
GRADES 40°C MINIMUM MAXIMUM
2 2.2 1.98 2.42
3 3.2 2.88 .3.53
5 4.6 4.14 5.06
7 6.8 6.12 7.48
10 10 9.00 11.0
15 15 13.5 16.6
22 22 19.8 24.2
32 32 28.8 35.2
46 46 41.4 50.6
68 68 61.2 74.8
100 100 90.0 110
150 150 135 165
220 220 198 242
320 320 288 352
460 460 414 506
680 680 612 748
1000 1000 900 1100
1500 1500 1350 1650

Notice from the table above that the grades above 68 are multiples of 10 or 100 of the grades from 10
through 68.

Beginning with ISO viscosity grade 10, each viscosity grade range is from 10% below to 10% above the
respective grade number. In the third and fourth columns of the table viscosity ranges are not continuous
from one grade to another. There is a gap between the maximum of one grade and the minimum of the next
higher grade. For products with viscosities between ISO ranges, the grade number indicates the
approximate kinematics viscosity at 40°C.

L6
 HYDRA RIG

NLGI Consistency Grades (ASTM D 217)

NLGI WORKED PENETRATION RANGE
GRADE @ 25°C (77°F) MM/10

000 445 to 474

00 400 to 430

0 355 to 385

1 310 to 340

2 265 to 295

3 220 to 250

4 175 to 205

5 130 to 160

6 85 to 115

L7
 HYDRA RIG

Binary Grease Mixtures Compatibility Chart

BARIUM CALCIUM
COMPLEX COMPLEX LITHIUM POLYUREA
AL LITHIUM
COMPLEX CALCIUM CLAY COMPLEX SODIUM

AL
COMPLEX

BARIUM
COMPLEX

CALCIUM

BORDERLINE
CALCIUM
COMPLEX
SAMPLE SHOULD BE
CLAY CHECKED

LITHIUM COMPATIBLE

LITHIUM
COMPLEX
INCOMPATIBLE

POLYUREA

SODIUM

This chart is only to serve as a guideline for determining compatibility. For the purposes of changing
products in the field, the compatibility of the greases in question should be determined by laboratory testing.

L8
 HYDRA RIG 180K NITROGEN UNIT

180K NITROGEN UNIT (HEAT PUMP)

Specifications
Weights
Nitrogen Unit (Full water and oil) ...........................................................14,000lb (6350kg)

Dimensions
Height...............................................................................................................96in (244cm)

Length ............................................................................................................132in (335cm)

Width ..............................................................................................................96in (244 cm)

Engine (Caterpillar C-15D DITA Industrial)

Speed....................................................................................................................... 2100rpm

Horse Power.....................................................................................................................500

Controls
Engine Throttle ........................................................................Electronic, 2-turn twist knob

Fuel Kill ................................................................................................................ Electronic

Emergency Engine Kill ........................................................................................ Electronic

Starter................................................................................................................ 12V Electric

Engine Fluid
OIL
SAE Viscosity Grade .........................................................................................................40

API Classification ......................................................................................................... CDII

Military Specification .................................................................................... MIL-L-2104D

Sulfated Ash.................................................................................................. Less than 1.0%

PAGE 1
 HYDRA RIG 180K NITROGEN UNIT

FUEL
Must meet properties of ASTM designation D975 of both grades 1-D and 2-D.

ANTIFREEZE

Any ethylene glycol based antifreeze. Do not substitute alcohol-based antifreeze.

(Alcohol based anti-freeze can be a flammable hazard) Add an inhibitor with antifreeze to
protect aluminum parts in engine system.

• Normal (to –34°F or –37°C) use 50% antifreeze/50% water

• Arctic (to -62°F or -52°C) use 60% antifreeze/40% water

Pumps
Nitrogen/Heat........................................................................................145.45gpm /5500psi

Triple Gear

Heat ......................................................................................................23.5gpm/4750psi

Coolant..................................................................................................150gpm/2000psi

Boost ....................................................................................................23.5gpm/2000psi

Lube .........................................................................................................19.48gpm/2000psi

Triplex Pump Lube Oil

Meropa 68 SAE 80 Weight Gear Oil (Or Equivalent)

NOTE: If Recommended Brands Are Not Available, A Suitable Brand Equivalent May Be Utilized.

PAGE 2
 HYDRA RIG 180K NITROGEN UNIT

Filters And Strainers

Strainer...................................................................................................................100 Mesh

Hydraulic Return Filter(s) .....................................................................................10 Micron

Coolant Return Filter(s) ...........................................................................................90 Mesh

Capacities
Fuel Tank .......................................................................................................100gal (379 L)

Vaporizer Coolant System ...............................................................................50gal (189 L)

Hydraulic Oil..................................................................................................120gal (454 L)

Vaporizer........................................................................................................180,000 SCFH

Triplex Lube System ..........................................................................................12gal (45 L)

NOTE: Refer To Fluid Specifications And Lubrication Charts.

PAGE 3
 HYDRA RIG 180K NITROGEN UNIT

Hydraulic Oil
AW68 is supplied with the unit. Many acceptable substitutes are available.

MANUFACTURER BRAND NAME

Citgo Citgo AW Hydraulic Oil - 68

Amoco Oil Company Rykon Oil No. 68
Arco Duro AW - 68
Chevron - Canada Chevron AW Hydraulic - 68
Conoco Super Hydraulic Oil - ISO-VG 68
Exxon Company - USA NUTO-H - 68
Pacer Lubricants, Inc. - USA Pacer Power V Hydraulic Oil - V68
Pennzoil Products Company - Pennzoil AWX Hydraulic Fluids - 68
USA
Shell Canada Ltd. Shell Tellus Oil - 68
Shell Company - Canada Tellus T37 (Multigrade)
Shell Company - USA Tellus - 68
Texaco, Inc. - USA Rando Oil - HD 68
Union Oil - USA Union UNAS AW ISO - 68

Hydraulic Fluid
When selecting the correct viscosity consider the following criteria:

The lowest temperature of the fluid that the hydraulic system will be started and allowed
to idle at low pressure. The fluid viscosity should not be above 4000 SUS (862 CST) at
this temperature.

The highest temperature at which the system will be run is at maximum engine speed
(RPM) and/or system pressure. The fluid viscosity should not be below 100 SUS (20
CST) at this temperature.

PAGE 4
 HYDRA RIG 180K NITROGEN UNIT

Nitrogen System
Working Pressure..............................................................Maximum 10,000psig (690 bars)

Hydrostatic Test ................................................................................15,000psig (1034 bars)

Flow Rates (Maximum) .................................................................................180,000 SCFH

Ambient Temperature Operation (Minimum).................................................. 20°F (-29°C)

Ambient Temperature Operation (Maximum).................................................120°F (49°C)

Liquid Nitrogen Pump ..............................................................................Hydra Rig NP200

Cold End Bore.............................................................................1.625in. (4.128cm)

Stroke .............................................................................. Stroke 1.375in. (3.493cm)

Maximum Speed ......................................................................................... 1000rpm

Vaporizer Pot ........................................................................................... Model ND057428

Capacity .............................................................................................................3000 SCFM

Boost Pump.............................................................................................................. 100gpm

Coolant..................................................................................................................... 120gpm

Vaporizer System
Vaporizer Coolant System
Texaco 2353. Do Not substitute alcohol-based antifreeze. Add an inhibitor with
antifreeze to protect aluminum parts in engine cooling system:

• Normal (to –13°F or –25°C) use 40% antifreeze/60% water

• Arctic (to -62°F or -52°C) use 60% antifreeze/40% water

PAGE 5
 HYDRA RIG 180K NITROGEN UNIT

PUMP SPEED vs. NITROGEN FLOW

HR NP 200 PUMP
With 1-5/8 BORE, 1-3/8 STROKE COLD END
3000 SCFM MAXIMUM / 84.96 SCMM MAXIMUM

PUMP SPEED (RPM) NITROGEN FLOW (SCFM) NITROGEN FLOW (SCMM)

100 300 8.50
150 450 12.75
200 600 17.00
250 750 21.25
300 900 25.49
350 1050 29.74
400 1200 33.98
450 1350 38.23
500 1500 42.48
550 1650 46.73
600 1800 50.98
650 1950 55.23
700 2100 59.47
750 2250 63.72
800 2400 67.97
850 2550 72.22
900 2700 76.46
950 2850 80.71
1000 3000 84.96

NOTE: Outputs Are Approximate And Based On Pump Volumetric Efficiency Of 87%.

PAGE 6
 HYDRA RIG 180K NITROGEN UNIT

Operation
The Hydra Rig Triplex Liquid Nitrogen (LN2) pump is a cryogenic unit that pumps
extremely cold liquid nitrogen (-320°F) and converts it to a usable gas (Max. 160°F) by
the use of a Vaporizer. The Hydra Rig nitrogen pump and vaporizer system consist of the
following:

Diesel Engine
The diesel engine is direct coupled to a single pump drive. Coupled to the drive is a
tandum combination of a piston pump and a triple gear pump. The diesel engine supplies
power to the pumps to drive several hydraulic functions that generate heat to vaporize
nitrogen at unit rated levels.

Heat Pumps
The heat pumps consist of the piston pump and one section of the gear pump. Each pump
generates the heat through a pressure drop generated by a pressure sequence valve (at the
piston pump discharge) or a relief valve (at the gear pump discharge). The piston pump
also acts as the drive force to the triplex hydraulic motor.

Centrifugal Charge Pump (Boost Pump)

This hydraulic motor driven pump supplies the triplex pump (cold ends) with a positive
head of LN2 to insure that a positive pressure of LN2 is available for pumping and
vaporization. The centrifugal charge (Boost) pump is used to maintain a pressure of 40-
100 psig on the intake side of the cold end.

Triplex Pump
This hydraulic motor driven positive displacement plunger pump discharges the LN2
pressure to maximum operating pressure of 10,000 psig. This pump consists of the
following:

Cold End(s) - The reciprocating positive displacement pistons are charged by the boost
pump with low pressure LN2 and then discharge high pressure LN2 vaporizer. The cold
ends are attached to and driven by the triplex pistons (also defined as the warm ends).

.Warm End - The mechanical drive and plunger section of the triplex pump assembly.
The warm end drives the attached cold ends.

PAGE 7
 HYDRA RIG 180K NITROGEN UNIT

Coolant Loop Circuit

The coolant loop circuit is a water-glycol recirculation system powered by a positive
displacement pump. The circuit links together several heat exchangers, each of which
recovers waste system heat from its particular system function. The final stage of this
circuit is the liquid nitrogen vaporizer. Refer to “LN2 Vaporizer” below.

Heat Exchanger
Two plate heat exchangers absorb heat to be used for heat of vaporization. One heat
exchanger provides heat from the engine and the other from the hydraulic system.

LN2 Vaporizer

This is the heart of the vaporization system. The vaporizer is actually a specially
designed heat exchanger consisting of a chamber filled with a wrapped tubing bundle to
pass the LN2. The coolant loop fluid floods the chamber and flows around the tubing
bundle at a pressure of 80 - 150 PSIG. When the LN2 (-320°F) circulates through the
tubes of the tubing bundle, the LN2 vaporizes into a Nitrogen gaseous (GN2) state. The
(GN2) temperature is controlled by the LN2 flow rate verses inlet water temperature and
flow rate. GN2 temperature is between 60° to 70°F. This discharge gas is measured in
Standard Cubic Feet per Minute (SCFM) or Standard Cubic Meters per Minute (SCMM).
The coolant loop temperature is manually controlled to maintain a steady input to the
vaporizer between 100° to 120°F. The heat generated in the coolant loop is from the
separate sources as listed below:

• Heat generated directly into the coolant system by the heat pump.

• Waste heat is transferred from the hydraulic heat exchanger.

• Waste heat is transferred from the engine cooling heat exchanger.

• Waste heat from lube system.

Hydraulic Cooling System

After the coolant-fluid leaves the vaporizer, it passes through the hydraulic heat exchanger. The
coolant fluid will absorb additional heat from the hydraulic oil.
In cold weather, a reverse heat exchange is possible. The coolant loop (warmed by use of
the heat pump) exchanges heat into the hydraulic oil. This heat potential reduces the
introduction time of rated system pressures.

PAGE 8
 HYDRA RIG 180K NITROGEN UNIT

Engine Cooling System

The engine water-cooling system also flows through one of the heat exchangers. A
significant percentage of heat required to heat the vaporization coolant circuit is provided
from this heat exchanger. The amount varies depending upon the horsepower draw or
engine load.

Controls and Indicators

Most of the controls and indicators needed to control the system are contained on the
Control Panel. (See Figure 5-1) The control panel is broken up into control areas with a
chart recorder (in most cases) to measure and chart GN2 discharge pressure. The
following is a brief description of the panel control areas and their purpose.

Nitrogen Discharge
NITROGEN DISCHARGE VALVE

A valve for selecting opens or closed position of the discharge valve. [(See Fig. 1 (1)]

PUSH TO ACTIVATE
A valve that isolates the nitrogen discharge valve from hydraulic or air pressure until
pushed to prevent accidental opening or closing of the discharge valve. [(See Fig. 1 (2)]

PRESSURE

A gauge that indicates the nitrogen discharge pressure. [(See Fig. 1 (3)]

TEMPERATURE

A gauge that indicates the nitrogen discharge temperature. [(See Fig. 1 (4)]

PAGE 9
 HYDRA RIG 180K NITROGEN UNIT

8 5 1 2 3 4

6
28
7

10

26
27

16 17 23 11 13 12 14
24 25 15 19 20
21 22 18

Fig. 1, System Control Panel

PAGE 10
 HYDRA RIG 180K NITROGEN UNIT

Nitrogen Controls
TRIPLEX HYDRAULIC PRESSURE
A gauge that indicates the main hydraulic pressure required to drive the triplex pump.
[(See Fig. 1 (5)]

HYDRAULIC CONTROL PRESSURE

A gauge that indicates that the piston pump powering the triplex drive circuit has the
proper control pressure to vary flow. [(See Fig. 1 (6)]

PUMP SPEED

A gauge (tachometer) that indicates the RPM’s of the triplex pump. [(See Fig. 1 (7)]

HYDRAULIC HEAT PUMP PRESSURE

A gauge that indicates the discharge pressure of the hydraulic heat pump. [(See Fig. 1 (8)]

PUMP SPEED CONTROL

A hydraulic control valve that controls the flow of the hydraulic pump that drives the
triplex pump. [(See Fig. 1 (9)]

MAIN HYDRAULIC CHARGE PRESSURE

A gauge that indicates the hydraulic charge pressure to the triplex drive pump. Nominal
pressure readings are 20 PSIG.. [(See Fig. 1 (10)]

PAGE 11
 HYDRA RIG 180K NITROGEN UNIT

LN2 Charge Pump

PUMP SAVER
A gauge with red, yellow, and green face (scale) that indicates the condition or
temperature of the LN2 being supplied to the cold ends. [(See Fig. 1 (11)]

(a) Red – Stop pumping.

(b) Yellow – Fluid condition is okay but use caution (watch gauge) and take steps to
prevent fluid condition going to red level.

(c) Green – Fluid condition good.

N2 BOOST PRESSURE

A gauge that indicates the discharge pressure of the nitrogen (boost) charge pump. [(See
Fig. 1 (12)]

PUMP SPEED
Remote pilot relief valve used to set the hydraulic pressure of the charge pump drive
system. [(See Fig. 1(13)]

HYDRAULIC PRESSURE
A gauge that indicates the hydraulic pressure required to drive the (boost charge pump).
[(See Fig. 1 (14)]

Engine Controls And Indicators

THROTTLE
A valve that variably controls the engine speed through an air actuator that is connected
to the engine. [(See Fig. 1 (15)]

ENGINE RPM

A meter (tachometer) that indicates the revolutions per minute of the engine. [(See Fig. 1
(16)]

OIL PRESSURE
A gauge that indicates the oil pressure of the engine. Normal oil pressure varies between
5 to 65 PSIG. [(See Fig. 1 (17)]

PAGE 12
 HYDRA RIG 180K NITROGEN UNIT

AIR PRESSURE
A gauge that indicates the air pressure of the unit. Its primary function is to indicate
sufficient air pressure for unit starting, stopping and proper air compressor operation.
[(See Fig. 1 (18)]

ENGINE START
A push button valve used to start the engine by either supplying air pressure to an air
driven start, or DC voltage to an electric starter. [(See Fig. 1 (19)]

ENGINE KILL
A push button valve used during normal shutdown, which shuts off the fuel supply to the
engine. [(See Fig. 1 (20)]

MDDM
Display and diagnostic module that allows the operator to access and toggle through all
gauge readings in case of gauge failure. [(See Fig. 1 (21)]

VOLTS

Battery output voltage indicator. [(See Fig. 1 (22)]

WATER TEMPERATURE
A gauge that indicates the water temperature of the engine. Engine thermostat-opening
settings (170 -190°F) and engine over temperature conditions is monitored with this
gauge. [(See Fig. 1 (23)]

Lube Oil
PRESSURE

A gauge that indicates the lube oil pressure. Normal reading is 20 PSIG (warm). [(See
Fig. 1 (24)]

TEMPERATURE
A gauge that indicates the temperature of the lube oil. Normal reading is 110 - 150°F
(warm). [(See Fig. 1 (25)]

PAGE 13
 HYDRA RIG 180K NITROGEN UNIT

Coolant
TEMPERATURE
A gauge that indicates the temperature of the coolant circuit.. Normal operational
temperature is between 100 to 160°F. [(See Fig. 1 (26)]

HEAT LOAD VALVE

A remote pilot relief valve used to set the hydraulic pressure of the heat pump. [(See Fig.
1 (27)]

Chart Recorder
A device to measure and chart GN2 discharge pressure. [(See Fig. 1 (28)]

Coolant Circuit

Coolant Temperature
A gauge that indicates the temperature of the coolant circuit. Normal operational
temperature is between 100 to 160°F.

CAUTION:
DO NOT EXCEED MAXIMUM TEMPERATURE OF 180°F.

PAGE 14
 HYDRA RIG 180K NITROGEN UNIT

Valve Definitions
LOW PRESSURE INLET #1
Globe valve on supply line leading to the boost pump.

LOW PRESSURE OUTLET

Globe valve on return line leading back to the tank.

COLD END RECIRCULATION

Gate valve between the cold end return port and the low pressure return.

RAPID COOL DOWN

Ball valve located after the boost pump discharge port. This valve allows flow directly
into the atmospheric through vent piping. Use this valve to vent LN2 supply boost pump
flow to atmosphere to help establish cool down and boost pump prime.

HIGH PRESSURE RECIRCULATION VALVE

The recirculation valve located below the control panel. Use this valve is to allow a small
amount of high-pressure flow to be vented.

TEMPERING
Valve used to lower the output temperature of the nitrogen gas. Located below the
control panel. This is accomplished by opening the valve and allowing high pressure LN2
to flow into the high pressure GN2 prior to the high-pressure discharge valve.

HEAT LOAD VALVE

PCV valve, located on the control panel, used to create hydraulic load to increase system
temperature.

BOOST PUMP RECIRCULATION

Ball valve (1.50) in tank return line located prior to intersection of cold end recirculation
line and return line. (THIS VALVE IS USED FOR COOLDOWN.)

PAGE 15
 HYDRA RIG 180K NITROGEN UNIT

Summary Of Operation
During normal operation, liquid nitrogen (LN2) flows from the supply tank into a centrifugal boost pump.
The centrifugal boost pump boosts the LN2 pressure to 40 - 100 PSIG before entering the triplex pump
cold end(s). This boosted pressure is required to ensure a positive pressure is on the suction side of the
cold ends. The triplex pump cold end(s) are a positive displacement pump capable of producing pressure
of up to a maximum operating pressure of 10,000 PSIG. The high pressure LN2 flows through the
nitrogen vaporizer. The vaporizer transfers sufficient heat to vaporize the LN2 . The heat transfer is
capable of raising maximum unit flow rate to temperatures of 60° to 70°F. Higher temperatures, up to
approximately 120°F, can be obtained at lower nitrogen flow rates.
The supply heat to the coolant loop system is acquired by means of heat exchangers mounted in series
within the coolant loop system. The heat is then transferred to the nitrogen through the vaporizer.
Because of the wide range of operating conditions that can be achieved with this unit, it is impossible to
write detailed operation instructions using all of the given rates and pressures. Only time and experience
with the unit will allow an operator to become totally acquainted with the system. The operator should
feel free to try different operating configurations with the system, being cautious not to exceed the
maximum operating condition and safe working limits of the unit.

PAGE 16
 HYDRA RIG 180K NITROGEN UNIT

Unit Pre-Start Check

Check the following fluid levels to insure levels are full or at safe working levels.
1. Coolant tank sight glass.
2. Triplex pump lubrication tank sight glass. (Check with engine at idle.)
3. Engine oil dip stick.
4. Engine radiator coolant level (sight glass or remove radiator cap and check).
5. Hydraulic reservoir sight glass.
6. Triplex drive box sight glass.
7. Diesel fuel level sight glass.

• Drain any condensation from pneumatic (air) and hydraulic reservoirs.

• Check that all hydraulic suction valves on the hydraulic tank are open.

• Grease bearings on coolant pump. (Super Lube M EP)

• Inspect the unit to insure all belts; fans and other rotating components are free of
obstructions.

• Check and set the following controls.

1. Control Panel (See Fig. 1)

(a) Set all hydraulic controls to zero. Fully counterclockwise.

(b) Turn the nitrogen discharge valve to the CLOSED position. Visually
check the valve to see if it is closed. If the valve is open, close the
valve before unit cool-down.
(c) Turn the engine throttle counter clockwise, to low idle position.

PAGE 17
 HYDRA RIG 180K NITROGEN UNIT

2. System Controls

(a) Turn the Tempering Valve to CLOSED position.

(b) Turn the LN2 High Pressure Bleed Valve to the CLOSED position.
(c) Turn the LN2 Return Valve to the CLOSED position.
(d) Turn the LN2 Supply Valve to the CLOSED position.
(e) Set the Boost Pump Recirculation Valve to the CLOSED position.
(f) Turn the Cold End Recirculation Valve clockwise to CLOSE.
(g) Set the Rapid Cool-down Valve to the CLOSED position.
(h) Place the Boost Pump Bypass to the CLOSED position.

System Start Procedure

1. Push the Engine Start Switch.

2. With the throttle, adjust the engine speed to idle, between 600 to 800 RPM.

3. Allow the engine to warm up before raising engine RPM.

4. Check the Engine Oil Pressure - 5 psi minimum at idle, 40 to 60 PSIG at 1800
RPM and higher.

5. Check the Lube Oil Tank Temperature - below 100°F.

NOTE: Lube Oil temperature will be approximately the same as the coolant temperature.

6. Check the Main Hydraulic Charge Pressure - Nominal pressure readings are
20 PSI.

7. Check the Water Temperature - 100°F before raising engine RPM above an
idle, maximum allowable temperature are 190°F at any RPM.

8. Check the System Air Pressure - 100 to 120 PSIG.

9. Slowly raise the engine speed with throttle to 1800 RPM as indicated on
Engine RPM Indicator and re-check the gauge readings as indicated above.

PAGE 18
 HYDRA RIG 180K NITROGEN UNIT

Cooldown Procedures
The cooldown procedure is required in order to cool all components, piping to subcooled
temperatures, and promote boost pump priming. There are two cooldown procedures.

Normal Cooldown
In a normal cooldown, the hydrostatic head pressure of the LN2 tank promotes LN2 flow
through the side piping to subcool the plumbing. Vent the LN2 tank to cause a
differential pressure and promote LN2 flow. Once the boost pump and all piping is
subcooled, boost pump priming is accomplished easily.

Rapid Cooldown
In a rapid cooldown, open the atmospheric skid mounted vent valve to vent off the
gasified fluid and promote LN2 flow through the skid piping. This is done to subcool the
skid plumbing and promote boost pump priming. Once there is a constant stream of
liquid LN2 exiting the vent valve, the valve is closed or partially closed and the boost
pump is activated to see if it will prime and pump. Repeat this procedure until the boost
pump primes and starts to operate.

A rapid cooldown takes less time than a normal cooldown and is the most used method.
The disadvantages of rapid cooldown are:

• More liquid is lost to the atmosphere than normal cooldown.

• The supply tank will become more agitated (energy put into the tank liquid) and
cause loss of prime to the boost pump at lower tanks liquid levels.

CAUTION

DO NOT SPIN BOOST PUMP LONGER THAN 10 SECONDS

WITHOUT THE BOOST PUMP BEING PRIMED OR BOOST PUMP
SEALS WILL LEAK DUE TO HEAT

PAGE 19
 HYDRA RIG 180K NITROGEN UNIT

Normal Cooldown Procedure

1. Set Discharge Valves to OPEN and Push to Activate switch.
2. Open the vent valve on LN2 tank completely.

3. Open the return valve on LN2 tank and nitrogen unit.

4. Open the supply valve on LN2 tank and nitrogen unit.

5. Open the Boost Pump Recirculation Valve.

6. Leave the rapid cool down valve in the CLOSED position.
7. Open the cold end recirculation valve one to two turns from fully closed position.
8. Once frost begins to appear on boost the pump housing, periodically spin the boost pump
for 3-5 seconds, every 5 minutes.
9. Let the unit cool down until the piping, valves and boost pump have a frost cover
approximately 1/8” thick.
10. After a coating of frost has formed on the boost pump housing, spinning of the boost pump
is no longer necessary.
11. Once there is a uniform frost cover on boost pump and related piping, including LN2 return
hose, the boost pump is flooded with LN2.

PAGE 20
 HYDRA RIG 180K NITROGEN UNIT

Boost Pump Priming

1.`Close the LN2 supply tank vent valve and build 20 PSIG tank pressure.

2. At 20 PSIG supply tank pressure, set engine RPM to approximately 1800 RPM using
the throttle (10) control.

3. Adjust the boost pump pressure with the hydraulic control to approximately 1000
PSIG as indicated on hydraulic pressure gauge.

4. Check the boost pump discharge pressure as indicated on the nitrogen pressure gauge
for a 5 to 10 PSIG rise over supply tank pressure. Tank pressure is shown on this
gauge when the boost pump is not turning.

NOTE: It may be necessary to partially open the tank vent line to maintain a constant 20 PSIG tank
pressure.

5. When the pressure rise occurs, the boost pump is primed or about primed.

CAUTION

DO NOT SPIN BOOST PUMP LONGER THAN 10 SECONDS

WITHOUT THE BOOST PUMP BEING PRIMED OR BOOST PUMP
SEALS WILL LEAK DUE TO HEAT.

6. Once the boost pump is primed, adjust the recirculation valve to nearly closed.
Nitrogen pressure should rise 60 to 100 PSIG.

NOTE: If The Nitrogen Pressure Does Not Rise 60 To 100 PSIG, The Boost Pump Has Lost Its’
Prime. Repeat The Priming Procedure.

7. If the pressure rises above 60 PSIG, reduce pressure by adjusting hydraulic control
counterclockwise.

8. Close the cold end recirculation valve fully and then open one full turn. Re-Check the
boost pump pressure with nitrogen pressure gauge to see if pressure increased.

9. Continue cooldown until a uniform coating of frost has formed on the piping to the
triplex cold end suction ports and around the cold end body up to the recirculation
ports. When this occurs, the unit is sufficiently cooled down for pumping.

10. Open the high pressure recirculation valve and rotate the triplex pump three to four
revolutions to insure a uniform cooldown and force trapped gas out of the cold end
chambers.

11. Close the high-pressure recirculation valve.

PAGE 21
 HYDRA RIG 180K NITROGEN UNIT

12. Once all 3 cold ends are frosted, cooldown is complete

This completes the normal cooldown procedure.

Rapid Cooldown Procedure:

1. Set nitrogen discharge valve to the CLOSED position.

2. Open the rapid cooldown vent valve.

3. Open the return valve and N2 tank.

4. Open the supply valve on LN2 tank and nitrogen unit.

5. Open the Boost Pump Recirculation Valve.

6. Close the cold end recirculation valve counterclockwise then open one to two turns.

7. Ensure that the road relief valve on the LN2 supply tank is closed.

8. Close the LN2 tank vent valve and allow tank pressure to build to 20 PSIG.

NOTE: Maintain 20 PSIG on the tank through entire cooldown procedure.

9. With 20 PSIG supply tank pressure, set engine RPM to approximately 1800 RPM with the
throttle control.

10. Monitor the atmospheric venting of gasified liquid from the rapid cool down vent piping.
When gasified liquid changes to liquid and a good (approximately 1/8” thick) coating of
frost is seen on the boost pump, and related piping, priming may be attempted.

11. Boost pump priming. Reference boost pump priming Step (11) and continue with boost
pump priming procedure.

PAGE 22
 HYDRA RIG 180K NITROGEN UNIT

Pumping Procedure For Low Pressure Operation

1. Once boost pump priming has been accomplished, bring the engine to full speed (2250
RPM) with throttle control.

2. Heat the main coolant temperature to 120°F by using the heat pump. Do this by adjusting the
Heat Load Control. The more the valve is adjusted the higher the horsepower draw on the
engine and the faster the heat builds in the coolant system.

3. Maximum heat into the system is accomplished when the heat pump has pulled the engine
speed down to between 2,050 and 2,100 RPM.

4. Once the coolant, temperature has reached 120°F, close the heat pump load valve.

5. Close boost pump recirculation valve.

6. Set Nitrogen charge boost pump pressure with pump speed control between 40 to 60 PSIG as
indicated on Nitrogen pressure gauge.

PAGE 23
 HYDRA RIG 180K NITROGEN UNIT

CAUTION
WHEN PUMPING AT LOW OR HIGH DISCHARGE PRESSURE,
THE UNIT IS CAPABLE OF PRODUCING PRESSURES MORE
THAN 10,000 PSIG. ALL SAFETY PROCEDURES SHOULD BE
TAKEN AS IF THE UNIT WAS CONTINUOUSLY OPERATING AT
10,000 PSIG. REVIEW SAFETY PRECAUTIONS AS STATED IN
THE FRONT OF THIS MANUAL.

7. Set the Nitrogen discharge valve to the OPEN position (open manually). Slowly adjust
pump speed control to start the triplex pump. Monitor the gas pressure gauge (19) as the
triplex RPM is slowly increased. If there is a rapid rise in pressure, STOP THE PUMP.
Check the discharge valve and other off skid valves to insure open flow paths. If no rapid
pressure increase occurs, bring pump speed to desired pump rate and maintain coolant
temperature between 100° and 120°F.

NOTE: During The Pumping Operation It Is Important That The Control Panel Gauges Be
Monitored To Ensure That All Systems Are Functioning Properly.

Pumping Procedure For High Pressure Operation

1. Once boost pump priming has been accomplished, bring the engine to full speed (2250 RPM) with
throttle control.
2. Heat the main coolant temperature to 120°F by using the heat pump. Do this by adjusting the Heat
Load Control. The more the valve is adjusted the higher the horsepower draw on the engine and the
faster the heat builds in the coolant system.
3. Maximum heat into the system is accomplished when the heat pump has pulled the engine speed
down to between 2,050 and 2,100 RPM.
4. Once the coolant, temperature has reached 120°F, lower the heat load control.
5. Close boost pump recirculation valve.

6. Set nitrogen charge (boost) pump pressure with pump speed control between 50 to 80 PSIG
as indicated on nitrogen pressure gauge. As the pump rate is increased, it may be necessary to
re-adjust the pump speed control to maintain the 50 to 80 PSIG nitrogen pressure.

PAGE 24
 HYDRA RIG 180K NITROGEN UNIT

CAUTION
WHEN PUMPING AT LOW OR HIGH DISCHARGE PRESSURE,
THE OPERATOR SHOULD REMEMBER THE UNIT IS CAPABLE OF
PRODUCING PRESSURES MORE THAN 10,000 PSIG. ALL
SAFETY PROCEDURES SHOULD BE TAKEN AS IF THE UNIT WAS
CONTINUOUSLY OPERATING AT 10,000 PSIG. REVIEW SAFETY
PRECAUTIONS AS STATED IN THE FRONT OF THIS MANUAL.

7. t the nitrogen discharge valve to OPEN (open manually). Slowly adjust pump speed
control to start the triplex pump. Monitor the triplex hydraulic pressure gauge as the
triplex RPM is slowly increased. If there is a rapid rise in pressure above expected
discharge pressure, STOP THE PUMP! Check the discharge valve and other off skid
valves to insure open flow paths. If no pressure rise is seen, bring pump speed to
operating pump rate ensuring the coolant temperature is maintained between 100°F
and 120°F.

NOTE: When Operating At High Discharge Flows And 10,000 PSIG, It May Be Necessary To Shut
The Heat pump Off Completely To Hold Down The Coolant Fluid Temperature.

During pumping operation, coolant fluid temperatures may fall below or rise above the
120°F level. There is no harm in letting the temperature rise or fall in an effort to
minimize heat pump usage and maintain a reasonable discharge temperature. The
temperature range in the coolant fluid can vary 100°F and 160°F.

The 100°F level normally occurs at high GN2 discharge flow rates and low GN2
discharge pressure. In this case, the heat pump is working its hardest to keep coolant
temperature warm enough for LN2 vaporization. The reason for this is the engine
horsepower demands are lowest on the other systems (for example, hydraulic driving the
triplex.)

NOTE: The 160°F Level Normally Occurs At High Pressure And Very Low GN2 Discharge Flow.

This is caused by low LN2 flow through the vaporizer cooling the coolant fluid. In this
case, the heat pump is completely shut off and the engine radiator fan will normally
function to keep the engine within its temperature limits. The tempering valve may be
used to lower GN2 discharge temperature.

The ideal situation for operating at low flows and high pressures would be by reducing
engine RPM, rather than running the heat pump to maintain the coolant temperature
above 100°F and below 160°F.

PAGE 25
 HYDRA RIG 180K NITROGEN UNIT

In this operating mode, the heat generated by just the engine coolant system and
secondary systems may be enough to satisfy the vaporization heat requirements without
using the heat pump.

NOTE: During The Pumping Operation, It Is Important That The Control Panel Gauges Be
Monitored To Ensure That All Systems Are Functioning.

Shutdown Procedure
1. Set the pump speed control to zero, indicated by zero or blank reading on the pump speed
indicator.

2. Set the nitrogen discharge valve to the closed position.

3. Throttle down the engine to low idle with the throttle control.

4. Set all hydraulic controls fully counterclockwise.

5. Close the LN2 supply and return valves on the LN2 tank.

6. Open the rapid cool down valve. Keep this valve open until all trapped liquid has vaporized.

7. Close supply valves.

8. Open the high-pressure bleed valve to insure pumping lines are bled off. Bleed off all
pressure before disconnecting pumping lines. Disconnect high-pressure pumping lines and
put discharge connection plug in place.

9. Shut the engine down with the engine kill switch.

10. Check and fill (as required) diesel, hydraulic and lubrication reservoirs. (Maintaining full
reservoir prevents condensation from forming.)

11. Check all high-pressure plumbing attaching hardware (such as nuts) for tightness and repair
as required.

12. Check for obvious leaks in hydraulic, coolant loop, lubrication, and N2 systems. Repair as
required.

NOTE: FOR FURTHER ASSISTANCE, CALL HYDRA RIG SERVICE DEPARTMENT, (817)
457-1521.

PAGE 26
 HYDRA RIG IPB

PARTS BREAKDOWN
A. INTRODUCTION

NOTE: PICTORIAL VIEWS OF TOP LEVEL ASSEMBLIES MAY NOT REFLECT LATEST REVISION.
BILLS OF MATERIALS DO REFLECT LATEST REVISIONS.

This breakdown is used for requisitioning, issuing and identifying parts. It may be used for illustrating
the assembly and disassembly relationship of parts of assembly of parts.

B. MAINTENANCE PARTS LIST

1. The Maintenance Parts Lists are for major assemblies, subassemblies.

2. To aid in identification by appearance, some parts in the listing are indexed to an exploded
view illustration. Each main assembly listed is followed immediately by its component or
detailed parts list which is indented to show the part’s relationship to the assembly and
recommended disassembly sequence.

Component parts of the system which are not included in any main assembly, but are used in
conjunction with, a part of, or attached to a main assembly, are listed together with the assembly.

C. HOW TO USE THE PARTS BREAKDOWN

1. When the part number is not known, proceed as follows:

(a) Determine the function and application of the part required.

(b) Turn to the Table of Contents and select the most appropriate title. Turn to the page
indicated and locate the desired part on the illustration.

(c) From the illustration, obtain the index number assigned to the desired part. Refer to the
accompanying description for specific information regarding the part.

2. When the part number is known, proceed as follows:

(a) When the part number is known, refer to the numerical index (When it is present).
Locate the part number and note the figure and index number assigned to the part.

PAGE 27
 HYDRA RIG IPB

(b) Turn to the figure indicated and locate the index number referenced in the numerical
index.

(c) For an illustration of a part or its location, refer to the same index number on the
accompanying illustration.

D. SYMBOLS AND ABBREVIATIONS

Symbols and abbreviations used in this Parts Breakdown are defined as follows:
BRS Brass
COP Copper
DIA Diameter
FT Foot/feet
IN Inch/inches
LB Pound/pounds
NPT American National Standard Taper Pipe Thread
OD Outer Diameter
PSIG Pounds-Force Per Square Inch Gage
REF Reference
UNC Unified Coarse Thread
= Alternate Item

LN2 Liquid Nitrogen

GN2 Gaseous Nitrogen

SCFM Standard Cubic Feet per Minute

SCFH Standard Cubic Feet per Hour
SCMM Standard Cubic Meters per Minute

PAGE 28
ITEM QTY. PART NO. DESCRIPTION
1 1 HPP00135 PISTON PUMP (SEE SERVICE LIT.)
2 1 HVD00548 VALVE 4-WAY 2-POSN
3 1 HPG00072 GEAR PUMP (SEE SERVICE LITERATURE)
4 1 HPG00085 TRIPLE VANE PUMP (SEE SERVICE LITERATURE)
5 1 HXH00141 HEAT EXCHANGER PLATE
6 1 NA001150 SPEC. HEAT EXCHANGER SHELL & TUBE
7 1 HVT00143 VALVE BUTTERFLY 4.00
8 1 HFR00120 FILTER IN-LINE
8A 1 HFR00125 ELEMENT, FILTER IN-LINE
9 1 HFR00119 FILTER TANK TOP 3.00
9A 1 HFR00124 ELEMENT, FILTER TANK TOP 3.00
10 1 HFP00045 PRESSURE FILTER
10A 1 HFP00054 ELEMENT PRESSURE FILTER
11 2 HVR00249 RELIEF VALVE
12 1 HVS00003 SEQ VALVE
13 2 HVR00195 RELIEF VALVE 0.25
14 1 HVP00004 PRESSURE VALVE REDUCING
15 1 HVR00168 RELIEF VALVE 1.50
16 1 HMP00116 PISTON MOTOR (SEE SERVICE LITERATURE)
17 1 HVR00043 RELIEF VALVE 2.00FNPT
18 1 HFP00064 FILTER PRESS 10 MICRON IN-LINE 0.50FNPT
18A 1 HFP00065 ELEMENT, FILTER PRESS 10 MICRON IN-LINE 0.50FNPT
19 1 HFS00069 FILTER MESH 100
20 1 NA000008 WATER PUMP SPEC.
21 1 CPC00081 CENTRIFUGAL PUMP (SEE SERVICE LITERATURE)
22 1 HFR00121 DIFFUSER TANK 2.00NPT
23 1 ITM00041 TEMPERATURE GAUGE 32/160F/C
24 1 HVD00147 SUB PLATE
25 1 IPM00068 PRESSURE GAUGE 0-5000 PSI/BAR 2.50 0.25
26 1 NA000459 TRIPLEX GEARBOX
27 2 IPM00159 PRESSURE GAUGE 0-60 PSI/BAR 2.50 0.25
28 1 IPM00048 PRESSURE GAUGE 0-5000 PSI/BAR 2.50 0.25
29 2 IPM00242 PRESSURE GAUGE 0-1000 PSI/BAR 4.00 0.25
30 1 HVR00008 VALVE RELIEF 1.50 SAE 4-BOLT
31 1 HVC00022 CHECK VALVE
32 1 HVT00001 BUTTERFLY VALVE 3.00
33 1 HXX00056 ADPTR PUMP DRIVE
34 1 HVP00041 PRESSURE VALVE 0.38FNPT
35 1 HVR00003 RELIEF VALVE 1.00FNPT
36 1 HVC00192 VALVE CHK 3.00NPTF INLINE RETURN

Fig. 1.1A, 180K N2 Hydraulic Schematic, NE090201A (Sheet 1 of 2)

PAGE 29
 ITEM QTY. PART NO. DE1SCRIPTION
2
37 1R HRS00002 SIGHT GLASS 12.00 0.25MNPT
38 1 HVC00019 CHECK VALVE 1.00FNPT
2
39 1R HRF00004 BREATHER 0.75 NPT
40 1 IPM00276 GAUGE PRESS 0-300 P/B 2.50 0.25
41 1 HVS00054 VALVE SEQUENCE 1.50
2
42 1R ITM00036 GAUGE TEMP 0/250F/C 3.00
43 2 HVC00020 CHECK VALVE 0.25MNPT IN-LINE
44 1 IPM00112 PRESSURE GAUGE 0-1000 PSI/BAR 2.50 0.25
45 2 ITM00005 GAUGE TEMP 0/250F/C 3.00
46 1 IPM00388 INDICATOR FILTER REMOTE 0.13FNPT
1
47 1R NB066093 FLANGE W/ADAPTER MOD
48 1 HVX00001 VALVE AUTO AIR BLEED-OFF 5000 PSI
49 1 HAB00018 ACCUM BLADDER GAL 0.25 CERT (SEE SERV. LIT.)
50 1 IPM00312 GAUGE PRESS 0-7500 PSI/BAR 2.50 0.25
51 1 IPM00111 PRESSURE GAUGE 0-3000 PSI/BAR 2.50 0.25
52 1R NA000547 VALVE PLUG ACTUATOR HYDR SPEC
53 1 HVD00038 VALVE DIR CONT 0.389 NPT
54 1 HVD00313 VALVE DIR 3-WAY 2-POSN 0.25FNPT
55 1 HAB00036 ACCUMULATOR (SEE SERVICE LITERATURE)
56 1 HVC00016 VALVE CHK 0.38FNPT

1
ITEM CALLED OUT ON TRIPLEX INSTL.
2
ITEM CALLED OUT ON HYD. TANK ASSEMBLY

Fig. 1.1A, 180K N2 Hydraulic Schematic, NE090201A (Sheet 2 of 2)

PAGE 30
Fig. 1.1B, 180K N2 Hydraulic Schematic, NE090201A
PAGE 31
 ITEM QTY. PART NO. DESCRIPTION
1 6 NB050079 VALVE RELIEF ASSY (SEE FIG. 2.6)
2 1 CVB00037 VALVE BALL 0.50 SW
3 2 CLS00004 STRAINER, BRONZE, 1.50FNPT, 100 MESH, 250 PSI
3
4 1R CPC00081 PUMP CENTRIFUGAL INST. (SEE SERVICE LITERATURE )
5 1 IPM00136 GAUGE, PRESSURE, 0-300 PSI/BAR, 4.00, 0.25MNPT
6 5 CVB00038 VALVE BALL 1.50 SW
7 1 CVG00033 VALVE, GLOBE, 1.00FNPT, BRONZE
8 3 NA005877 COLD END BORE 1.63 STROKE 1.38 (SEE FIG. 2.7)
9 1 NE050119 PUMP LN2 200 HP DRIVE DIRECT ASSY (SEE FIG. 2.8)
10 1 NA000547 VALVE PLUG ACTUATOR HYD SPEC
1
11 4 HHF00046 FLARE NUT 0.25
12 2 CVH00010 VALVE, 2-WAY, ANGLE REGULATING 0.56 TUBE
13 1 ND057428 VAPORIZER ASSEMBLY (SEE FIG. 2.9)
14 1 IPM00375 GAUGE PRESS 0-15000 P/B 4.00 0.25MNPT
15 1 CVC00095 VALVE CHK 1.00FAE-1.00FAE
16 1 HVC00041 VALVE CHK 1.00FNPT 125# BRONZE
17 1 CVR00199 VALVE RELIEF 0.56 AE - 0.50FNPT
18 1 CVH00015 VAVLE REGULATOR 2-WAY 0.25 TUBE ANGLE
19 1 NA000472 VALVE REGULATOR 2-WAY 0.25 TUBE ANGLE
20 1 ITE00042 GAUGE TEMP -50 TO +1800F
1
21 4 HHF00047 FLARE SLEEVE
22 1 IPP00001 DEBOOSTER 4:1 FLG MNT (SEE SERVICE LITERATURE)
23 1 IPP00032 PRESSURE SENSOR
3
24 1R NC020001 GAUGE PRESS SATURATION ASSY

1
ITEM NOT SHOWN
2
ITEM CALLED OUT ON LOW PRESSURE PLUMBING
3
ITEM CALLED OUT ON CONTROL PANEL ASSEMBLY

Fig. 1.2A, 180K SCFH Nitrogen Schematic, ND090202

PAGE 32
Fig. 1.2B, 180K N2 Schematic, ND090202
PAGE 33
ITEM QTY. PART NO. DESCRIPTION
1
1 1R NA000008 WATER PUMP SPECIFICATION
1
2 1R HXH00141 HEAT EXCHANGER PLATE
3 1 HFR00025 BREATHER
4 1 HXH00140 HEAT EXCHANGER PLATE
5 1 ITM00076 TEMPERATURE GAUGE 0-180 F/C
6 5 ITM00005 TEMPERATURE GAUGE 0-250 F/C
7 1 HFR00073 FILTER, RETURN LINE
7A 1 HFR00093 ELEMENT, RETURN LINE FILTER
8 1 IPM00032 PRESSURE GAUGE 0-200 P/B
9 1 AVT00101 VALVE TEMP NORMALLY CLOSED SET 200F
10 1 HRT00019 EXPANSION TANK
1
11 1R NA001150 LUBE HEAT EXCHANGER SPEC
2
12 1R AVD00007 3-WAY THRMSTC VALVE
13 1 AVS00001 VALVE SHUTTLE 0.25NPT

1
ITEM CALLED OUT ON HYDRAULIC SCHEMATIC
2
ITEM CALLED OUT ON PNEUMATIC SCHEMATIC

Fig. 1.3A, 180K SCFH Coolant Schematic, ND090204

PAGE 34
 Fig. 1.3B, 180K SCFH Coolant Schematic, ND090204
PAGE 35
 ITEM QTY. PART NO. DESCRIPTION
1 1 HVT00073 VALVE, GATE 0.75FNPT 150#
2 1 AAD00002 AIR DRYER (SEE SERVICE LITERATURE)
3 1 AVC00001 CHECK VALVE 0.50 MNPT – 250PSI
4 1 AVR00011 RELIEF VALVE 0.25 MPT – 140 PSI
5 1 AVT00001 VALVE (DRAINCOCK) 0.25
6 1 AXT00037 AIR TANK 7.0 GALLON HORIZONTAL
7 1 HVT00021 GATE VALVE 0.50 FNPT
8 1 HVT00022 VALVE BALL 0.25 FNPT
9 1 AVD00007 VALVE THRMSTC 3-WAY
10 1 IPM00074 PRESSURE GAUGE
11 1 HHD16006 UNIVERSAL HOSE COUPLING, 1”NPT
12 1 AVS00001 VALVE SHUTTLE
13 1 HVT00057 VALVE, BALL
14 * 1R NA000472 VALVE, HYDRAULIC AIR
15 1 AVT00104 VALVE TEMP NORMALLY CLOSED SET 200F

* ITEM CALLED OUT ON NITROGEN SCHEMATIC

Fig. 1.4A, Pneumatic Schematic, NC090203

PAGE 36
 Fig. 1.4B, Pneumatic Schematic, NC090203
PAGE 37
 ITEM QTY. PART NO. DESCRIPTION
1 * 4R NB050079 VALVE RELIEF ASSY (SEE FIG. 2.6)
2 * 1R CVR00005 VALVE REGUALTOR 0.50 PRESS BACK SET15PSI
3 * 1R NA000550 RUPTURE DISC 56 PSI COMPOSITE
4 * 1R C00179 HOLDER RUPTURE DISC SPEC
5 * 1R CVG00132 VALVE GLOBE 1.50 SKT WELD PIPE
6 * 1R CVG00033 VALVE GLOBE 1.00FNPT BRZ
7 * 1R ND058869 COIL WLDMNT PRESSURE BLDG
8 * 1R CVG00010 VALVE GLOBE 1.50FNPT BRZ
9 * 4R CVG00008 VALVE GLOBE 2.00FNPT BRZ
10 * 5R CVG00158 VALVE GLOBE 0.38FNPT BRASS, LONG STEM"T"
11 * 1R CVR00203 VALVE RELIEF 0.75MNPT-1.00FNP 45 PSIG
12 * 1R CVG00003 VALVE GLOBE 0.50FNPT BRZ

* ITEM CALLED OUT ON TANK PLUMBING DRAWING

Fig. 1.5A, Nitrogen Tank Plumbing Schematic, NC090208

PAGE 38
Fig. 1.5B, Nitrogen Tank Plumbing Schematic, NC090208
PAGE 39
ITEM QTY. PART NO. DESCRIPTION
1 1 EEJ00107 ENCL 12.00-10.00 NEMA 4X FIBERGLASS
2 1 EEJ00120 PANEL BACK 10.88-8.88 ALUMINUM
3 2 CA160004 BATTERY W/BOX SPEC
4 1 EPD00007 SWITCH BATTERY
5 2 EAB00019 BATTERY TRAY VINYL COATED STEEL 13.00
6 2 EAB00018 BATTERY HOLD DOWN 5.75-8.50 WIDTH
7 2 EAB00020 KIT BATTERY HOLD DOWN J TYPE 0.25X10.0
8 1 ITE00087 GAUGE TEMP DIGITAL
9 2 IRE00006 GAUGE RPM DIGITAL
10 2 EKV00009 PREAMPLIFIER IN-LINE
11 2 IRS00038 PICKUP MAGNETIC INTRINSICALLY SAFE
12 1 ESC00042 SWITCH IGNITION
13 1 ECR00184 CAP RECEPTACLE W/CHAIN SIZE 10 97 SERIES
14 1 ECR00164 RECEPTACLE MS3102A PIN 2 SOLDER
15 1 ECR00185 RECEPTACLE FLG GASKET SIZE 10SL
16 2 ECC00469 BSHG 0.220
17 2 ECP00018 CLAMP CABLE MS3057A 0.31 MAX O.D.
18 2 ECP00016 PLUG MS3106A 2 SOCKET SOLDER
19 1 ECR00227 CONNECTOR GASKET FLANGED RECEPTACLE
20 1 ECR00228 CONNECTOR CAP RECEPTACLE
21 1 ECR00231 CONNECTOR RECEPTACLE FLANGED
22 2 ECP00261 PLUG SEALING SIZE 12
23 7 ECP00256 CONNECTOR PIN SIZE 16
24 1 ECP00259 CONNECTOR PIN 3 WIRE
25 1 ITE00088 GAUGE TEMP WATER 0-250 F/C
26 1 ECR00218 CONNECTOR RECEPTACLE CLIP TYPE
27 1 ECR00221 CONNECTOR PLUG SEAL 3 WIRE
28 6 ECR00226 CONNECTOR SOCKET SIZE 16
29 1 ECP00255 CONNECTOR PLUG 3 WIRE SEAL MOD
30 1 ECP00260 CONNECTOR PLUG SEAL 3 WIRE
31 2 ECR00225 CONNECTOR RECEPTACLE BOOD
32 * 1R ICX00035 GAUGE DISPLAY DIAGNOSTIC
33 1 EPB00068 BREAKER CIRCUIT 20AMP TYPE I12VDC"T"
34 * 1R IPE00027 GAUGE PRESS OIL 0-100 PSI/KPA
35 1 IEV00004 GAUGE VOLT 8-18VD
36 2 EPB00115 BREAKER CIRCUIT THERMAL 15A MAN RESET
37 1 ITS00004 THERMOCOUPLE
38 25 FT ITS00022 WIRE THERMOCOUPLE TYPE K
39 * 1R TGX00046 CONTROLLER SPEED ELECTRONIC PTO "T"
Fig. 1.6A, Electrical Schematic, NE090209A (Sheet 1 of 2)

PAGE 41
 ITEM QTY. PART NO. DESCRIPTION
40 1 EST00019 SWITCH TOGGLE SPS
41 1 EPG00003 GUARD TOGGLE FULL THROW SNGL THRW "T"
42 * 40 FT EWC00017 CABLE 16 AWG PAIR 2
43 * 100 FT EWC00007 CABLE CONDUCTOR 3 18 AWG COPPER TINNED
44 1 NC020268 TERMINAL ASSY
45 * 40 FT EWC00012 CABLE WELDING 1/0 AWG 600V
46 1 ECW00364 CONN HARNESS
47 2 ECW00365 CONN HARNESS GAUGE
48 1 ECW00366 CONN HARNESS 12V POWER ML
49 1 ECW00367 CONN HARNESS ASSY

* ITEM SUPPLIED WITH ENGINE

Fig. 1.6A, Electrical Schematic, NE090209A (Sheet 2 of 2)

PAGE 42
Fig. 1.6B, Electrical Schematic, NE090209A
PAGE 43
 ITEM QTY. PART NO. DESCRIPTION
1 1 ND080369 SKID WELDMENT 180K CAT ENGINE
2 1 ND080373 FRAME OUTER WELDMENT
3 1 NE010074 POWER UNIT INST. (SEE FIG. 3.1)
4 1 NE056094 TRIPLEX INSTALLATION (SEE FIG. 3.2)
5 1 ND030082 TANK INSTALLATION (HYD, FUEL, PNEU) (SEE FIG. 3.3)
6 1 NE050215 PLUMBING LOW PRESSURE 180K SCFH (SEE FIG. 3.6)
7 1 ND050216 PLUMBING HIGH PRESSURE 180K (SEE FIG. 3.7)
8 1 ND026082 CONSOLE CONTROL INST.
9 *1 ND090202 N2 SCHEMATIC 180K SCFH (SEE FIG. 1.2)
10 *1 ND090204 SCHEMATIC COOLANT 180K SCFH (SEE FIG. 1.3)
11 *1 NC090203 SCHEMATIC PNEUMATIC (SEE FIG. 1.4)
12 *1 NE090201 SCHEMATIC HYDR 180K N2 UNIT. (SEE FIG. 1.1)
13 *1 NE090209 SCHEMATIC ELECTRICAL (SEE FIG. 1.6)
14 *1 NC070769 MOUNT HYD FILTER WLDMNT
15 *1 ND022010 VALVE SHUTDOWN TRIPLEX INST. (SEE FIG. 3.10)
16 *1 NA090206 HOSE KIT (SEE FIG. 2.3)
17 *1 NA090207 HOSE KIT PANEL CONTROL 180K N2 (SEE FIG. 2.14)
18 1 ND060274 TUBE HOSE STORAGE INSTL
19 1 NE070762 PLUMBING COOLANT INST. (SEE FIG. 3.5)
20 1 ND020264 BATTERY BOX INSTL
21 1 ND020261 PANEL CONTROL W/CHART ASSEMBLY (SEE FIG. 2.5)
22 1 ND060141 OPERATORS SEAT INSTL
23 1 NC060269 NAMEPLATE INSTL
24 *1 A00079 FLUID SPEC. (SEE FIG. 2.4)
25 *1 ND050061 LABELS SKID N2
26 *1 ND030083 LUBE PLUMBING INSTALLATION (SEE FIG. 3.8)
27 1 NB066339 STORAGE BOX
28 *1 ND036106 MANIFOLD RETURN INSTL. (SEE FIG. 3.9)
29 2 NB060273 HOSE TRANSFER

* ITEM NOT SHOWN

Fig. 2.1A, 180K Nitrogen Unit Final Assembly, NE000548

PAGE 44
Fig. 2.1B, 180K Nitrogen Unit Final Assembly, NE000548
PAGE 45
 ITEM QTY. PART NO. DESCRIPTION
1 1 NA020228 TRAILER NITROGEN (SEE FIG. 2.7)
2 1 ND060268 HANDRAIL INSTL
3 1 NE150051 TANK PLUMBING INSTL (SEE FIG. 3.4)
4 1 ND160014 TANK N2 (SEE FIG. 3.11)
5 1 ND060271 TRAILER PIN INSTL
6 1 NE000548 FINAL ASSY 180K NPS (SEE FIG. 2.1)
7 1 ND060275 TRAILER AWNING ASSY
8 1 ND060259 PLATFORM TRAILER INSTL (STREETSIDE)
9 *1 NC090208 NITROGEN TANK PLUMBING SCHEMATIC (SEE FIG. 1.5)
10 1 ND060258 PLATFORM TRAILER INSTL (CURBSIDE)
11 1 ZBM00277 TANK – 500 GAL W/2 BAFFLES ¼”
12 4 ND080375 TREATING IRON RACK WLDMNT
13 4 ND080378 TREATING IRON RACK WLDMNT
14 1 PTU00176 PIPE ASSY 2.00 X 48.00 LG

* ITEM NOT SHOWN

Fig. 2.2A, Nitrogen Unit Trailer Assembly, NE000546

PAGE 46
Fig. 2.2B, Nitrogen Unit Trailer Assembly, NE000546
PAGE 47
Standard Notes: Applies to all hoses on list

None

Special Notes: Applies to indicated hoses only

1. Compressor hose needs to be 100R2- C2ATH high temp hose

2. Gates hose number 32G4H-3105-00006 (Mega Vac)
3. Gates hose number 56G4H-3105-0015 (Mega Vac)
4. Gates hose number 20G6K-4651-0664 (6000 PSI)

Abbreviations:

Quick Disconnect Size End Fittings

MST = Male Snaptite -4 = 1/4” MPR = Male Pipe Rigid

FST = Female Snaptite -6 = 3/8” FPR = Female Pipe Rigid
MHD = Male Hyd. Inc. -8 = 1/2” MPS = Male Pipe Swivel
FHD = Female Hyd. Inc. -10 = 5/8” FPS = Female Pipe Swivel
MA = Male Aeroquip -12 = 3/4” FJR = Female JIC Rigid
FA = Female Aeroquip -16 = 1” FJS = Female JIC Swivel
-20 = 1 1/4” SF = Split Flange
-24 = 1 1/2”

Hose No. Qty Size End Fitting Type Length End Fitting Routing Description

1 1 1.25 ID None Longhorn 14 ft None triplex lube suction to lube pump

2 1 -16 FJS 90 100R2 34 in FJS lube pump to check valve on filter

3 1 -16 FJS 90 100R2 174 in FJS lube filter to lube heat exchanger

4 1 -16 FJS 100R2 120 in FJS lube heat exchange to bottom of ful-flo

5 1 -12 FJS 100R2 24 in FJS bottom of ful-flo to manistrip

6 1 -16 FJS 100R2 59 in FJS ful-flo return to bottom of triplex

7 1 -12 FJS 100R2 40 in FJS manistrip to lube swivel

8 1 -4 FJS 100R2 14 in FJS 90 lube manifold to center warm end

9 2 -4 FJS 100R2 12.5 in FJS 90 lube manifold to right and left warm ends

10 1 -4 FJS 100R2 80 in FJS 45 lube manifold to console – lube pressure

11 1 -8 FJS 100R2 135 in FJS 90 fuel return on engine to fuel tank

12 1 -8 FJS 100R2 105 in FJS fuel supply on engine to fuel tank

13 1 -4 FJS 100R2 150 in FJS 45 debooster to console

14 1 -8 FJS 100R2 65 in FJS air dryer to air tank

Fig. 2.3, Hose Kit NPS 180K Cat, NA090206 (SHEET 1 OF 4)

PAGE 48
Hose No. Qty Size End Fitting Type Length End Fitting Routing Description

15 1 -8 FJS Spec Note 1 136 in FJS air dryer to compressor

16 1 -4 FJS 100R2 122 in FJS compressor governor to dryer unloader

17 1 -4 FJS 100R2 180 in FJS 45 air tank to console air supply

18 1 -4 FJS 100R2 160 in FJS compressor governor to air tank

19 1 -4 FJS 100R2 31 in FJS90 thermostat to fan clutch

20 1 -4 FJS 100R2 25 in FJS amot valve to thermostat

21 1 -4 FJS 100R2 55 in FJS air tank to amot valve supply

22 1 -4 FJS 90 100R2 19 in FJS air from ideal specialty valve

to bulk head #3

23 1 -6 FJS 45 100R2 30 in NONE unloader on dryer to deck

24 1 -32 FJS Spec Note 2 30 in FJS coolant pump to vaporizer

25 1 2.00 ID NONE Longhorn 94 in NONE vaporizer pot to lube heat exchanger

26 1 2.00 ID NONE Longhorn 52 in NONE lube heat exchanger

to hydraulic heat exchanger (S-3)

27 1 2.00 ID NONE Longhorn 26 in NONE hydraulic heat exchanger

to engine heat exchanger

28 1 2.00 ID NONE Longhorn 33 in NONE engine heat exchanger (S-1) to engine

29 1 2.00 ID NONE Longhorn 55 in NONE radiator to engine heat exchanger (S-2)

30 1 2.00 ID NONE Longhorn 41 in NONE engine heat exchanger (S-4)

to coolant filter

31 1 3.00 ID NONE Longhorn 31 in NONE coolant filter to coolant pump suction

32 1 1.00 ID NONE Longhorn 30 in NONE expansion tank to coolant filters

33 1 -4 FJS 100R2 112 in FJS 45 coolant from vaporizer in to console

34 1 -4 FJS 100R2 116 in FJS 45 coolant pump suction to console

35 1 -4 FJS 100R2 34 in FJS 45 charge pressure port

on P-16 pump suction to console

36 1 -4 FJS 100R2 21 in FJS differential indicator to return filter

37 1 -4 FJS 100R2 12 in FJS differential indicator

to coupling on hydraulic tank

38 1 3.50 ID NONE Spec Note 3 10 ft NONE hydraulic heat exchanger to return filter

Fig. 2.3, Hose Kit NPS 180K Cat, NA090206 (SHEET 2 OF 4)

PAGE 49
Hose No. Qty Size End Fitting Type Length End Fitting Routing Description

39 1 -16 FJS 100R2 83 in FJS return on heat pump relief

to hydraulic return manifold

40 1 -12 FJS 100R2 94 in FJS 90 return on 2.93 pump relief

to hydraulic return manifold

41 1 -12 FJS 100R2 108 in FJS 90 2.93 pump to coolant

pump hydraulic motor

42 1 -12 FJS 100R2 41 in FJS 90 coolant pump hydraulic motor

to return manifold

43 1 -8 FJS 100R2 58 in FJS 45 filter on 2.93 pump

to console sun valve supply

44 1 -4 FJS 100R2 30 in FJS 45 port ‘P’ on parker valve to console control

45 1 -4 FJS 100R2 26 in FJS 45 port ‘B’ on parker valve

to gauge in console

46 1 -4 FJS 100R2 46 in FJS 45 P-16 pump controller to console

47 1 -4 FJS 100R2 90 in FJS parker valve port ‘T’ to case drain manifold

48 1 -4 FJS 100R2 36 in FJS check valve on 5.96 pump relief

to console

49 1 -8 FJS 100R2 18 in FJS 90 accumulator to P-16 servo

50 1 -32 FJS 100R2 48 in FJS hydraulic return manifold

to hydraulic heat exchanger

51 1 -12 FJS 100R2 140 in FJS 1.27 pump relief to boost pump

52 1 -12 FJS 100R2 32 in FJS 90 hydraulic return jumper hose

53 1 -4 FJS 100R2 44 in FJS 45 1.27 pump relief vent

to console boost pump control

54 3 -4 FJS 100R2 70 in FJS 45 hydraulic return from console

to case drain manifold

55 1 -6 FJS 100R2 120 in FJS 90 boost pump case drain

to case drain manifold

56 1 -6 FJS 100R2 13 in FJS case drain jumper – sequence to motor

57 1 -12 FJS 100R2 72 in FJS 90 boost pump motor

to hydraulic return manifold

58 1 -6 FJS 100R2 100 in FJS 90 coolant pump motor to case drain manifold

59 1 -12 FJS 100R2 21 in FJS Rexroth case drain to case drain manifold

Fig. 2.3, Hose Kit NPS 180K Cat, NA090206 (SHEET 3 OF 4)

PAGE 50
Hose No. Qty Size End Fitting Type Length End Fitting Routing Description

60 1 -4 FJS 100R2 24 in FJS Rexroth return flange

to bottom of rexroth case

61 1 -20 FJS 100R2 77 in FJS Rexroth return to return manifold

62 1 -8 FJS 100R2 65 in FJS 45 console to accumulator (servo press)

63 1 -4 FJS 100R2 65 in FJS 45 sequence valve vent on P-16 pump

to console heat control

64 1 -20 -24SF90 Spec Note 4 43 in FJS P-16 pump sequence valve

Spec Note 5 to Rexroth pressure port

65 1 -4 FJS 100R2 63 in FJS 45 Rexroth pressure port

to console – triplex hydraulic pressure

66 1 -20 FJS 100R2 42 in FJS case drain manifold to case drain filter

67 1 -20 FJS 100R2 37 in FJS case drain filter to hydraulic tank

68 1 -24 FJS 100R2 52 in FJS P-16 pump case drain

to case drain manifold

69 1 -16 FJS 100R2 70 in FJS P-16 pump relief

to hydraulic return manifold

70 1 -6 FJS 100R2 52 in FJS P-16 pump sequence valve case drain

to case drain manifold

71 1 -8 FJS 100R2 12 in FJS pressure reducing valve (HVP00070)

supply - in console

72 1 -8 FJS 100R2 14 in FJS pressure reducing valve (HVP00070)

reduced pressure to bulkhead in console

73 1 -4 FJS 100R2 39” FJS inside of panel bulkhead #3 to bulkhead

#35 jumper hose

74 1 -4 FJS 100R2 17” FJS bulkhead #35 to Parker pilot port

NOTE: HOSES FOR HYDRAULIC PUMP SPEED CONTROL AND AIR START ARE NOT UTILIZED ON THIS
UNIT.

Fig. 2.3, Hose Kit NPS 180K Cat, NA090206 (SHEET 4 OF 4)

PAGE 51
 NITROGEN PUMPING SYSTEMS

• Triplex Lube (warm end)

Reduction Box (if pressent)

Water Brake (if present)

15 gallons: Gear Oil Meropa 68 Texaco

Omela 68 Shell

Lyondell Pennant NL68

Mobil Mobilgear 626

Exxon Spartan EP68

• Coolant System

55 gallons antifreeze (ethelyne glycol) with rust inhibitor and anti-foaming agent.

Texaco Startex

• Hydraulic System

125 gallons: Texaco Rando 68

Texaco SynStar DE-68

Lyondell AB-68

Exxon Univis N68

• Pump Drive

Triplex Transfer Box (if equipped)

1 gallons: Mobil 630

Texaco Meropa 220

Lyondell Pennant 220

Shell Omela 220

If ambient temperature is high, and boxes are running near 200o F, it is recommended to use:
Meropa 460

Mobilgear 634

Fig. 2.4, Nitrogen Pumping Systems Fluid Specification, A00079C

PAGE 52
ITEM QTY. PART NO. DESCRIPTION
1 1 ND020263 PANEL CONTROL W/CHART ENGRAVING
2 18 BFC00165 SHCS 0.25-20UNC 0.75
3 18 BFN00048 NUT HX STD 0.25-20UNC
4 18 BFW00045 WSHR LOCK SPLIT 0.25 18-8 SST
1
5 1R ITM00076 GAUGE TEMP 0-180 F/C W/2.25 FT CAP “T”
2
6 2R HVR00195 VALVE RELIEF 0.25 SAE
4, 5
7 1R ESX00042 SWITCH IGNITION
2
8 1R ITM00041 GAUGE TEMP 32/160F/C
4, 5
9 1R TGX00046 CONTROLLER SPEED ELECTRONIC PTO
10 1 EST00019 SWITCH TOGGLE
11 1 EPG00001 GUARD TOGGLE FULL THROW SNGL THRW "T"
2
12 1R HVD00313 VALVE DIR 3-WAY
13 4 BFM00030 SCR MACH #8-32UNC 0.50
14 1 IPM00074 GAUGE PRESS 0-160 P/B 2.50 0.25
15 1 NC020001 GAUGE PRESS SATURATION ASSY
2
16 1R IPM00048 GAUGE PRESS 0-5000 P/B 2.50 0.25
3
17 1R IPM00136 GAUGE PRESS 0-300 P/B 4.00 0.25
2
18 2R IPM00159 GAUGE PRESS 0-60 P/B 2.50 0.25
2
19 1R HVP00041 VALVE PRESS RED 0.38FNPT MOUNT PANEL
4
20 1R IRS00038 PICKUP MAGNETIC INTRINSICALLY SAFE
4
21 1R IRS00051 CABLE SHIELDED 192.00 LG ASSY
4
22 1R IRE00006 GAUGE RPM 0-1000 ELEC DIGITAL
2
23 2R IPM00242 GAUGE PRESS 0-1000 P/B 4.00 0.25
3, 4
24 1R ITE00087 GAUGE TEMP DIGITAL
3
25 1R IPM00375 GAUGE PRESS 0-15000 P/B 4.00 0.25 MNPT
26 1 CHA00052 ADPTR 0.25MAE HP-0.25FAE MED PRS
27 4 BFC00733 SHCS 0.38-16UNC X 1.00
2
28 1R HVD00038 VALVE DIR CONT 0.38NPT
29 3 BFW00071 WSHR LOCK SPLIT #10 18-8 SST
30 3 BFM00048 SCR MACH #10-32UNF 1.00 PNH SLTD 18-8
31 3 BFN00128 NUT HX STD #10-32UNF
32 1 NA000278 RECORDER CHART 1 PEN
33 1 CHA00001 ADPTR 0.25FNPT-0.56 18 STR
34 1 ICR00014 CHART 4HR 0-10K PSI/BAR
35 1 ITS00004 THERMOCOUPLE
36 18 FT ITS00022 WIRE THERMOCOUPLE
2
37 1R IPM00276 GAUGE PRESS 0-300 P/B 2.50 0.25

Fig. 2.5A, Control Panel W/Chart Assembly, ND020261 (Sheet 1 of 2)

PAGE 54
 ITEM QTY. PART NO. DESCRIPTION

1
ITEM CALLED OUT ON COOLANT SCHEMATIC
2
ITEM CALLED OUT ON HYDRAULIC SCHEMATIC
3
ITEM CALLED OUT ON NITROGEN SCHEMATIC
4
ITEM CALLED OUT ON ELECTRICAL SCHEMATIC
5
ITEM SUPPLIED WITH ENGINE
6
ITEM CALLED OUT ON PNEUMATIC SCHEMATIC

Fig. 2.5A, Control Panel W/Chart Assembly, ND020261 (Sheet 2 of 2)

PAGE 55
 Fig. 2.5B, Control Panel Assembly, ND020261
PAGE 56
 ITEM QTY. PART NO. DESCRIPTION
1 0.76 FT RST00004 TUBING 0.05 OD X 0.083 WALL
2 1 HHA10227 CONNECTOR, TUBE SOCKET WELD
3 1 CVR00008 VALVE RELIEF

Fig. 2.6A, Relief Valve Assembly, NB050079

PAGE 57
 Fig. 2.6B, Relief Valve Assembly, NB050079
PAGE 58
 Scope:

This specification contains information for a 63,000 Lb GVWR flat rail type tandem axle trailer
with the following features:

Trailer General Dimensions:

1. Overall length: 42’- 0”

2. Overall width: 8’ - 6” Overall Width
3. King pin size: 2”
4. King pin distance from front of trailer: 24”
5. Fifth wheel height 52”
6. Deck height (loaded) 62” (59.5” at rear)
7. Centerline of suspension from front of trailer: 441” (417” from king pin to center of center axle)
8. Trailer weight should not exceed 9,500#

Construction:

1. Trailer will be fitted with 400 gallon fuel tank mounted across frame rails at kinpin, 3,000
nitrogen tank mounted centered 171” behind kingpin, and nitrogen pumping unit mounted over
trailer axles.
2. Trailer provided with DOT approved lighting, reflectors and rear bumper. Lighting will be Truck-
lite LED or equivalent with harness type wiring installed protected and junction boxes as
required.
3. Standard DOT air and electrical connections at front of trailer.
4. Deck section between tank and N2 unit is 48” long and full 102” wide, with access ladder up
driver’s side.
5. Deck surface to be 1.75” Apitonge flooring.

Axles:

1. Two 22,500 lb. capacity axles spaced at 50” center to center.

2. Track (77”) as required to space outside of tires within 1” of outside width of trailer
3. Front left axle end fitted with Engler or equivalent hubometer reading in miles with blank
tenth wheel

Fig. 2.7, Trailer Specification, NA020228 (Sheet 1 of 2)

PAGE 59
 Suspension:

1. Ridewell air-ride suspension.

2. 22,500 lb. Each Axle
3. Barksdale Height Control on center axle set, Override axle restraint on all axles

Brakes:

1. Auto Slack Adjusters

2. Anti-lock brake system. (2 Sensors and 1 Modulator)
3. Brakes rated at 22,500# per axle.

Wheels:

10 hole Budd type, hub piloted

Tires:

275 / 70R22.5 PR 16 Bridgestone R 294 LP or equivalent on 8.25” x 22.5 steel rims.

Surface Finish:

1. All surfaces of the trailer are sandblasted, primed and painted to spec.
2. Skip weld seams are sealed after blast and prime prior to finish paint.
3. Trailer, including hubs, is painted to spec.

Accessories:

1. Heavy duty landing gear, 50,000# capacity with two speed manual power with pads
appropriate for loads
2. Rear section of trailer over tires and forward to deck is covered for fender protection.
3. Front section left clear for tank mounting by others.
4. Rear tow loops 1” thick with holes for shackles and front lifting lug are fitted on the trailer.

Fig. 2.7, Trailer Specification, NA020228 (Sheet 2 of 2)

PAGE 60
ITEM QTY. PART NO. DESCRIPTION
1 1 NE050120 CASE POWER END MACHINING
2 3 D24P1268 COLD END PUMP ADAPTER
3 1 ND050112 SHAFT 200 HP
4 3 D24P1345 PISTON
5 1 NDO50113 CAM C’BALANCE DRIVE SIDE
6 1 D24P1794 CAM C’BALANCE PUMP SIDE
7 3 D24P3096 PUMP ROD
8 3 C24P1316 PISTON PUMP BARREL
9 3 C24P1317 PISTON SLEEVE
10 3 C24P1327 PUMP CAM
11 6 C24P1346 RETAINER BEARING
12 1 NB050168 PILOT PLATE
13 12 BFW00033 WASHER PL TYPE B 0.38
14 2 C24P1610 HSG BEARING WITH DUAL BEARINGS
15 1 NC050092 TRIPLEX END LUBE PLATE
16 2 C24P1652 RETAINER BEARING
17 12 BFC00035 HHCS 0.38-16UNC X 1.00
18 3 B24P1308 WRIST PIN
19 3 B24P1309 PISTON SEAL RING
20 1 B24P1322 CRANKCASE PUMP COVER
21 12 B24P1329 PUMP TIE BOLT
22 2 PCP00020 SQUARE HEAD PLUG
23 1 BFN00052 HEX LOCK NUT
24 4 BFC00023 HHCS 0.31-18UNC X 1.50
25 4 BFW00002 SPLIT LOCK WASHER 0.31
26 2 B24P1653 PUMP SHIM SET
27 1 NA000126 PUMP LUBE SWIVEL
28 4 TBB00004 BALL BEARING 1-ROW
29 6 TBR00005 ROLLER BEARING 3.149
30 3 TBR00006 ROLLER BEARING 4.724
31 1 HS000023 O-RING 2-246
32 1 HS000267 O-RING 2-142
33 3 HS000005 O-RING 2-236
34 1 PCP00023 SQUARE HEAD PLUG
35 3 HS000009 O-RING 2-260
36 6 BSR00005 EXTERNAL RETAINING RING 1.500
37 3 BSR00004 INTERNAL RETAINING RING 3.500
38 6 BSR00006 RETAINING RING 4.724
39 3 BSR00007 EXTERNAL RETAINING RING 4.875
40 18 BFW00003 SPLIT LOCK WASHER 0.38

Fig. 2.8A, 200HP Direct Drive Pump Assembly, NE050119C (Sheet 1 of 2)

PAGE 62
 ITEM QTY. PART NO. DESCRIPTION
41 1 BSR00008 EXTERNAL RETAINING RING 3.156
42 1 PCB00047 HEX HEAD BUSHING 2.00MP-1.00FP 3000#
43 2 TXS00008 OIL SEAL 3.375 SHAFT
44 3 HSP00001 PISTON SEAL
45 3 HSR00001 WIPER RING ROD SEAL
46 1 HC050155 LOCKING SLEEVE
47 12 BFN00113 FLANGE NUT 0.7516UNF
48 1 AAF00001 FILTER AIR
48A 1 AAF00035 ELEMENT, FILTER AIR
49 12 BFC00493 CTSK SCR SCH 0.31-18UNC 0.50
50 12 BFC00004 HHCS 0.25-2OUNCE X 0.75
51 1 B24P1797 FLANGE PUMP GASKET
52 18 BFC00033 HHCS 0.38-16UNC X 0.75
53 6 BPD00016 WOODRUFF KEY #406
54 4 BFC00120 HHCS 0.75-10UNC X 2.25
55 4 BFW00008 SPLIT LOCK WASHER 0.75
56 1 HRS00040 SIGHT GLASS 4/00 0.50MNPT

Fig. 2.8A, 200HP Direct Drive Pump Assembly, NE050119C (Sheet 2 of 2)

PAGE 63
Fig. 2.8B, 200HP Direct Drive Pump Assembly, NE050119C
PAGE 64
 ITEM QTY. PART NO. DESCRIPTION
1 1 PSF00004 FLG SLIP-ON 1.50 150#
2 1 CVG00010 VALVE GLOBE 1.50FNPT BRZ
3 1 NB050079 VALVE RELIEF ASSY (SEE FIG. 2.6)
4 1 CVG00158 VALVE GLOBE 0.38FNPT BRASS, LONG STEM"T"
5 1 CLC00002 CONN 1.50CGA-1.50FNPT WITH LUGS
6 1 CLC00004 CAP CGA 1.50 LOCKING-CLC00025
7 0.20 FT RSO00010 PIPE 1.50 SCH 40
8 0.61 FT RSO00010 PIPE 1.50 SCH 40
9 1 BCC00022 RING-CHAIN ASSY
10 1 PSN00025 NIP/H SCH 40 0.25NPT 1.50
11 1.65 FT RSB00231 BAR FLT 0.50-5.50
12 2 BFC00720 HHCS 0.50-13UNC X 1.50 18-8 SST
13 2 BFW00053 WSHR LOCK SPLIT 0.50 18-8 SST
14 2 BFN00198 NUT HX STD 0.50-13UNC 18-8 SST
15 0.13 FT RSB00231 BAR FLT 0.50-5.50
16 1 HHA60135 ADPTR 0.38MNPT-0.38MJIC 90 SST
17 1 PSN00071 NIP/H SCH 40 1.50NPT 1.50

Fig. 2.9A, Recirculation Plumbing Assembly, ND150055A

PAGE 65
Fig. 2.9B, Recirculation Plumbing Assembly, ND150055A
PAGE 66
 C15D DITA Industrial Engine:
500 HP @ 2100 rpm, counterclockwise rotation
Separate circuit turbo after cooler and wet exhaust
EPA Certified Tier II

Air Inlet System:

SCAC (turbo aftercooler) and watercooled turbo

Charging System:
12V, 115 amp alternator

Control System:
ADEM III electronic engine control
Electronic diagnostics, fault logging
Remote electronic speed control capability

Cooling System:
Thermostats and housing
Jacket water pump, gear driven, centrifugal

Exhaust System:
Exhaust manifold, wet

Flywheels & Flywheel Housings:

SAE #1 housing
Flywheel for 14" clutch, 3.937 pilot

Fuel System:
Electronic injector
Fuel transfer pump LH, front
Fuel priming pump LH, middle
Primary fuel filter LH
Secondary fuel filter LH, 2 micron

Instrumentation: furnished loose for remote mounting (all dual scale)

Oil pressure gauge – electric 2.06” automotive
Water temperature gauge – electric 2.06” automotive
Engine tach, w. hour meter – digital
Engine kill switch
Red and amber check engine and warning lights
Plug-ins and connections (40 pin) for instrument interface with operator’s control panel

Fig. 2.10, Cat Engine Specification, NA010072 (Sheet 1 of 2)

PAGE 67
Lube System:
Crankcase breather
Oil cooler RH
Oil filter, dipstick both LH
Oil filler LH
Oil pan
Oil pump

Mounting:
Front support, (narrow)
2 rear mounts, (mount from engine’s horizontal pads at rear flywheel housing)

Start System:
12V Electric LH

General:
Paint, Caterpillar yellow
Vibration damper with guard
Lift eyes

Other Features:
1. Air compressor, 15.5 CFM – gear driven
2. Pump drive, 1.41:1 ratio, front side opposite air compressor, SAE A, 11 tooth
3. Air cleaner, panel type – mounted on engine
4. Throttle control electronic, 2 turn twist knob – locking design, CCW to increase
5. Remote start switch, Off/On/Start – spring return to On
6. Radiator (9.5 ft.2 or smaller) harsh environment resistance coated,
radiator mounts separate from engine, water connections
7. Coolant level sensor
8. Crowley blower fan, fiberglass
9. Horton fan clutch, air to engage (with direct drive safety feature)
10. Exhaust flex
11. Exhaust El
12. Exhaust flange
13. Exhaust pipe
14. Exhaust rain cap
15. Exhaust muffler, 8” spark arresting
16. Location for magnetic pickup in flywheel housing (pickup not furnished)
17. All necessary guards for fan, belts and accessories to be installed

Fig. 2.10, Cat Engine Specification, NA010072 (Sheet 2 of 2)

PAGE 68
ITEM QTY. PART NO. DESCRIPTION
1 1 ND086084 HYDRAULIC TANK WELDMENT
2 1 NC076109 MANIFOLD WELDMENT HYDRAULIC TANK
3 1 NC076113 FLANGE WELDMENT 3” SUCTION
4 1 NC076122 FLANGE WELDMENT 4” SUCTION
5 1 NC076126 FLANGE WELDMENT 3” BOLT SAE
6 2 NB076135 NIPPLE WELDMENT 3” HALF NIPPLE
1
7 1R NE090201 SCHEMATIC HYD (SEE FIG. 1.1)
2
8 1R HFR00119 FILTER TANK TOP 3.00 25 PSI
2
8A 1R HFR00124 ELEMENT, FILTER TANK TOP 3.00 25 PSI
2
9 1R HFR00120 FILTER TANK TOP 3.00 25 PSI
2
9A 1R HFR00125 ELEMENT, FILTER TANK TOP 3.00 25 PSI
2
10 1R HVC00022 VALVE CHK 3.00 NPT
2
11 1R HVC00192 VALVE CHK 3.00 NPTF INLINE RETURN
2
12 1R HVR00043 VALVE RELIEF 2.00FNPT
2
13 1R HFR00121 DIFFUSER TANK 2.00NPT
2
14 1R HFS00069 FILTER MESH
2
15 1R IPM00388 INDICATOR FILTER REMOTE 0.13FNPT
2
16 1R HVT00143 VALVE BUTTERFLY 4.00
2
17 1R HVT00001 VALVE BUTTERFLY 3.00
18 1 HRS00002 SIGHT GLASS 12.00 0.25MNPT
19 1 ITM00036 GAUGE TEMP 0/250F/C 3.00 0.50MNPT
21 1 HRF00004 BREATHER 0.75 NPT
22 1 HVT00163 HANDLE VALVE HVT00159 HVT00161
23 4 HXC00001 CLAMP T-BOLT 3.00
3
24 1.05 FT HHH00196 HOSE HYDR 3.50 ID SAE 100R4
26 1 HVT00057 VALVE BALL 0.75FNPT 600PSI
27 1 HHA10068 ADPTR 1.25MNPT-1.25MJIC
28 3 HHA20028 ADPTR 0.25MNPT-0.25MJIC
29 1 HHA10010 ADPTR 0.75MNPT-0.75MNPT
30 1 HHA20113 ADPTR 1.25MJIC-1.00MOR
31 1 HHA10201 ADPTR 1.00MOR-1.25MJIC
32 1 HHA60005 ADPTR PLUG 0.75MNPT
33 1 HHA20047 ADPTR 0.75MNPT-0.75MJIC
34 1 PCE00080 ELL THD 90 150# 3.00
35 1 PCE00110 ELL THD ST 90 150# 3.00
36 1 PCE00108 ELL THD ST 90 150# 2.00
37 2 PCE00106 ELL THD ST 90 150# 1.25
38 1 PCN00060 NIP SCH 40 3.00NPT 10.00
39 1 PCN00068 NIP SCH 40 3.00 NPT CLS
40 1 PCN00018 NIP SCH 40 2.00NPT
Fig. 2.11A, Hydraulic Tank Assembly, ND066075C (Sheet 1 of 2)

PAGE 70
 ITEM QTY. PART NO. DESCRIPTION
41 1 PCN00443 NIP SCH 40 1.25 NPT 28.00
42 12 BFC00111 HHCS 0.63-11UNC X 5.00
43 12 BFW00007 WASHER LOCK SPLIT 0.63 STL
44 12 BFN00035 NUT HX STD 0.63 - 11 UNC
45 2 BFC00417 HHCS 0.31-18UNC X 3.50
46 2 BFW00002 WSHR LOCK SPLIT 0.31
47 1 HHA60047 ADPTR 0.75FJIC CAP
48 1 PCC00050 CPLG THD HALF 3000# 0.25
49 1 HHA10003 ADPTR 0.25MNPT-0.25MNPT
2
50 1R HVX00001 VALVE AUTO AIR BLEED-OFF 5000PSI
51 3 HHA20025 ADPTR 0.13MNPT-0.25MJIC
52 1 HHA10042 ADPTR 0.25MNPT-0.25MJIC
53 3 BFS00002 SSCR SCH 0.25-20UNC 0.50 CONE POINT

1
ITEM NOT SHOWN, FOR REFERENCE ONLY.
2
CALLED OUT ON HYDRAULIC SCHEMATIC.
3
ITEM #24 SHOWN PHANTOM FOR CLARITY

Fig. 2.11A, Hydraulic Tank Assembly, ND066075C (Sheet 2 of 2)

PAGE 71
Fig. 2.11B, Hyraulic Tank Assembly, ND066075C
PAGE 72
=============================================================================
HOSE Q.D. | SIZE | HOSE ENDS
| |
MST - Male Snaptite | -4 = 1/4" | MPR - Male Pipe Rigid
FST - Female Snaptite | -6 = 3/8" | FPR - Female Pipe Rigid
MHD - Male Hyd. Inc. | -8 = 1/2" | MPS - Male Pipe Swivel
FHD - Female Hyd. Inc. | -10 = 5/8" | FPS - Female Pipe Swivel
MA - Male Aeroquip | -12 = 3/4" | FJR - Female JIC Rigid
FA - Female Aeroquip | -16 = 1" | FJS - Female JIC Swivel
| -20 = 1-1/4" |
| -24 = 1-1/2" |

HOSE ROUTING
NO. QTY SIZE END TYPE LENGTH END DESCRIPTION
=============================================================================
6 1 -4 FJS 100R2AT 16" FJS Specialty Valve Supply
To Air Guage

7 1 -4 FJS 100R2AT 41” FJS 90° Air Guage To Priorty

Valve Activator SupplyY

8 1 -4 FJS 100R2AT 16" FJS Vaporizer Pot In Port To

Vaporizer Pot Out Port

9 1 -4 FJS 100R2AT 18" FJS Lube Port To Lube Gauge

12 1 -4 FJS 100R2AT 20" FJS 90° Main Hydr Port To

MHP Gauge

14 1 -4 FJS 100R2AT 16" FJS 90° Chart Port To Chart

Recorder

18 1 -4 FJS 100R2AT 55" FJS 90° Priority Valve Port 1 To

Priority Valve Selector Port 1

19 1 -4 FJS 100R2AT 55" FJS 90° Priority Valve Port 2 To

Priority Valve Selector Port 2

22 1 -4 FJS 100R2AT 41" FJS Tank Return Port To

HVD00387 Tank Port

23 1 -4 FJS 100R2AT 17" FJS Selector Valve Port To

Specialty Valve Out Port

Fig. 2.12, 180K Control Panel Hose Kit, NA090207 (Sheet 1 of 3)

PAGE 73
HOSE ROUTING
NO. QTY SIZE END TYPE LENGTH END DESCRIPTION
=============================================================================
25 1 -4 FJS 100R2AT 40” FJS 90° HVD00387 Function
Port To Priority Valve
Selector P Port

26 1 -4 FJS 100R2AT 39" FJS 90° Priority Valve Selector

R Port To HVD00387
Tank Port

27 1 -4 FJS 100R2AT 18" FJS 90° Priority Valve Activator

Out Port To HVD00387
Air Port

11 1 -4 FJS 100R2AT 16" FJS 90° MHCP Port To MHCP

Gauge

17 1 -4 FJS 100R2AT 27" FJS 90° Pump Speed Return To

Heat Load Return

20 1 -4 FJS 100R2AT 44” FJS Hydr Supply Port To

HVD00387 Press Port

21 1 -4 FJS 100R2AT 24” FJS 90° Heat Load Return To

Tank Return Port

28 1 -4 FJS 100R2AT 36” FJS 90° Heat Load Press Into

Hydr Heat Pump Gauge

29 1 -4 FJS 100R2AT 31" FJS 90° Heat Load Press Into

Heat Load Press Port In

30 1 -4 FJS 100R2AT 22" FJS 90° HVP00041 Working To

Working Port For Pump
Spec

31 1 -4 FJS 100R2AT 24" FJS 90° HVP00041 Press Into

HVP00070 Working

32 1 -4 FJS 100R2AT 36" FJS 90° HVP00041 Return To

Tank Return Port

Fig. 2.12, 180K Control Panel Hose Kit, NA090207 (Sheet 2 of 3)

PAGE 74
HOSE ROUTING
NO. QTY SIZE END TYPE LENGTH END DESCRIPTION

33 1 -4 FJS 100R2AT 26" FJS 90° HVP00070 Return To

Tank Return Port

34 1 -4 FJS 100R2AT 36" FJS 90° HVP00070 Press To

Hydr Control Press
Gauge

35 1 -4 FJS 100R2AT 40" FJS 90° HVP00070 Press To

HVP00070 Press Into Port

36 1 -4 FJS 100R2AT 16” FJS Pump Speed Press To

Hydr Press Gauge

37 1 -4 FJS 100R2AT 9” FJS 90° Pump Speed Press To

Pump Speed Press To Port In

Fig. 2.12, 180K Control Panel Hose Kit, NA090207 (Sheet 3 of 3)

PAGE 75
 ITEM QTY. PART NO. DESCRIPTION
1 2 CLH00055 HOSE METAL 1.50 SST X 9.00 OAL
2 16 BFC00352 HHCS 0.50-13UNC X 2.50
3 4 CXS00051 GASKET FLG 1.50-150# FULL FACE 0.06 PTFE
4 16 BFN00183 NUT HX NYLOCK 0.50-13UNC 18-8
5 16 BFW00077 WSHR PL TYPE A SERIES N 0.50
6 0.34 FT RSO00002 PIPE 1.50 SCH 40 (4.00 LG)
7 1 CVG00033 VALVE GLOBE 1.00FNPT BRZ
8 2 PSF00004 FLG SLIP-ON 1.50 150#
9 1 PSF00017 FLG SLIP-ON 1.00 150#
10 3 PSE00006 ELL WLD 90 LR SCH 40 1.00
11 1 PSR00003 RDCR CONC WLD SCH 40 1.50-1.00
12 0.86 FT RSO00020 PIPE 1.00 SCH 40 (10.25 LG)
13 0.13 FT RSO00020 PIPE 1.00 SCH 40 (1.25 LG)
14 0.15 FT RSO00020 PIPE 1.00 SCH 40 (1.75 LG)
15 0.34 FT RSO00020 PIPE 1.00 SCH 40 (4.00 LG)
16 0.39 FT RSO00020 PIPE 1.00 SCH 40 (4.63 LG)
17 4 PSE00004 ELL WLD 90 LR SCH 40 1.50
18 0.39 FT RSO00002 PIPE 1.50 SCH 40 (4.68 LG)
19 2.05 FT RSO00002 PIPE 1.50 SCH 40 (24.50 LG)
20 0.16 FT RSO00002 PIPE 1.50 SCH 40 (1.88 LG)

Fig. 2.13A, Pressure Building Coil Plumbing Assembly, ND150056

PAGE 76
Fig. 2.13B, Pressure Building Coil Plumbing Assembly, ND150056
PAGE 77
ITEM QTY. PART NO. DESCRIPTION
1 1 CXX00016 VAPORIZER POT 180K
2 2 A10416 NUT VAPORIZER
3 1 HVF00015 VALVE NDL 0.25MNPT BRASS-0.25FNPT
4 *1 CA980068 TEST PROCEDURE 15K PSI HYDRO PROOF
5 *1 CA980187 RISK ANALYSIS DOCUMENT
6 *1 CA980119 PROOF TEST 265 PSI HYDROSTATIC TEST PROC.
7 *1 CA980117 RISK ANALYSIS DOCUMENT

* ITEM NOT SHOWN

Fig. 2.14A, Vaporizer Assembly, ND057428B
PAGE 78
Fig. 2.14B, Vaporizer Assembly, ND057428B
PAGE 79
 Cold End Kit, 1.63 Bore x 1.38 Stroke

THE FOLLOWING PARTS ARE SUPPLIED TO MAKE (1) COLD END ASSEMBLY FOR HYDRA
RIG 200 HP TRIPLEX PUMP:

Item Qty H/R Part Number

1 COLD END 1 CPP00149

2 SPLIT COUPLING 1
3 SHCS (for split cplg) 1
(.250-20 x 2.00)
4 LOCK WASHER (.250) 1
(for split cplg)
5 PONY ROD ADPTR 1
6 ROLL PIN 1
7 SHCS 1
(.375-16 x 1.25)
8 LOCK WASHER (.375) 1

ALL ITEMS STAINLESS STEEL EXCEPT FOR

ITEM 7 WHICH IS HIGH STRENGTH STEEL

Fig. 2.15, Cold End Assembly, NA005877

PAGE 80
 HIGH PRESSURE MANIFOLD (CONTROLS)

Material: Bar Square 3.00 A276-316 Stainless Steel X 13.00 Lg. 35000 PSI Min. Yield
strength, 80000 PSI Tensile

Notes: 1.) Manifold complete with glands, collars and anti-vibe adapters.

2.) MAWP = 10000 PSI.

Fig. 2.16, High Pressure Manifold Controls Specification, NA000465B

PAGE 81
 HIGH PRESSURE MANIFOLD (TRIPLEX)

Material: Bar Square 3.00 A276-316 Stainless Steel X 20.00 Lg. 35000 PSI Min. Yield
strength, 80000 PSI Tensile.

Note: 1.) Manifold complete with glands, collars and anti-vibe adapters except for a 1.00
x 0.56 anti-vibe adapter on the right side 1.00 port (See drawing below).

2.) MAWP = 10000 PSI

Fig. 2.17, High Pressure Manifold Triplex Specification, NA000467C

PAGE 82
ITEM QTY. PART NO. DESCRIPTION
1 0.60 SqFt RCP00023 PL 1.000 (2 @ 4.75 X 9.00)
2 0.62 SqFt RCP00023 PL 1.000 (5.38 X 16.50)
3 6.00 FT HHH00194 HOSE HYDR 2.50 ID 100R4
4 8 HXC00003 T-BOLT CLAMP 2.00
5 0.50 FT RCO00027 PIPE 2.00SCH 40 (2 @ 3.00 LG)
6 2 PCE00029 ELL WLD 90 SR SCH 40 2.00
7 0.67 FT RCO00027 PIPE 2.00SCH 40 (2 @ 4.00 LG)
8 2 NB076118 NIPPLE WELD
9 2 HXF00013 FLANGE SAE 4 BOLT 3000# 2.00 SW O-RING
10 1 NA010072 ENGINE CATERPILLAR SPEC. (SEE FIG. 2.10)
11 * 1R HVR00168 VALVE RELIEF 1.50 SAE 4-BOLT
12 1 HXF00189 FLG SAE 4 BOLT 6000# 1.50
13 1.34 FT BFA00058 ALLTHREAD 0.63-11UNC (QTY 4 @ 4.00 LG)
14 1 HXF00021 MTG KIT FLG 1.50
15 2 HHA20051 ADPTR 1.00MNPT-1.00MJIC
16 * 1R HPG00085 PUMP GEAR TRIPLE SAE 6’1 2.00-1.50-2.7 (SEE SERV. LIT.)
17 * 1R HPP00135 PUMP PISTON (SEE SERVICE LITERATURE)
18 12 BFC00116 HHCS 0.75-10UNC X 1.25
19 12 BFW00038 WSHR PL TYPE B SERIES R 0.75 STL
20 1 HXF00046 FLG KIT SAE 4 BOLT CODE 61 1.50FNPT
21 2 HHA10032 ADPTR 1.50MNPT-1.00FNPT
22 1 HXF00060 FLANGE SAE 4 BOLT 500# 3.50 SW
23 1 HHA10042 ADPTR 0.25MNPT-0.25MJIC
24 1 PCE00032 ELL WLD 90 SR SCH 40 3.50
25 1 PCR00036 RDCR CONC WLD SCH 40 4.00-3.50
26 1 NB076156 4.00 PIPE NIPPLE WELDMENT
27 1 HXF00066 FLG SAE 4 BOLT 3000# 0.75FNPT O-RING
28 1 HHA10057 ADPTR 0.75MNPT-0.50MJIC
29 * 2R HVR00249 RELIEF SAE PORTS AND .031 ORIFICE
30 3 HHA20047 ADPTR 0.75MNPT-0.75MJIC 90
31 2 PCP00029 PLG 0.25 150# HD
32 1 HHA40086 ADPTR 0.50FJIC-MJIC
33 1 HHA20093 ADPTR 0.50FJIC-MJIC
34 * 1R HVR00008 VALVE RELIEF 1.50 SAE 4-BOLT
35 4 BFC01132 HHCS 0.50-13UNC X 5.50
36 3 HHA20028 ADPTR 0.25MNPT-0.25MJIC
37 4 HXC00035 CLAMP T-BOLT 4.00
38 3.00 FT HHH00195 HOSE HYDR 4.50 ID LOW PRESS
39 1 HHA10053 ADPTR 0.50MNPT-0.50MJIC
40 1 HHA10313 ADPTR 0.38MOR-0.50MJIC

Fig. 3.1A, 180K N2 Power Unit Installation, NE010074A (Sheet 1 of 2)

PAGE 84
 ITEM QTY. PART NO. DESCRIPTION
41 1 HHA40055 ADPTR 0.50FJIC-0.50MJIC-0.50MJIC SWVL
42 1 HHA10289 ADPTR 0.50FNPT-0.50FJIC
43 12 BFC00396 HHCS 0.44-14UNC X 1.25
44 12 BFW00004 WSHR LOCK SPLIT 0.44
45 4 BFC00364 HHCS 0.75-10UNC X 2.00
46 4 BFW00008 WSHR LOCK SPLIT 0.75
47 4 BFC00355 HHCS 0.50-13UNC X 1.75
48 4 BFW00005 WSHR LOCK SPLIT 0.50
49 2 BFC00434 HHCS 0.38-16UNC X 1.25
50 2 BFW00102 WSHR PL TYPE 0.38
51 1 HXF00180 FLG SAE 4 BOLT 3000# 1.50 O-RING
52 1 HXF00033 FLG SAE 4 BOLT 6000# 1.50FNPT O-RING
53 1 HHA10021 ADPTR 0.50MNPT-0.25FNPT
54 1 NC066295 SUPPORT PUMP INSTL
55 4 BFN00055 NUT HX HVY 0.63-11RNC
56 4 BFW00007 WSHR LOCK SPLIT 0.63
57 * 1R HVS00054 VALVE SEQUENCE 1.50
58 * 1R HXX00056 ADPTR PUMP DRIVE
59 1 HHA20104 ADPTR 1.50MJIC-1.50MOR 90
60 * 1R HFP00064 FLTR PRESS 10 MICRON IN-LINE 0.50FNPT
60A * 1R HFP00065 ELEMENT FLTR PRESS 10 MICRON 0.50 NPT
61 * 1R IPM00068 GAUGE PRESS 0-5000 P/B 2.50 0.25
62 * 1R IPM00111 GAUGE PRESS 0-3000 P/B 2.50 0.25
63 * 1R IPM00112 GAUGE PRESS 0-1000 P/B 2.50 0.25
64 * 1R IPM00312 GAUGE PRESS 0-7500 PSI/BAR 2.50 0.25
65 * 1R HAB00018 ACCUM BLADDER GAL 0.25 CERT (SEE SERV. LITERATURE)
66 1 HAC00012 CLAMP ACCUM 4.49 DIA BOLT SINGLE
67 1 HHA20070 ADPTR 0.75MNPT-0.75FNPT 90
68 1 HHA10010 ADPTR 0.75MNPT-0.75MNPT
69 2 HHA10209 ADPTR 0.75MNPT-0.75FNPT
70 1 HHA10093 ADPTR 0.25FNPT-0.25MNPT
71 2 ADPTR
HHA20065 ADPTR 0.25FNPT-0.25MNPT 90
72 1 HHA40049 ADPTR 0.75MNPT-0.75MJIC-0.75MJIC
73 1 HHA40077 ADPTR 0.75MNPT-0.75MNPT-0.75FNPT
74 1 HHA20066 ADPTR 0.75MNPT-0.50FNPT 90
75 1 HHA10008 ADPTR 0.50MNPT-0.50MNPT
76 2 NC080381 MOUNT RADIATOR WELDMENT
77 1 NC080380 MOUNT ENGINE BRACKET
* ITEM CALLED OUT ON HYDRAULIC SCHEMATIC

Fig. 3.1A, 180K N2 Power Unit Installation, NE010065B (Sheet 2 of 2)

PAGE 85
Fig. 3.1B, 180K N2 Power Unit Installation, NE010074A
PAGE 86
 ITEM QTY. PART NO. DESCRIPTION
1 1R NE050119 PUMP ASSEMBLY (SEE FIG. 2.8)
2 1R NA000459 TRIPLEX GEARBOX
3 1R HMP00116 PISTON MOTOR (SEE SERVICE LITERATURE)
4 10 BFW00008 LOCK WASHER 0.75
5 6 BFC00117 HHCS 0.75-1OUNC X 1.50
6 4 BFC00284 SHCS 0.75-10UNC X 2.00
7 1 HXF00025 FLG KIT SAE SPLIT 1.25
8 1 NB06693 FLANGE W/ADPTR MOD
10 1 NC070482 GUARD TRIPLEX SWIVEL
11 1 HHA20120 ADPTR 1.25MJIC-1.25SAE FLG
12 1 TDF00020 O-RING SPACER
13 4 BFC00614 HHCS 0.50-13UNC X 3.25
14 1 HHA20127 ADPTR 0.25MNPT-0.25MJIC 90
15 1 HRS00029 SIGHT GLASS PLUG 0.75MNPT

Fig. 3.2A, Triplex Installation, NE056094C

PAGE 87
Fig. 3.2B, Triplex Installation, NE056094C
PAGE 88
 ITEM QTY. PART NO. DESCRIPTION
1 1 ND066075 TANK ASSEMBLY (SEE FIG. 2.11)
2 1 ND080109 FUEL TANK WLDMT
3 1 ND060250 AIR TANK HORIZONTAL
4 6.0 FT RCB00196 BAR FLT 0.50-2.00 (6 @ 12.00 LG)
5 4 BFN00003 NUT HX HVY 0.38-16UNC
6 14 BFW00005 WASHER LOCK SPLIT 0.50
7 14 BFC00068 HHCS 0.50-13UNC X 1.50
8 4 BFW00033 WASHER PL TYPE B SERIES R 0.38
9 W BFC00036 HHCS 0.38-16UNC X 1.25
10 1 ND036181 MANIFOLD DRAIN CASE ASSY
11 4 BFW00003 WSHR LOCK SPLIT 0.38 STL

Fig. 3.3A, Hydraulic/Fuel/Air Tanks Installation, ND030082

PAGE 89
Fig. 3.3B, Hyraulic/Fuel/Air Tanks Installation, ND030082
PAGE 90
 ITEM QTY. PART NO. DESCRIPTION
1 1 ND150054 PRESSURE BUILDING COIL MTG ASSY
2 1 ND150053 LIQUID TRANSFER ASSY
3 1 ND150050 PLUMBING RELIEF DEVICE ASSY
4 1 ND150052 SIDE FILL PLUMBING ASSY
5 1 ND150012 GAUGE LEVEL LIQUID ASSY
6 4 BFC00352 HHCS 0.50-13UNC X 2.50
7 8 BFW00052 WSHR PL TYPE B SERIES W 0.50
8 4 BFW00053 WSHR LOCK SPLIT 0.50
9 4 BFN00064 NUT HX STD 0.50-13UNC
10 8 BFC00354 HHCS 0.63-11UNC X 2.75
11 8 BFW00054 WSHR LOCK SPLIT 0.63
12 16 BFW00055 WSHR PL TYPE B 0.63
13 8 BFN00101 NUT HX STD 0.63-11UNC
14 1 ND150055 PLUMBING RECIRCULATION ASSY (SEE FIG. 2.9)
15 1 ND150056 PLUMBING PRESSURE BLDG COIL ASSY (SEE FIG. 2.13)
16 4.09 FT RSA00007 ANGLE 2.00-2.00-0.25 (2 @ 24.50 LG)
17 1 ND150057 FRONT FILL PLUMBING ASSY
18 2 HXC00020 CLAMP PIPE 1.90 ID HEAVY DUTY
19 0.50 FT RST00149 TBG SQ 2.00-0.250W
20 0.05 SqFt RSP00001 PL 0.188 (2 @ 1.75 X 1.75)
21 1 ND180021 PAN DRIP NIT WLDMNT
22 3 ND180022 PAN DRIP NIT WLDMNT
23 3 CXS00051 GASKET FLG 1.50-150# FULL FACE 0.06
24 3 CXS00052 GASKET FLG 2.00-150# FULL FACE 0.06
25 1 CXS00119 GASKET FLG 3.00-150# STYLE WRI
26 1 NC180023 PAN DRIP NIT WLDMNT
27 1 CXS00049 GASKET FLG 1.00-150# FULL FACE 0.06

Fig. 3.4A, Tank Plumbing Installation, NE150051

PAGE 91
Fig. 3.4B, Tank Plumbing Installation, NE150051
PAGE 92
 ITEM QTY. PART NO. DESCRIPTION
1 1 PCE00108 ELL THD ST 90 150# 2.00
2 1 PCR00152 RDCR CONC THD BELL 150# 3.00-2.00
3 1 NB038135 NIP KC 3.00 THRD
4 1 PCN00018 NIP SCH 40 2.00NPT
5 10.0 FT. HHH00196 HOSE HYDRAULIC 3.50
6 1 PCB00044 BSHG HX HD 3.00MP-1.50FP 150#
7 1 PCN00070 NIP SCH 40 1.50NPT CLS
8 1 PCE00222 ELL THD ST RDCG 90 150# 2.00-1.50
9 9 HHX00004 NIP KC 2.00 BLACK UNPLATED
10 9 HXC00003 CLAMP T-BOLT 2.00
11 30.0 FT HHH00003 HOSE PETROLEUM TRANSFER 2.00 ID
1
12 8R ITM00005 GAUGE TEMP 0/250F/C 3.00 0.50MNPT
1
13 1R HFR00073 RETURN LINE FILTER
1
13A 1R HFR00093 ELEMENT RETURN LINE FILTER
14 1 PCT00070 TEE THD 150# 3.00
15 6 NB070317 ELL GAUGE TEMPERATURE WELDMENT
16 1 HHX00007 NIP KC 1.00 BLACK UNPLATED
17 2 HXC00022 T-BOLT CLAMP
18 2 PCP00010 SQUARE HEAD PLUG 150# 2.00
2
19 1R NC040071 EXPANSION TANK INSTL
20 3 HXC00001 CLAMP T-BOLT
21 1 PCE00105 ELL THD ST 90 150# 1.00
22 13.00 FT HHH00006 PETROLEUM TRANSFER HOSE 1.00 ID
23 1 PCB00011 HEX HEAD BUSHING 3.00MP-2.00FT 150#
24 4 NB070686 ELL GAUGE TEMPERATURE
25 2 PCN00129 NIP/H SCH 40 2.00NPT 5.00
26 1 HHA10076 ADPTR 2.00MNPT-2.00MJIC
27 2 HHX00001 NIP KC 3.00
1
28 1R ITM00076 TEMPERATURE GAUGE 0-180F/C W/2.25 FT CAP “T”
1
29 1R IPM00032 PRESSURE GAUGE 0-200 PSI/BAR 2.50 0.25
30 1 PSC00008 CPLG THD HALF 150# 0.75
31 2 HHA30034 ADAPTER 2.00MNPT-2.00MJIC
32 1 PCB00043 BUSHING HEX HEAD
33 2 PCN00119 NIP SCH 40 2.00NPT 3.00
34 4.00 FT HHH00001 HOSE PETROLEUM TRANSFER
35 1 PCE00110 ELL THD
36 3 HHA60096 ADPTR PLUG 0.50MNPT HX HD PLD
37 1R HXH00140 HEAT EXCHANGER PLATE
38 1R HXH00141 HEAT EXCHANGER PLATE
1
ITEM CALLED OUT ON COOLANT SCHEMATIC
2
ITEM CALLED OUT ON FINAL ASSY

Fig. 3.5A, Coolant Plumbing Installation, NE070762

PAGE 93
Fig. 3.5B, Coolant Plumbing Installation, NE070762
PAGE 94
ITEM QTY. PART NO. DESCRIPTION
1 1R CPC00081 CENTRIFUGAL PUMP INSTALLATION (SEE SERV. LIT.)
2 1 NB000033 HOSE SPECIFICATION 2-1/2 X 1-1/2
3 2 NB000034 HOSE SPECIFICATION 1-1/2
2
5 5R CVB00038 BALL VALVE 1.50 SW
2
6 1R CVG00033 GLOBE VALVE 1.00 FNPT
2
7 2R CLS00004 STRAINER 1.50 FNPT 100 MESH 250PSI
2
8 6R NB050079 RELIEF VALVE
9 6 CLC00032 COPPER GASKET 1.50
10 3 NB070676 PIPE BRACKET WLDMNT
11 4 PSN00157 NIP/H SCH 40 1.50NPT 3.75
12 3 PSF00004 SLIP-ON FLANGE 1.00 150#
13 0.50 FT RSO00018 PIPE 1.50 SCH 10 SMLS
14 1 PSF00017 SLIP-ON FLANGE 1.00 150#
15 1 NCO70437 SUCTION MANIFOLD WELDMENT
16 1 NCO76417 RETURN MANIFOLD WELDMENT
17 3 CLC00002 CONNECTION 1.50CGA-1.50FNPT WITH LUGS
18 3 CLC00016 DUST CAP 1.50 CGA
19 2 PBP00008 HEX HEAD PLUG 0.75NPT
2
20 1R CVB00037 BALL VALVE 0.50 SW
21 3 NB070700 SUCTION TUBE ASSEMBLY ¾
22 3 NB070682 RETURN TUBE ASSEMBLY ½
23 3 HHA10352 ADAPTER 0.50MNPT-0.50MJIC
24 3 HHA10591 ADAPTER 0.75MNPT-0.75MJIC
25 3 HHA10518 ADAPTER 1.00MNPT-0.75MJIC
26 1 PSC00025 HALF COUPLING 3000# 0.50
27 1 PSE00003 LR SCH ELL WLD 10 0.50
28 4 PSN00299 SMLS NIP/HSCH 40 1.50NPT 2.00
29 1 PSN00020 SMLS NIP SCH 40 1.00NPT 3.00
30 0.25FT RSO00018 PIPE 1.50 SCH 10 SMLS 3.00 LG
31 0.92FT RSO00018 PIPE 1.50 SCH 10 SMLS 11.00 LG
32 2 PSN00042 NIP/H SCH 40 1.00NPT 1.50
33 1.77FT RSO00005 PIPE 1.00 SCH 10 SMLS 21.25 LG
34 3 PSE00001 ELL WLD 90 SR SCH 10 1.50
35 2 PST00001 TEE WLD S10 1.50
36 1 PSE00106 ELL WLD 90 SR SCH 40 1.00
37 1 PST00003 TEE WLD S10 1.00-1.00-0.50
1
38 2 HXC00095 HEAVY DUTY PIPE CLAMP 1.31
39 0.34FT RSO00004 PIPE 0.50 SCH 10 SMLS
40 1 PSC00043 HALF COUPLING 3000# 0.25

Fig. 3.6A, Low Pressure Plumbing Installation, NE050215A (Sheet 1 of 2)

PAGE 95
 ITEM QTY. PART NO. DESCRIPTION
2
41 1R HVC00041 CHECK VALVE 1.00FNPT 125#
1
42 1 CXS00053 FLANGE GASKET 2.50-150 FULL FACED 0.06 PTFE
1
43 5 CXS00051 FLANGE GASKET 1.50-150# FULL FACED 0.06 PTFE
1
44 1 CXS00049 FLANGE GASKET 1.00-150# FULL FACED 0.06 PTFE
1
45 4 HHF00046 NUT 0.25 TB FLARE END
1
46 4 HHF00047 SLEEVE FLARE TB END 0.25 TB
47 4 BFN00285 NUT HX HVY 0.63-11UNC
48 4 BFW00054 WSHR LOCK SPLIT 0.63
49 4 BFC00940 HHCS 0.63-11UNC X 3.25
50 3 HHA60024 ADPTR 0.25MNPT—0.50MJIC
51 24 BFC01033 HHCS 0.50-13UNC X 2.25
52 24 BFW00053 WSHR LOCK SPLIT 0.50
53 24 BFN00284 NUT HX HVY 0.50-13UNC
54 0.16 FT RSO00018 PIPE 1.50 SCH 10 X 2.00 LG
55 8 BFW00271 WSHR PL TYPE A R 0.63
56 0.88 FT RSO00018 PIPE 1.50 SCH (10.50 LG)

1
ITEM NOT SHOWN
2
ITEM CALLED OUT ON NITROGEN SCHEMATIC

Fig. 3.6A, Low Pressure Plumbing Installation, NE050215A (Sheet 2 of 2)

PAGE 96
Fig. 3.6B, Low Pressure Plumbing Installation, NE050215A
PAGE 97
ITEM QTY. PART NO. DESCRIPTION
2
1 1R ND057428 VAPORIZER ASSEMBLY (SEE FIG. 2.14)
2
2 3R NA005877 COLD END ASSEMBLY (SEE FIG. 2.15)
3 1 NA000465 HIGH PRESSURE CONTROLS (SEE FIG. 2.16)
4 2 CHA00036 ADAPTER
5 1 NA000467 HIGH PRESSURE CONTROLS (SEE FIG. 2.17)
2
6 1R IPP00001 DEBOOSTER (SEE SERVICE LITERATURE)
2
7 1R IPP00032 PRESSURE SENSOR 1:1 15K FLG MNT
1
8 3 HHA60024 ADAPTER 0.25MNPT-0.50MJIC
9 6 CHA00020 COLLAR ADAPTER 0.56Odtb
10 4 CHA00015 ANTI-VIBRATION ADAPTER 0.56ODTB
11 20 FT RST00007 TUBING RND 0.25 OD – 0.070W X 24.00 LG
12 3 CHA00019 COLLAR ADAPTER 1.000DTB
13 3 CHA00014 ANTI-VIBRATION ADAPTER 1.000DTB
14 10 FT RST00001 TUBING 1.000 OD-0.219W X 120.00LG
2
15 1R NA000547 SPEC PLUG VALVE W/ HYDR OPERATOR
2
16 1R CVC00095 CHECK VALVE 1.00FAE-1.00FAE
17 1 CHA00018 ADAPTER 1.00MAE MED PRS-0.38FAE
18 20.0 FT RST00002 TUBING 0.563 OD-0.124W X 240.OOLG
19 1 CHA00095 1 INCH BULL PLUG
1
20 20.0FT RST00007 TUBING 0.250 OD-0.070W X 240.00LG
1
21 1 NC051875 VALVE RECIRC-TEMP 90K/120K INST (SEE FIG. 3.12)
22 1 CHA00085 PLUG
23 1 CHA00096 NUT
24 1 CHA00031 ADAPTER 0.56MAE -0.25FAE
25 1 CHA00061 PLUG 0.25
26 1 CHA00062 GLAND 0.25
27 1 CHC00048 UNION CPLG 1.00 TUBE
3
28 1R ITS00004 THERMOCOUPLE
29 2 BFC00046 HHCS 0.38-16UNC X 4.00
30 8 BFN00031 NUT HX STD 0.38-16UNC
31 6 BFW00046 WSHR LOCK SPLIT 0.38
32 4 BFC00401 HHCS 0.38-16UNC X 1.38
33 1 CHA00012 ADAPTER 1.000DTB-1.000DTB-0.56FAE
34 1 CHA00017 ADAPTER 1.00MAE MED O.56FAE MED
35 1 NC066355 BRACKET MOUNTING MANIFOLD
36 2 BFC00689 HHCS 0.38-16UNC X 3.75
37 2 BFW00003 WSHR LOCK SPLIT 0.38
38 2 BFU00001 U-BOLT 3.00
1
39 1 NB026059 HOSE ASSY N2 1:1 ISOLATOR TO GAUGE

Fig. 3.7A, High Pressure Plumbing Installation, ND050216A (Sheet 1 of 2)

PAGE 98
 ITEM QTY. PART NO. DESCRIPTION
1
41 1 CA980068 TEST PROCEDURE 15KPSI HYDRO PROOF
1
42 1 CA980116 RISK ANALYSIS DOCUMENT
43 1 CHA00057 ADPTR 0.25ODTB-0.25ODTB-0.25ODTB
44 4 CHA00027 ADAPTER 0.25ODTB ANTI-VIB
45 4 CHA00029 ADAPTER 0.25ODTB COLLAR

1
ITEM NOT SHOWN
2
ITEM CALLED OUT ON NITROGEN SCHEMATIC
3
ITEM CALLED OUT ON ELECTRICAL SCHEMATIC

Fig. 3.7A, High Pressure Plumbing Installation, ND050216A (Sheet 2 of 2)

PAGE 99
Fig. 3.7B, High Pressure Plumbing Installation, ND050216A
PAGE 100
ITEM QTY. PART NO. DESCRIPTION
1
1 1R NA001150 HEAT EXCHANGER LUBE SPEC.
2 2 PCB00043 BSHG HX HD 3.00MP-1.00FP 150#
3 3 HHA20051 ADPTR 1.00MNPT-1.00MJIC 90
4 1 PCT00066 TEE THD 150# 1.25
5 1 HHA20053 ADPTR 1.25MNPT-1.00MJIC
6 2 HHX00019 NIP KC 1.25 BLACK UNPLATED
7 1 PCB00007 BSHG HX HD 1.25MP-1.00FP 150#
8 2 PCN00165 NIP SCH 40 1.00NPT CLS
2
9 1R NA000126 SWIVEL PUMP LUBE 200HP SPEC
10 2 HHA10059 ADPTR 0.75MNPT-0.75MJIC
11 1 HHX00022 MANIFOLD
12 1 HHA10279 ADPTR 0.75MNPT-0.38MNPT
13 1 PCT00064 TEE THD 150# 0.75
14 1 HHA20360 ADPTR 1.00MJIC-0.88 MOR 90
15 1 HHA20037 ADPTR 0.38MNPT-0.75MJIC 90
16 1 PBB00004 BSHG HX HD 2.00MP-1.00FP 250#
2
17 1R AAF00001 FILTER, AIR
2
17A 1R AAF00035 ELEMENT, FILTER, AIR
18 1 HHA10061 ADPTR 1.00MNPT-0.75MJIC
1
19 1R HVR00003 VALVE RELIEF 1.00FNPT
20 3 HHA10062 ADPTR 1.00MNPT-1.00MJIC
21 0.20 SqFt RCP00003 PL 0.250 X 5.00 X 5.50
22 1 HHB10004 ADPTR 1.00MNPT-1.00MJIC BHD
23 2 HHA10487 ADPTR 1.00MNPT-1.00FJIC SWVL
24 1 PCT00065 TEE THD 150# 1.00
25 1 HHA20091 ADPTR 1.00MJIC-1.00FNPT 90
1
26 1R HVC00019 VALVE CHK 1.00FNPT BRASS
1
27 1R HFP00045 FLTR PRESS SAE 24
1
27A 1R HFP00054 ELEMENT, FLTR PRESS SAE 24
28 2 HHA10274 ADPTR 1.50MOR-1.00MJIC
1
29 1R HPG00099 PUMP GEAR (SEE SERVICE LITERATURE)
30 4 HHA30013 ADPTR 0.25MNPT-0.25MJIC 90
31 2 PCP00035 PLUG 0.75 150# HX HD
32 3 HHA10038 ADPTR 0.13MNPT-0.25MJIC
33 2 BFC00022 HHCS 0.31-18UNC X 1.25
34 2 BFW00002 WSHR LOCK SPLIT 0.31 STL
35 2 BFN00030 NUT HX STD 0.31-18UNC
36 0.67 FT RCA00011 ANGLE 1.50-1.50-0.13
37 4 BFM00053 SCR MACH #8-32UNC X 1.75 HX HD STL
38 4 BFW00096 WSHR PL TYPE A #8 STL
39 4 BFW00056 WSHR LOCK SPLIT #8 STL
Fig. 3.8A, Lube Plumbing Installation, ND030083 (Sheet 1 of 2)
PAGE 101
 ITEM QTY. PART NO. DESCRIPTION
40 4 BFN00104 NUT HX STD #8-32UNC
41 1 HHA10192 ADPTR 1.00MNPT-1.25FNPT

1
ITEM CALLED OUT ON HYDRAULIC SCHEMATIC
2
ITEM CALLED OUT ON PUMP ASSEMBLY
Fig. 3.8A, Lube Plumbing Installation, ND030083 (Sheet 2 of 2)
PAGE 101-A
Fig. 3.8B, Lube Plumbing Installation, ND030083
PAGE 102
 ITEM QTY. PART NO. DESCRIPTION
1 1 NC076103 MANIFOLD WELDMENT RETURN
2 2 HHA20047 ADPTR 0.75MNPT-0.75MJIC
3 1 HHA20050 ADPTR 1.00MNPT-0.75MJIC
4 1 HHA20051 ADPTR 1.00MNPT-1.00MJIC
5 1 HHA10032 ADPTR 1.50MNPT-1.00FNPT
6 1 HHA30030 ADPTR 1.50MNPT-1.00MJIC
7 1 HHA30034 ADPTR 2.00MNPT-2.00MJIC
8 1 HHA20056 ADPTR 1.50MNPT-1.25MJIC
9 3 BFC00037 HHCS 0.38-16UNC X 1.50
10 3 BFN00003 NUT HX HVY 0.38-16UNC
11 3 BFW00003 WSHR LOCK SPLIT 0.38
12 1 HHA60007 ADPTR PLUG 1.25MNPT

Fig. 3.9A, Return Manifold Installation, ND036106B

PAGE 103
 Fig. 3.9B, Return Manifold Installation, ND036106B
PAGE 104
 ITEM QTY. PART NO. DESCRIPTION
1 * REF NA000472 VALVE AIR OVER HYD (PRES SHTDWN SW) 10
2 2 HHA10042 ADPTR 0.25MNPT-0.25MJIC
3 1 AAM00007 MUFFLER 0.25MNPT (AIR)
4 2 BFC00004 HHCS 0.25-20UNC X 0.75
5 2 BFN00042 NUT HX STD 0.25 20UNC
6 2 BFW00001 WSHR LOCK SPLIT 0.25
7 1 CHA00044 ADPTR 0.25MNPT-0.25FAE
8 15.0 FT RST00018 TBG RND 0.25 OD-0.070W 180.00 LG
9 1 CHA00027 ADPTR 0.250DTB ANTI-VIB (ASSY)
10 1 CHA00029 ADPTR 0.250DTB (COLLAR)
11 1 CHA00036 ADPTR 0.250DTB-0.250DTB-0.250DTB (ASSY)
12 1 NC050120 TUBE GAUGE HIGH PRESS (INSTL)
13 * REF HVD00147 SUBPL
14 * REF HVD00548 VALVE 4-WAY 2-POSN
15 4 BFC00437 SHCS #10-24UNC X 1.50
16 4 BFW00044 WSHR PL TYPE A #10 STL
17 4 BFN00070 NUT HX STD #10-24UNC

* ITEM CALLED OUT ON HYDRAULIC SCHEMATIC

Fig. 3.10A, Triplex Shutdown Valve Installation, ND022010B

PAGE 105
Fig. 3.10B, Triplex Shutdown Valve Installation, ND022010B
PAGE 106
 ITEM QTY. PART NO. DESCRIPTION
1 2.34 FT RCA00121 ANGLE 8.00-6.00-0.50 (4 @ 7.00 LG)
2 1 NC170021 PLATE TANK MTG
3 8 BFN00073 NUT HX LOCK 0.63-18UNF IFI 100/107
4 24 BFN00080 NUT HX LOCK 0.75-10UNC IFI 100/107
5 8 BFW00106 WSHR PL TYPE A SERIES N 0.63 STL
6 16 BFC00663 HHCS 0.75-10UNC X 2.25
7 8 BFC00433 HHCS 0.63-18UNF X 3.00
8 0.79 SqFt RCP00085 PL 0.50 (2 @ 9.44 X 6.00)
9 * 1R NA100018 TANK 3000 GALLON SPEC.
10 8 BFC00615 HHCS 0.75-10UNC X 3.25
11 48 BFW00107 WSHR PL TYPE A SERIES N 0.75 STL

* CUSTOMER SUPPLIED

Fig. 3.11A, Nitrogen Tank Installation, ND160014

PAGE 107
Fig. 3.11B, Nitrogen Tank Installation, ND160014
PAGE 108
 ITEM QTY. PART NO. DESCRIPTION
1
1 REF CVH00010 VALVE REGULATOR 2-WAY 0.56 TUBE ANGLE
2 2 CHA00067 ADPTR 0.56DTB-0.56ODTB-0.56ODTB ASSY
3 1 CHA00097 ADPTR 0.50MNPT-0.56FAE ANTI-VIB
4 2 CHA00020 ADPTR 0.56DTB COLLAR
5 1 CHA00015 ADPTR 0.56ODTB ANTI-VIB ASSY
1
6 REF CVR00176 VALVE RELIEF 0.56AE-0.50FNPT “T”
7 1 CHA00143 ADPTR CPLG 0.56 TB
8 1 HHA40198 ADPTR 0.50MNPT-0.50MNPT-0.50FNPT SS
9 1 NB074625 BRACKET WELDMENT HP TUBING
12 2 HXC00024 CLAMP PIPE 0.56 ID STD DUTY
2
13 4 HXC00021 CLAMP PIPE 0.25 ID STD DUTY
14 12 FT RST00002 TBG RND 0.563 OD-0.124W X 144
15 12 FT RST00007 TBG RND 0.250 OD-0.070W X 144
16 1 PSE00108 THREADED ELBOW 150#

1
ITEM CALLED OUT ON NITROGEN SCHEMATIC
2
ITEM NOT SHOWN

Fig. 3.12A, Recirculating and Tempering Valve Installation, NC051875D

PAGE 109
Fig. 3.12B, Recirculating and Tempering Valve Installation, NC051875D
PAGE 110
 HYDRA RIG MAINTENANCE AND TROUBLESHOOTING

Maintenance And Troubleshooting

Inspection
Perform periodic inspections as presented in Maintenance instructions. Operator and maintenance
personnel must be aware of any discrepancies and the discrepancies shall be corrected before the system
is put into operation. During these inspections, check the following:
• Cleanliness: Inspect all nitrogen components for cleanliness. Remove all forms of foreign
material and contaminants from equipment. Give special attention to couplings to ensure
that no contamination or foreign materials can enter the nitrogen system.
• Corrosion: Inspect entire nitrogen system for any forms of corrosion. Clean and inspect
corrosion area. Repair as needed. Take preventive measures to inhibit future corrosion.
• Weldments: Inspect all welded parts for evidence of cracked or broken welds. Determine
cause and take measures to prevent future failures. Repair as needed
• Glass: Inspect all glass components for cracks or breaks. Repair or replace as needed.
• Leakage: Inspect all fittings and tubing for looseness and signs of leakage. Repair as
needed.
• Valves: Check all valves for general condition, missing parts, and signs of leakage. During
operation of the system, inspect valves for ease of operation and positive seating. Note
problem areas and make repairs when conditions permit.
• Hoses: Inspect hoses for excessive wear. Inspect fittings for wear or physical damage.
Remove and Repair as needed.
• Attaching Hardware: Inspect entire system for loose or missing hardware (such as nuts,
bolts, etc.). Replace and re-torque as required.

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 HYDRA RIG MAINTENANCE AND TROUBLESHOOTING

Daily Maintenance (Before Start-Up) (Ref.: Fluid Specifications)

1. Check the following fluid levels:
• Coolant tank
• Triplex Pump lube tank
• Engine oil
• Engine radiator coolant
• Hydraulic reservoir
• Triplex gear box sight glass
• Diesel fuel.
2. Drain any condensation from pneumatic (Air) and hydraulic reservoirs.
3. Check that all hydraulic suction valves on the hydraulic tank are open.
4. Grease bearings on water pump.

Daily (After Shutdown)

1. Fill diesel, hydraulic, and lubrication reservoirs. Maintaining full reservoirs prevents
condensation from forming inside the tank.
2. Check all high-pressure plumbing attaching hardware (such as nuts) for tightness.
3. Check all hydraulic and lubrication lines for leaks.
4. Check coolant circuit for leaks.
5. Check engine belts.

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 HYDRA RIG MAINTENANCE AND TROUBLESHOOTING

Weekly (Every 75 Hours of Operation)

1. Drain and clean all drip pans.
2. After the first 60 to 80 hours of operation of a new unit, change the hydraulic fluid and clean
or replace the following hydraulic filter elements.
• Both Suction Strainers (hydraulic and lube oil).
• Coolant Filter.
• Lube Oil Filter
• Return Filter(s).
3. Check all critical bolted connections for tightness, including but not limited to, the
following:
• High and low pressure plumbing supports.
• All major component mounting bolts.
• Guard bolts.
4. Refer to Engine Service Manual for scheduled maintenance and procedures for the engine.

Bi-Weekly (Every 150 Hours of Operation)

1. Drain and replace engine oil and filters. (Refer to Engine Service Manual).
2. Check and replace, if necessary, engine fuel filters. (Refer to Engine Service Manual).
3. Check engine air intake connections for tightness. Check rubber seals and ducts for
deterioration that could cause leaks.

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 HYDRA RIG MAINTENANCE AND TROUBLESHOOTING

Monthly (Every 300 Hours of Operation)

1. Perform Bi-Weekly Maintenance.
2. Replace coolant return filter(s).
3. Replace engine air filter elements. (Refer to Engine Service Manual).
4. Check engine drive belts for tension and deterioration. (Refer to Engine Service Manual).
5. Remove, clean or replace air compressor intake filter as required

Annually (Every 2000 Hours of Operation)

1. Perform Monthly Maintenance.
2. Drain hydraulic and lubrication tanks and clean thoroughly. (US POT Petroleum Naphtha
UN1255 or equivalent.)
• Replace the following filters:
a) Both Suction Strainers (hydraulic and lube oil).
b) Coolant Filter.
c) Return Filter(s)
d) Lube Oil Filter.
• Check suction hoses for deterioration and replace as necessary.
• Replace fluids with new clean fluid. (Refer to Fluids Specifications.)
3. Check all hoses and clamps on hydraulic, lubrication, and coolant circuits. Replace, repair
or tighten as required.

4. Drain coolant fluids in vaporizer coolant circuit and engine coolant circuit. Flush system
with clean water. Replace coolant fluids (ethylene glycol mixture and fresh water.
(Reference fluid specification.)

NOTE: Fill Coolant Tank Then Run Engine Until Tank Level Falls To About Ten Inches
(25.4cm) Deep. Refill And Repeat The Process Until Water Level Does Not Fall After
Starting Engine. It Will Be Necessary To Bleed The Air Out Of The Engine Block
While The Unit Is Running Using The Air Bleed Valve Located In The Coolant
Header Over The Front Of The Engine. Failure To Do This Will Cause Engine
Overheating.

PAGE 115
 HYDRA RIG MAINTENANCE AND TROUBLESHOOTING

Cleaning
• Cleaning Precautions – Follow precautions related to cleaning the system and its
components. Follow specific precautions that accompany cleaning solutions or solvents. The
following precautions are standard to the system. Always observe them when cleaning is
required.
1. Wear appropriate safety equipment when using cleaning solutions, solvents and
compressed air.
2. Always follow specific warnings that apply to soaps and solvents.
3. Provide adequate ventilation when using solvents. Avoid prolonged breathing of
vapors and contact to the skin. Know what to do if any personnel become over exposed
to solvents.
4. When using solvents, always keep these items away from any source of flame, sparks or
heat. Do not leave any containers open. These substances can ignite or form harmful
gases when heated.
• Cleaning Procedures - Cleaning the system and its components may require different
methods depending on the part and the degree of contamination.
1. System: Use Hotsy Detergent Super XL or equivalent in general cleaning of the system.
Use standard cleaning methods. After washing, thoroughly rinse all affected areas with
water. Allow to air dry and wipe clean with a clean lint free cloth.
2. Nitrogen Parts - Observe common solvent handling procedures while cleaning. Use
trichlorotrifluoroethane to clean nitrogen parts. The nitrogen parts must be cleaned
removing any forms of oil or grease. These substances will freeze on contact with liquid
nitrogen (LN2) and contaminate the system or interfere with its operation. Remove all
forms of moisture and debris on couplings before replacing protective caps.

CAUTION
CGA CAPS DO NOT SEAL. USE A SEAL (SUCH AS A PLASTIC BAG)
BEFORE STEAM CLEANING OR PRESSURE WASHING.

PAGE 116
 HYDRA RIG MAINTENANCE AND TROUBLESHOOTING

Troubleshooting:
In many instances a component or system may develop a problem for which there is no immediate clear
cause. It is recommended, to avoid needless disassembly, the following procedures be taken to isolate
the portion of the circuit where the problem exists. REVIEW SAFETY SUMMARY BEFORE
TROUBLESHOOTING. The procedures are as follows:
1. Operate the system or circuit to confirm the problem actually exists.
2. Check for obvious problem's first.
3. Check the oil level in the hydraulic reservoir to ensure that it is full.
4. Check to ensure hydraulic filters are clean
5. Check to ensure all system gauges, valves and other components are functioning correctly.
6. Check to see what recent repair or maintenance has been performed. Inspect these areas for
possible cause of problems.

NOTE: It Should Be Emphasized That Cleaning The Equipment Prior To Inspection Will
Make The Job Easier, Take Less Time, And Will Reduce The Chances Of
Contamination.

Common equipment malfunctions are presented in the following sections:

• Engine Troubleshooting Guide
• Nitrogen Pumping System Troubleshooting Guide
• Tank Troubleshooting Guide

NOTE: These Guides Are Summarized Lists Of Troubles, Probable Causes And Remedies.
Should A Series Of Malfunctions Occur, Then Suspect A Lack Of Daily Scheduled
Inspections And Maintenance.

NOTE: The Following Troubleshooting Guides Are Simple Checks That Field Maintenance
Can Make. Any Detailed Engine Problems Should Be Performed By An Authorized
Engine Repair Facility.. Field Maintenance Personnel Should Possess A Good
Understanding And Working Knowledge Of The Properties And Dangers Of
Nitrogen And High Pressure Pumping Equipment Before Attempting To
Troubleshoot This Unit.

PAGE 117
 HYDRA RIG MAINTENANCE AND TROUBLESHOOTING

Engine Troubleshooting Guide

Problem A: Engine Starter Not Turning Over

PROBABLE CAUSE REMEDY

1. Low Voltage Check electrical connections.

Check alternator out feed.

Check disconnect switches.

Charge battery.

2. Starter not engaging or does not remain engaged. Defective solenoid or bad starter bendix

3. Seized bearings. Replace bushings.

4. Burned commentator or brushes Replace brushes; clean commentator.

5. Bad switch at console. Check voltage and continuity. Replace if switch

is the cause.

Problem B: Engine Cranks But Will Not Start

PROBABLE CAUSE REMEDY

1. Slow cranking speed Refer to A

2. Low ambient temperature Using starting aid (ether) below 15°F. Check engine
manual to be certain ether starting is approved

3. Engine not getting fuel Check fuel tank level, fuel filters, fuel lines, valves,
supply and return, and fuel pump

4. Check Normal Kill cylinder to see if it is stuck Repair or remove and replace normal kill cylinder
in Kill position

5. Throttle linkage binding Check linkage and make adjustments as necessary

6. Poor quality fuel, incorrect fuel or water in fuel Drain fuel, change filters, and replace fuel

7. Improper oil viscosity Drain oil, change filters, and replace oil

8. Check the Emergency Kill “Flapper” to see if it Reset Emergency Kill “Flapper”.
is in closed position.

Problem C: Engine Misfiring

PAGE 118
 HYDRA RIG MAINTENANCE AND TROUBLESHOOTING

PROBABLE CAUSE REMEDY

1. Poor quality fuel Drain fuel, change filters, and replace fuel

2. Air in fuel system Check for air in fuel system mainly on suction side
of fuel pump.

3. Broken or leaking fuel lines Check for fuel leaks and replace defective parts

4. Restrictions in fuel lines Check fuel flow. Replace fuel lines as necessary

5. Low fuel pressure Check fuel level and kinks in fuel lines. Change fuel
filters

6. Defective fuel injectors or pump Contact authorized engine repair representative

Problem D: Engine Stalls

PROBABLE CAUSE REMEDY

1. Fuel tank vent plugged Check tank vent and repair as necessary

2. Low fuel supply Refer to C, Item 5

3. High parasitic loading (e.g., LN2 pump Check for engine loading during starting
hydraulic pump speed control.)

Problem E: Erratic Engine Speed

PROBABLE CAUSE REMEDY

1. Air leaks in fuel suction line Check for air leaks and repair as necessary

2. Throttle linkage loose Check throttle linkage

3. Engine governor problems Contact authorized repair representative

PAGE 119
 HYDRA RIG MAINTENANCE AND TROUBLESHOOTING

Problem F: Low Power

PROBABLE CAUSE REMEDY

1. Restrictions in air intake system, clogged air Check air pressure in air inlet manifold. Replace air
filter filter and make necessary repairs to air system

2. Poor fuel quality Refer to B, Item 6

3. Damaged or restrictions in throttle linkage Check linkage, adjust or replace if necessary

4. Emergency Kill “Flapper” partially closed Check “Flapper”, reset or repair as necessary

5. Normal Kill cylinder partially extended Reset cylinder or Repair as needed

Problem G: Engine Over-Heating

PROBABLE CAUSE REMEDY

1. Coolant level low Determine cause, replace defective parts and replace
coolant

2. Expansion tank cap Replace expansion cap

3. Defective thermostat Replace thermostat

4. Defective coolant pump Replace coolant pump

5. Fan not engaging fully (full RPM) or turning Inspect fan speed. Repair as necessary

Problem H: Low Engine Oil Pressure

PROBABLE CAUSE REMEDY

1. Oil leakage, low level Check for leaks and repair as necessary

2. Incorrect oil viscosity Drain oil, change filters and replace oil

3. Defective oil gauge Replace oil gauge

4. Clogged oil filter Replace oil and filters

5. Defective oil pump Contact authorized repair representative

6. Excessive engine wear Contact authorized repair representative

PAGE 120
 HYDRA RIG MAINTENANCE AND TROUBLESHOOTING

Problem I: Oil In Coolant

PROBABLE CAUSE REMEDY

1. Defective oil cooler core or seals Contact authorized repair representative

2. Blown head gasket Contact authorized repair representative

Problem J: Coolant In Oil

PROBABLE CAUSE REMEDY

1. Defective oil coolant core or seals Contact authorized repair representative

2. Blown head gasket Contact authorized repair representative

3. Defective coolant pump Contact authorized repair representative

4. Cylinder sleeve seals failure Contact authorized repair representative

PAGE 121
 HYDRA RIG MAINTENANCE AND TROUBLESHOOTING

Nitrogen Pumping System Troubleshooting Guide

Problem A: Low Flow Rate To Unit From LN2 Tank

PROBABLE CAUSE REMEDY

1. Low tank pressure Increase tank pressure

2. Supply valve not fully open Open valve fully on LN2 tank and skid

3. Return valve closed or partially closed Open valve fully on LN2 tank and skid

4. Suction strainer on LN2 tank clogged Clean or replace strainer

5. Y strainer on skid clogged Clean or replace strainer

6. Clogged piping or transfer hoses Inspect piping and hoses to insure free flow

Problem B: Moisture In Stem Packing

PROBABLE CAUSE REMEDY

Moisture in stem packing Thaw valve and dry out packing

Problem C: Boost Pump Will Not Turn

PROBABLE CAUSE REMEDY

1. Hydraulic valve closed at boost pump Open valve

2. Locked up from ice formation Turn the shaft coupling with a pipe wrench. Do not
use excessive force. If pump will not turn, thaw out
and dry out pump

3. Suction valve to hydraulic pump closed Open valve

4. Defective hydraulic pump Disconnect motor supply hose. Plug hose and cap
motor. Test pump pressure if pump does not build
pressure. Check system relief valve. If relief valve
is all right, remove and replace pump

5. Defective motor. Replace motor

6. Defective sequence valve Replace sequence valve.

PAGE 122
 HYDRA RIG MAINTENANCE AND TROUBLESHOOTING

Problem D: Triplex Pump Will Not Rotate.

PROBABLE CAUSE REMEDY

1. Improperly adjusted cold end. Adjust cold end properly

2. Over pressure shutdown is active or tripped Reset to operating position

3. Check pump drive coupling to insure drive Replace damaged or broken drive coupling
components are not slipping off input shaft

4. Check main system pressure. If pressure rises Remove Triplex dump drive coupling. Attempt to
above required to drive Triplex, one of the rotate Triplex. If hydraulic motor and reduction
following is locked up: gearbox rotate, the Triplex is locked up. If the
motor and reduction gear box do not turn, remove
• Hydraulic drive motor.
motor from the gearbox and attempt to rotate
• Reduction gear box motor. If the hydraulic motor rotates, the gearbox
• Triplex pump should be repaired or replaced. If the hydraulic
motor does not turn, repair or replace the hydraulic
motor

PAGE 123
 HYDRA RIG MAINTENANCE AND TROUBLESHOOTING

Tank Troubleshooting Guide

Problem A: Low Flow Rate To Pumping Skid

PROBABLE CAUSE REMEDY

1. Low tank pressure Build pressure on LN2 tank

2. One or more valves required for liquid supply Check supply and return valves to make sure they
not fully open are fully open

3. Ice or contamination in supply line filters Check for ice or contamination in LN2 supply
filters/strainers

Problem B: Frozen Valve Stem

PROBABLE CAUSE REMEDY

Moisture in stem packing Thaw and dry valve packing and packing gland with
dry nitrogen gas

Problem C: Valve Leaking Vapor And Liquid

PROBABLE CAUSE REMEDY

Foreign material or ice on valve seat Disassemble valve and repair or replace as required

Problem D: Tank Will Not Build Or Maintain Pressure

PROBABLE CAUSE REMEDY

1. Line to pressure building coil obstruction. Ice Clear obstruction and/or open valve
or valve closed

2. Low liquid level Fill tank

3. Leak to atmosphere Locate leak and repair

Problem E: Excessive Tank Pressure

PAGE 124
 HYDRA RIG MAINTENANCE AND TROUBLESHOOTING

PROBABLE CAUSE REMEDY

1. Defective pressure gauge Check indicator. Replace if necessary

2. Road relief not functioning Repair or replace road relief as required

3. Pressure building valve open Close valve

NOTE: FOR FURTHER ASSISTANCE CALL HYDRA RIG SERVICE DEPARTMENT

(817) 457-1521.

PAGE 125
 COLD END

COLD END
INSTALLATION AND MAINTENANCE

1. General
It is recommended that any major maintenance on cold ends be done at Hydra Rig, where
proper tools, parts, facilities, and experienced personnel are available. Field replacement
of many components can be made by trained personnel. Procedures for cold end removal,
installation, disassembly, and assembly are as follows.
2. Cold End Removal Procedure
• Disconnect suction, vent, equalizing and discharge lines. Cover open lines to prevent
contaminates from entering.

• Loosen and remove coupling clamp screw, lockwasher and coupling clamp that
couples cold end piston to piston knob.

• Loosen large jam nut on cold end.

• Remove cold end assembly from intermediate by unscrewing.

3. Cold End Installation Procedure

Note: Use clean tools in a clean work area. Replacement cold end assemblies have been
cleaned at the factory. Caution should be exercised to prevent contaminating any internal fittings
or tubing during replacement.

• Thoroughly clean internal and external threads of the intermediate and cold end
respectively. Inspect threads for damage and correct if necessary.

• Lightly coat internal and external threads with a suitable anticease compound; no
heavy grease.

• Rotate pump until cross head is in full discharge position (End of crosshead is as far
away from crank shaft as possible).

PAGE 1 OF 4
 COLD END

• Screw cold end into intermediate until it bumps shoulder, back up until fittings are in
correct position (Large suction fittings on bottom).

• Use the long socket head cap screw from the coupling clamp, place the bolt across the
end of the cold end piston, rotate pump until the crosshead bottoms the cold end
piston solid against the discharge end of cold end.

• Rotate the pump backwards slightly to remove the bolt.

• Rotate pump until the crosshead is in the extreme discharge position, (Meaning the
crosshead end is as close to the piston as possible, and at the point of changing
directions).

• Measure the gap between the end of the cross head and the end of the cold end piston,
the gap must be 1/8 inch to 3/16 inch, if not, back cold end up 1 turn and measure,
repeat until you obtain the clearance and then install coupling clamp and socket head
capscrew and tighten.

• Rotate pump at least a full turn to make sure cold end piston is not bottoming out on
discharge end of pump, if it does, back off one more turn.

• Repeat above steps on each cold end.

• Start suction fittings by hand. Do not tighten yet.

• Start top (vent) fittings by hand.

• Tighten suction fittings and top (vent) fittings tight.

• Tighten the lock nut on the cold end.

• Install discharge lines and tighten.

4. Disassembly of the Cold End

Note: Replace all seals, gasket, piston rings, rider rings and scraper ring each time cold
end is disassembled.

• During disassembly of the cold end, care should be taken to keep all parts free of
moisture, lubricants, and foreign materials.

• Remove intermediate jam nut.

• Remove packing nut, retaining ring, and scraper ring from packing nut.

PAGE 2 OF 4
 COLD END

• If the piston is loose, pull it from the cylinder together with the low pressure seal
elements. If the piston is tight, remove it after the pump head is removed.

• Loosen discharge nut and set screws. Unscrew discharge nut from cylinder.

• Remove discharge fitting, gasket, seal, spring and poppet.

• Remove pump head and head gasket.

• Remove suction valve plate and spring.

• The suction and discharge valve sealing faces should be lapped for proper flatness and
sealing surfaces if flaws are indicated. (It is recommended that this be done by Hydra
Rig).

• If piston was not removed previously, press it through the head end of the housing.

• Remove piston and expander rings from the piston.

• If not previously removed, remove 0-ring, seal ring, hat seal, seal spacers, belleville
springs and spring spacer.

• Inspect all metal parts, (e.g. piston and sleeve) for signs of wear or damage and
replace where necessary.

• Heat housing to 300 degrees and using sleeve removal tool, press sleeve from
housing. (Sleeve may come out after heating).

5. Assembly of the Cold End

Note: Clean all parts prior to assembling according to service requirements, (Clean with
alcohol for nitrogen service). During assembly of cold end, care should be taken to keep
all parts free of moisture, lubricants, and foreign materials.

• Install rider ring, piston ring expanders and piston rings. All piston ring cuts should be
120 degrees out of phase with each other and expander right joints.

• Install piston into sleeve using split installation tool.

• Install sleeve with piston into housing.

• Install belleville spacer.

• Install belleville springs with inside edges together, allowing outer edges to deflect.

• Install seal spacers with chamber outwards in sequence with hat seals with lip inward.

PAGE 3 OF 4
 COLD END

• Install O-ring (Lubricate lightly with silicone lubricant) and seal ring.

• Install scraper and retaining ring in packing nut assembly.

• Lubricate threads lightly and install packing nut. Tighten to approximately 15-20 foot
pounds.

• Install lock nut. Lubricate thread lightly.

• Turn cylinder assembly so that discharge end is up. Install suction valve spring and
valve plate in cylinder. The valve and spring must operate freely in the cavity.

• Install head gasket.

• Install pump head.

• Install wedge seal.

• Install discharge gasket.

• Lubricate set screws and install in the discharge nut so that they are just flush with the
inside surface.

• Install the discharge poppet, with rider ring, spring, and discharge fitting.

• Lubricate the discharge nut threads lightly and install. Tighten set screws gradually
and evenly to the specified torque of 47-50 foot pounds.

• Cap or plug suction, vent, and discharge ports.

PAGE 4 OF 4
 AAD00002 AIR DRYER

AAD00002
AIR DRYER

INTRODUCTION
The AAD00002 Air Dryer is designed and built to provide thousands of miles and years
of trouble-free service. Periodic or scheduled maintenance is not required. For continuous
trouble-free operation, the following items should be checked occasionally.
• Steam clean cooling fins to remove accumulated road grime.

• Check to be sure the cooling fins have not been accidentally painted.

• Check air lines to be sure they have not become kinked, cracked, broken or chafed.

• Check and compare the temperature at the air dryer inlet and outlet ports. This check can be made by
holding a hand on each of the port areas.

WARNING
THE INLET PORT MAY BE VERY HOT

The inlet port should be warmer than the outlet port; the outlet port should be at or
slightly above ambient temperature.

Note: NOTE: Since The Vehicle Is Stationay, The Air Dryer Will Become Warmer Than
Normally Experienced During Over The Road Operation. If Both Inlet And Outlet
Temperatures Are High Or At The Same Temperature (Approximately 150°F), The
Deflector May Need Servicing.

• If the air compressor is rebuilt or replaced or if the air dryer is moved from one vehicle to another, it is
recommended that the unit be completely disassembled and cleaned.

PAGE 1 OF 7
 AAD00002 AIR DRYER

TECHNICAL SPECIFICATIONS
Weight............................................................................................................ 22lbs (9.98kg)
Size
Length......................................................................................................18.50in. (47cm)
Diameter.................................................................................................. 6.75in. (17cm)
Material ................................................................................................. Die Cast Aluminum
Recommended Application............................................................................12 To 14.5cfm
Amperage Draw
12v.........................................................................................................................4.2amp
24v.........................................................................................................................2.1amp
Inlet And Outlet Fitting Size..................................................................................... 0.50npt
Unloader Port Fitting Size ........................................................................................ 0.25npt
Temperature Drop ........................................................................................................100°F
Recommended Service Interval
Filter ....................................................................Service When Compressor Is Serviced
Check Valve ........................................................Service When Compressor Is Serviced
Unloader Valve ...................................................Service When Compressor Is Serviced
Deflector...............................................................Scheduled Maintenance Not Required

PAGE 2 OF 7
 AAD00002 AIR DRYER

This illustration is of a vertical mount unit.

Horizontal mount units are exactly the same except for bottom cap configuration.

PAGE 3 OF 7
 AAD00002 AIR DRYER

PARTS LIST
ITEM DESRIPTION QTY
A NUT 1
B GASKET 2
C SPINDLE 1
D SPINDLE 1
E SAFTEY VALVE 1
F TOP CAP 1
G HEX HEAD SCREW (3/8-16 X 1) 8
H GASKET 3
I SPRING 1
J FILTER CUP 1
K FILTER (STAINLESS STEEL) 1
L STRAINER 1
M V - SPRING 1
N PACKING RING 1
O NUT HEX (3/8-16) 3
P 3/8 EXT. TOOTH LOCKWASHER 3
Q WASHER 2
R SUPPORT ROD 1
S DEFLECTOR 1
T BODY 1
U DEFLECTOR SUPPORT PLATE 1
V BOTTOM CAP 1
W BOLT 8
X UNLOADER NUT 1
Y SLEEVE 1
Z PISTON 1
AA O-RING 1
BB U-CUP 1
CC SPRING 1
DD RETAINING RING 1
EE THERMOSTAT 1
FF HEATER STANDARD 1
HEATER OPTIONAL
GG SPRING 1
HH SEAT RING 1
II SPINDLE 1
JJ GASKET 2
SPROCKET ASSEMBLY (not shown) 1

PAGE 4 OF 7
 AAD00002 AIR DRYER

TROUBLESHOOTING
PROBLEM EXPLANATION SOLUTION
A. Air is exhausted from the 1. Inlet side of the compres- 1. Consider changing the
exhaust part of the air dryer soris connected to the outlet compressor inlet connection.
when the compressor is in side of the turbocharger. 2. Clean or replace the
the stand-by mode. 2. Check valve at the outlet of check valve assembly.
the air dryer is stuck open. 3. Repair or replace.
3. Governor valve is defec-tive. 4. Replace.
4. Unloader piston needs
service.
B. System air pressure 1. Leak in air line connec- 1. Tighten or replace fittings.
bleeds off rapidly when air tion(s). 2. Repair or replace faulty
operated equipment is not 2. Leak in air line or reservoir. item(s).
being used. 3. Check valve at the outlet of 3. Clean or replace the
the air dryer is stuck open. check valve assembly.
C. Compressor goes into the 1. Leak in air system. 1. Correct the leak.
“stand-by” mode but cycles 2. Check valve in the air dryer 2. Clean or replace the
rapidly. outlet port is stuck open. check valve assembly.
3. Defective seal in the un- 3. Replace the unloader
loader. valve.
4. Unloader sleeve is defec- 4.Replace the unloader
tive. valve.
5. Governor valve is defec-tive. 5. Repair or replace
6. Unloader valves th the governor valve.
compressor are sticking. 6. Repair unloader valves in
7. Air line from the reservoir is compressor.
partially blocked. 7. Clean or replace the air
lines.
D. Compressor runs 1. Leak in air line connec- 1. Tighten or replace fittings.
continuously (will not go into tion(s). 2. Repair or replace faulty
the stand-by mode). 2. Leak in the air line or res- item(s).
ervoir. 3. Rebuild or replace the
3. Compressor is defective. compressor.
4. Unloader valve is stuck 4. Clean or replace unloader
open. valve assembly.
5. Compressor capacity is too 5. Install a larger
low for the vehicle. compressor.

PAGE 5 OF 7
 AAD00002 AIR DRYER

PROBLEM EXPLANATION SOLUTION

E. Air flows from the exhaust 1. Unloader valve is stuck 1. Rebuild the unloader
port when the compressor is open. valve.
attempting to build-up 2. Seat or unloader valve is 2. Rebuild the unloader
pressure in the air system. chipped or nicked. valve.
3.Piece or dirt or foreign mat- 3. Rebuild the unloader
erial is stuck in the unloader valve.
valve. 4. Replace the valve or
4. Unloader valve is held open install a heater.
by ice.
F. Compressor attempts to 1. See item “D”. 1. See item “D”.
build pressure but system 2.The line between the com- 2. Replace the line or
pressure will not build up. pressor and the air dryer is remove blockage.
blocked. 3. Clean the outlet and
3. Check valve in the air dryer replace the check valve.
outlet is stuck or closed. 4. Replace the device.
4. Pressure sensing device is 5. Remove the blockage.
defective. replace the device.
5. Blockage is in the air line
between the compressor and
sensing device. (If the air
dryer’s safety valve opens,
blockage is after the unit).
G. The air dryer does not 1. Mounted in a location where 1. Relocate the unit.
cool air (initial installation). it cannot be cooled by ambient
air. 2. Relocate the unit.
2. Mounted too close to heat
producing equipment or too
near other heat dissipating 3. Increase the length of
equipment. copper tubing.
3. Copper tubing from the
compressor to the air dryer inlet
is too short.
H. Air dryer does not 1. UNL port of governor is 1. Connect or repair the line.
“unload” when the either not connected to the air
compressor goes into the dryer’s unloader port, or the 2. Replace the unloader
stand-by mode. line is broken. valve.
2. Unloader valve compo-nents
are worn. 3. Replace the heater or
3. Ice has formed in the un- check electrical connections.
loader valve.
4. Air dryer heater is not
operating.

PAGE 6 OF 7
 AAD00002 AIR DRYER

PROBLEM EXPLANATION SOLUTION

I. Safety valve in the air dryer 1. Check valve in the outlet is 1. Clean the outlet and
opens. stuck closed. replace the check valve
2.Obstruction is in the air line assembly.
beyond the air dryer. 2. Remove the obstruction.
3. Compressor governor valve 3. Replace the valve.
is defective. 4. Replace the valve.
4. Safety valve is defective.
J. Water exhausted by the 1. Compressor rings are de- 1. Rebuild or replace the
air dryer contains excessive fective. compressor.
oil and/or soot.
K. No water is exhausted 1. Insufficient water in am-bient 1. No solution necessary.
during the unloading cycle. (inlet) air.
2. Air dryer is not cooling air 2. Relocate the air dryer to
sufficiently to condense water. an area with greater ambient
air flow.
L. Air dryer unit removed 1. Covered with dirt or paint. 1. Steam clean and/or
moisture after initial instal- 2. Deflector is damaged or remove paint.
lation but no longer removes broken. 2.Replace the deflector
moisture from the system. assembly.

PAGE 7 OF 7
 CPC00081 CENTRIFUGAL PUMP

CPC00081
CENTRIFUGAL PUMP
OPERATIONS AND MAINTENANCE MANUAL

CONTENTS

Section

1.0 Maintenance Guide (Troubleshooting)

2.0 Inspection and Maintenance
3.0 Lubrication
4.0 Disassembly
5.0 Reassembly

PAGE 1 OF 11
 CPC00081 CENTRIFUGAL PUMP

1.0 Maintenance Guide (Troubleshooting)

Until the operating personnel become familiar with the pump, the following are the most
probable causes of operational difficulties:

Pump will not prime Wrong rotation

Insufficient suction pressure

Liquid not delivered Pump not primed

Vapour pocket in suction line

Failure to deliver rated Available NPSH not sufficient

capacity and pressure Wrong rotation
Loss of suction pressure
Impeller or volute passages clogged
Worn wear rings
Impeller damaged
Vapour in liquid
Vapour pocket in suction line
Total head greater than head for which pump
was designed

Pump overload driver Flow greater than rated flow

Low voltage or other electrical trouble

Pump vibration Available NPSH not sufficient

Vapour in liquid
Worn bearings
Damaged rotating element
Foundation not rigid
Pump operating below minimum recommended
Flow

PAGE 2 OF 11
 CPC00081 CENTRIFUGAL PUMP

2.0 Inspection And Maintenance

For satisfactory operation and long pump life, the following inspection and maintenance
is recommended:

2.1 Every Month

General visual inspection of the pump.

2.2 Every Three Months

Inspect bellows shaft seal assembly and replace if necessary. Check bearings for
wear and replace if necessary. Check valves, gauges, etc., for condition and
accuracy.

2.3 Every Twelve Months

Thoroughly check entire pump system. Disassemble pump and motor

completely. Inspect all parts for wear and replace parts if necessary.

3.0 Lubrication

3.1 The direct-coupled hydraulic motor driven foot mount pump is equipped with
sealed, grease-lubricated ball bearings. No lubrication maintenance is required
for the life of these bearings.

3.2 The flexible-gear coupling requires lubrication, after each 4000 hours of use, as
follows (coupling removed from the shaft - see section 4.0).

a. Remove one snap ring and slide the sleeve off of the hubs. (A seal will be
forced out of one end by this operation).

b. Clean parts thoroughly to remove all of the old lubricant and inspect seals for
damage.

c. Hand-pack hub and sleeve teeth with grease, forcing some of the grease
between the hub faces to provide a reserve of lubricant. Lightly coat both
seals with grease. Reassemble.

PAGE 3 OF 11
 CPC00081 CENTRIFUGAL PUMP

NOTE To relubricate without disassembling the coupling, remove both lube

plugs, located in the sleeve, and position the holes at 45° to horizontal. Force
grease into the top hole until clean grease flows out of the opposite hole.
Reinstall plugs.
4.0 Disassembly

The following outlined procedure will assist in the disassembly - reassembly of the
pumps. Also, refer to the assembly drawing.

4.1 Disconnect and cap-off all hydraulic lines to the motor parts to keep all foreign
matter out during the disassembly - reassembly operation.

4.2 Remove the suction and discharge lines from the pump volute. If convenient,
detach the pump from its foundation and place on a clean bench.

4.3 Prepare a clean area large enough to lay the parts out in the sequence they are
removed from the pump to aid reassembling the parts in reverse order of
disassembly.

4.4 Remove the bolts fastening the volute and bearing housing together. Carefully
remove the volute and the spiral wound gasket from the bearing housing.

NOTE DO NOT FORCE - THE IMPELLER CAN BE DAMAGED.

4.5 Remove the impeller screw (right hand thread) along with its star lock washer
and safety wire.

4.6 Slide the impeller and impeller cap off the shaft. Do not force in any manner
that could damage the impeller. Remove the impeller key.

4.7 Slip the rotating seal ring (do not touch the ring face with fingers or allow it to
become scratched or dirty) from the shaft. Remove the shims.

4.8 Remove the backplate, complete with the bellows seal assembly and insulator
ring.

4.9 Place the backplate assembly in a vice or similar holding device that will not
damage the backplate while removing the bellows seal assembly. Unscrew the
bellows seal assembly (left hand thread) out of the backplate.

PAGE 4 OF 11
 CPC00081 CENTRIFUGAL PUMP

CAUTION
IT IS RECOMMENDED THAT THE SEAL ASSEMBLY BE REMOVED/REPLACED
USING A SEAL TOOL DESIGNED AND MADE FOR THIS PURPOSE.

NOTE Pumps fitted with the alternative lip seal will require the lip seal to be
removed from its housing using a suitable drift taking care not to damage the
housing.
4.10 Loosen the set-screw in the slinger and slide it off of the shaft.

4.11 Remove the cover on the pump in the coupling housing. Loosen the coupling set
screw accessible through the opening the plug was removed from.
4.12 Remove the motor fastening bolts. Slide the hydraulic motor-coupling assembly
out of the coupling housing.

4.13 Loosen the coupling set screw and pull the coupling off of the motor shaft.

4.14 Refer to section 3.2 for coupling lubrication instructions.

4.15 Remove the bearing housing bolts and pull the housing out of the foot-mount
stand.

4.16 Unscrew the bearing locknut (right hand thread) located on the coupling end of
the shaft and recessed into the back of the bearing housing.

4.17 Pull the bearing cap with its backup ring and ‘O’ ring off the shaft.

4.18 Slide the shaft, front bearing and shaft bearing spacer out of the bearing housing.

4.19 Remove the bearing from the opposite end of the bearing housing.

5.0 Reassembly

5.1 Arrange all removed parts in the order of disassembly. Substitute new parts for
worn items.

NOTE Used gaskets and ‘O’ rings often lose their resilience and may not seal, it
is recommended that new ones be used.

5.2 Gaskets and ‘O’ rings may be lightly coated with a lubricant compatible to the
intended service for ease of assembly.

5.3 Assemble the parts in the reverse order of disassembly noting the following
recommended procedures and suggestions:

PAGE 5 OF 11
 CPC00081 CENTRIFUGAL PUMP

5.3.1 Install the bellows seal assembly, with its ‘O’ ring in place, into the
backplate.

5.3.2 Tighten the bellows seal assembly using the recommended seal tool.

PAGE 6 OF 11
 CPC00081 CENTRIFUGAL PUMP

NOTE The bellows seal assembly carbon face and the rotating seal ring face have
both been polished to a super precision finish and flatness at the factory and
must not be damaged in any way. The faces (mating surfaces) must be kept
clean. DO NOT TOUCH EITHER OF THE SEAL FACES WITH THE FINGERS. Do
not alter the factory established length of the bellows.

Lip seals should always be replaces using the relevant seal tool.

The bellows seal assembly supplies both a static and a dynamic seal. Spring
force is employed to hold the seal faces in contact. The seal compression must
be correctly set to establish the spring force required as follows:

CAUTION
MAKE SURE THAT THE BACKPLATE ASSEMBLY IS FIRMLY AGAINST THE
INSULATOR RING GASKET AND THE INTERMEDIATE WHEN THE FOLLOWING
MEASUREMENTS ARE MADE.

5.4 Place the rotating seal ring against the bellows seal assembly carbon face.

5.5 Measure the distance from the surface of the back-side of the rotating seal ring to
the end of the shaft, using a precision depth gauge and measuring to the nearest
thousandth of an inch.

5.6 Press on the back of the rotating seal ring until it bottoms.

5.7 Measure the distance from the surface of the back-side of the rotating seal ring to
the end of the shaft to the nearest thousandth of an inch.

5.8 The difference between the two measurements is the seal compression.

5.9 Install the required number of shims between the shaft shoulder and the rotating
seal ring to establish the seal compression as specified on the assembly drawing.

5.10 Check seal compression after installing shims.

CAUTION
NEVER HAVE MORE COMPRESSION OF THE BELLOWS THAN THE AMOUNT OF
CARBON EXTENDING OUT OF THE METAL CARBON FACE HOLDER IN THE
BELLOWS SEAL ASSEMBLY.

5.11 The impeller screw should be torqued to approximately 150 inch-pounds down
onto its star lock washer.

5.12 Install the safety wire and cut off excess wire.

PAGE 7 OF 11
 CPC00081 CENTRIFUGAL PUMP

5.13 The bolts that join the volute, backplate and intermediate are to be tightened
lightly and uniformly until the insulator ring and gasket is squarely in place.

5.14 Tighten the bolts evenly until the gasket and insulator are sealed.

5.15 Check the shaft for rotation after gasket sealing.

5.16 When the pump is completely reassembled, flush it out to remove any foreign
material that may have accumulated in the passages during reassembly.

PAGE 8 OF 11
CPC00081 CENTRIFUGAL PUMP

PAGE 9 OF 11
 CPC00081 CENTRIFUGAL PUMP

PARTS LIST
ITEM DESCRIPTION QTY
1 Slinger 1
2 Ring, Seal 1
3 Shims AR
4 Bellows type seal or CR026Double Lip Seal & Carrier CR009-9 1
5
6 Volute Assy 1
7 Backplate Assy 1
8 Insulator 1
9 Impeller 1
10 Screw, Impeller 1
11 Cap, Impeller 1
12
13 Shaft (Early type used with bellows seal only) 1
14 Spacer, Shaft, Bearing 1
15 Stand, Foot Mount 1
16 Cap, Bearing 1
17 Housing Assy, Bearing 1
18 Guard 1
19 Washer, Flat - No 8 Reg St. St. 3/16″ 4
20
21 Washer, Star, Lock .3125 St. St. (Purchased) 1
22 Gasket, Spiral Wound 6.532 O.D. x 6.157 I.D. x .125 Thk (Purchased) 1
23 Locknut, Bearing 1
24 Bearing Ball (Purchased) 2
25 Coupling Complete 1
26 Motor, Hydraulic Volvo 1
27 Stud - .312-18 UNC 2A St. St x 1-7/8″ Long 3
28 Key – Impeller 1
29 Key – Coupling 1
30
31 O-Ring 2.0 I.D. x 2.125 O.D. Buna ‘N’ 1
32 O-Ring 1.625 I.D. x 1.8125 O.D. Buna ‘N’ 1
33 Ring, Back-Up 2
34
35 Nut, Hex - .312-18 UNC-2B St.St. 7
36 Washer, Spring St.St. 12
37 Washer, Flat - .312 - Reg St.St. 16

PAGE 10 OF 11
 CPC00081 CENTRIFUGAL PUMP

PARTS LIST
ITEM DESCRIPTION QTY
38
39 Bolt, Hex Head - .312-18 UNC-2A x 2″ Lg At. St 6
40 Screw, Set, Hex Soc, Cup Point 3mm x 0.5mm x 10mm 5
41 Screw, Cap Soc Head #8-32 UNC x .500″ Lg St. St. 4
42 .312-18″ UNC x 1¼″ Long Set Screw 5
43 Wire, Safety -.1/32″ 6
44
45
46 Backplate - Wear Ring 1
47 Volute - Wear Ring 1
48 Shaft (Double Lip Seal Type) 1
49 Shaft Sleeve (For use with Double Lipseal Type Shaft) 1
50 .375 UNC x 1¾″ Set Screw 2
51 .375 Flat Washers 2
52 .375 Spring Washers 2

PAGE 11 OF 11
 HAB00018 ACCUMULATOR

HAB00018
ACCUMULATOR ASSEMBLY

SPECIFICATIONS FOR DISMANTLING AND ASSEMBLING

Dismantling
General Information
The regulations that apply at the point of installation of the accumulator must always be
observed (e.g. accident prevention regulations for pressure vessels).
Never retighten or slacken threaded connectors if the hydraulic system is pressurized.
Before removing an accumulator, the hydraulic system must be turned off and
depressurized. Close all ports in order to prevent hydraulic liquid from running out and
contaminating.

Note: The hydraulic system taken out of operation must be made safe such that no unauthorized
person can switch it on.

The accumulator should be repaired using the sets of seals and wearing parts given in the
spare parts list.
When repairing, maximum cleanliness is necessary. The work bench must be kept free of
dirt (metal swarf and chips etc.)
The dismantled parts must be protected from any kind of damage.
Improper discharge of nitrogen from the accumulator bladder often leads to the gas valve
being damaged. This can happen, for example, if one attempts to reduce the pressure in
the accumulator bladder by removing the gas valve instead of by depressing the pin. This
can cause the valve stem to tear out.
Damaged bladders cannot be repaired. They should be replaced using the sets of
replacement parts.

PAGE 1 OF 17
 HAB00018 ACCUMULATOR

Tools And Aids

Gas-valve Remover

FIGURE 1

FIGURE 2

Clamp accumulator in vise (using two flat iron strips for the accumulator).

Gas Valve

FIGURE 3

PAGE 2 OF 17
 HAB00018 ACCUMULATOR

Unscrew valve guard, remove valve cap and seal ring.

FIGURE 4

Blow off nitrogen: depress pin.

FIGURE 5

PAGE 3 OF 17
 HAB00018 ACCUMULATOR

Unscrew and with draw valve element.

FIGURE 6

Slacken hexagon nut on gas valve.

FIGURE 7

Unscrew bleeder screw.

Liquid Valve

FIGURE 8

PAGE 4 OF 17
 HAB00018 ACCUMULATOR

Undo slotted nut with hook wrench.

FIGURE 9

Remove support ring, seal ring and washer.

FIGURE 10

Remove retaining ring.

FIGURE 11

PAGE 5 OF 17
 HAB00018 ACCUMULATOR

Grip rubber ring.

FIGURE 12

Extract rubber ring.

FIGURE 13

Remove liquid valve from the shell.

FIGURE 14

PAGE 6 OF 17
 HAB00018 ACCUMULATOR

Remove nut and name-plate cap. Slightly fold bladder and pull out while twisting
slightly. If bladder is slippery, hold with rag.
Cleaning:
Wash parts with, for example. trichlorotrifluoroethylene or cold cleansing agent.
Dry parts.
Please note the following when cleaning with trichlorotrifluoroethylene or
perchloroethylene:
Accumulator bladder. O-ring and, rubber ring may not be washed with these. For
parts made of butyl and viton, methylated spirits or water can be used. For parts
made of perbunan, tricnlorotrifluoroethylene or cleaning petrol can be used.

FIGURE 15

Examination
Screw in valve element. Inflate accumulator bladder with compressed air to 1.7 times its
size in the case of perbunan (black) and to 1.4 times its size in the case of butyl (brown).

Accumulator bladder

FIGURE 16

PAGE 7 OF 17
 HAB00018 ACCUMULATOR

Brush over accumulator bladder with soap solution. If soap bubbles are formed, discard.
Exhaust the air immediately after the test. Unscrew and remove the valve element.

FIGURE 17

Examine complete liquid valve for damage and check that the spring functions properly.
In the case of accumulators used for water. check particularly for rust spots.

Liquid Valve

FIGURE 18

Examine inside and outside of shells. Look out especially for damage to the plastic
coating on the inside of certain types of shell.

Shells

FIGURE 19

PAGE 8 OF 17
 HAB00018 ACCUMULATOR

Assembly
General Information
Only nitrogen may be used. Never charge with oxygen or air. Danger of explosion.
Attention must be paid to the information given on the nameplate cap. The nitrogen pre-
charge pressure specified by the machine manufacturer must always be maintained.
Assembly Instructions
Wet bladder and inside of shell with liquid. Fold bladder and screw assembly rod into the
gas valve.

Accumulator Bladder

FIGURE 20

Carefully insert bladder

FIGURE 21

PAGE 9 OF 17
 HAB00018 ACCUMULATOR

Dip valve into the specified pressure liquid and place complete in the accumulator. Fold
the rubber ring, introduce it into the shell and push onto the valve body. In the shell,
center the retaining ring onto the rubber ring and pull the valve body outwards.

Liquid Valve

FIGURE 22

Dip new valve element in oil and screw in. Fill bladder with compressed air while
centering liquid valve and retaining ring. Screw in nut at gas valve.

Gas Valve

FIGURE 23

PAGE 10 OF 17
 HAB00018 ACCUMULATOR

Wind adhesive tape around thread. Slip over support washer (steel). Push seal ring
uniformly into inside of shell using blunted screwdriver. Mound support ring (plastics).

FIGURE 24

Tighten slotted nut. Screw in bleeder screw with new seal ring (observe torque). Release
air from the bladder.

FIGURE 25

Fill in the liquid permitted for the particular accumulator (approx. 1/10 of the
accumulator content). Roll bottle. Accumulator bladder and internal wall of bottle must
be well wetted. Allow liquid to drain off again.

FIGURE 26

PAGE 11 OF 17
 HAB00018 ACCUMULATOR

Specifications And Information For Special Cases:

Hydraulic Accumulator For Use With Water
Since the original test is performed with oil, it is necessary in certain cases (e.g. in
systems with drinking water) for the accumulator to be cleaned before being put into
service. Cleaning must be performed as follows: Observe regulations for handling
inflammable liquids.
• Relieve gas pressure.

• Fill bottle (on the liquid side) 2/3 full with cleaning petrol (perbunan bladder).
Introduce compressed air tube through liquid valve (cover valve aperture with rag).

• Blow in compressed air. After 2-3 minutes pour out cleaning petrol.

• Repeat rinse.

• The fine film of oil on the accumulator bladder can be removed by rinsing again with
soapy water.
Downstream Nitrogen Bottle
If large quantities are drawn off and the pressure difference is small, nitrogen bottles can
be connected downstream. The charge pressure characteristics thus obtain a sharper slope,
i.e., the oil volume available can be drawn off at a lower pressure drop.
If discharging or charging is rapid (adiabatic) it is pointless to connect a nitrogen bottle
because the additional gas volume has no effect as a result of the restrictive action of the
connecting line. It must be ensured in particular that the charge pressure is maintained as
otherwise the bladder will be over loaded.
In order to prevent the bladder failing immediately when overloaded, however, a shut-off
valve is provided at the gas connection shutting off the line to the nitrogen bottle and
preventing greater deformation of the bladder (FIGURE 27)
Additionally, if the connecting line breaks between accumulator and gas bottle. the
escaping gas causes the valve to close. The accumulator discharges until the accumulator
bladder bears against and seals the valve. A sudden pressure drop with the known
consequences is thus avoided.

PAGE 12 OF 17
 HAB00018 ACCUMULATOR

FIGURE 27

Oil Filling In Accumulator Bladders

In order to avoid excessive deformation, oil can be filled into the accumulator bladder. As
a result, an incompressible residue volume remains in the accumulator bladder even in the
case of high-pressure rations.
• Advantage: Higher pressure ratio can be allowed.

• Disadvantage: Capacity of the accumulator is reduced.

Instructions for filling oil into accumulator bladders:

• Filling arrangement for oil:
An intermediate vessel, with a capacity of 0.5 to 1 litre and capable of
withstanding at least 5 bar pressure, should be mounted oil-tight on the gas valve
of the accumulator whose valve element has previously been removed. A nipple
for connecting a compressed air line is screwed in gas-tight into the upper opening
of the intermediate vessel.
• Filling:
Using a funnel, measured sub-quantities of the hydraulic liquid to be filled is
poured into the intermediate vessel. The compressed air line is then connected and
compressed air is used to force the oil out of the intermediate vessel into the
accumulator bladder. This process is repeated until the required quantity of oil has
been filled.

PAGE 13 OF 17
 HAB00018 ACCUMULATOR

Nitrogen Charging Of Hydraulic Accumulators With Charge

Pressures >150bar Gauge Pressure

Hydraulic accumulators approved for maximum pressures of up to 315bar can
require a charge pressure p1>=150 bar (p1=nitrogen pre-charge pressure).
Commercially, nitrogen bottles up to 200bar are approved. There is thus no
difficulty in charging up to 200bar. If the charge pressure p1>=200bar and the
nitrogen bottle charge<=200 bar, a circuit arrangement as shown in is required for
the charging operation.
Charging With Gas Requirements
• A circuit arrangement (e.g. oil reservoir with hydraulic pump. adjustable pres-
sure limiting valve, flow control valve D1, and pressure gauge M2).
• An auxiliary accumulator
• A connector with non-return valve fitted.
• The charging device.
• Hoses
• Adapters for nitrogen bottle
• Cross-type screw fitting for pipe diameter 6 mm, nominal pressure 400bar
gauge.
• Connecting pipe 6 mm dia. with cutting ring and lock nut for nominal pressure
400bar.
Charging Operation
• Connect charging device to the hydraulic accumulator to be filled. Connect
auxiliary accumulator (without gas valve) and gas bottles to the HY circuit as
shown in Fig. 29.
• Open valves V1 until no further pressure increase is shown on the pressure
gauge M1. Close valves V1.
NOTE: The pressure indication on the pressure gauge M1 may not be less than 140bar
gauge pressure (danger of damaging the auxiliary accumulator bladder).

• Open flow control valve D1. Allow pump to run. Slowly close DI and read
charge pressure on pressure gauge M1. Switch off pump. If the desired charge
pressure is not reached during a charging operation, then it must be repeated
as often as necessary. After each charging operation carefully open bleeder
valve on the charging device and reduce pressure to approx. 140bar (necessary
in order to check the gas bottle contents at the next charge).

PAGE 14 OF 17
 HAB00018 ACCUMULATOR

NOTE: In order to be able to reach the charge pressure, a sufficient number of nitrogen bottles are
required. The auxiliary accumulator may also be a HY piston accumulator with suitable volume
and operating pressure (max. 315bar).

• After the charging operation, open flow control valve D1 until no more pres-
sure is shown on M2. Allow nitrogen in the hose to escape through the bleeder
valve on the charging device until M1 indicates no pressure.

Safety Valves
According to German accident prevention regulations, each accumulator shell must be
provided with a suitable safety valve. These valves are tested in the factory in accordance
with TOV (technical inspector) instructions. A certificate for the component symbol is
supplied with each safety valve. After repair the safety valves and connection blocks must
be checked. accepted and sealed by the TOV (Bosch seal is inadmissible).

FIGURE 28

FIGURE 29

Storing Accumulator Bladders

Accumulator bladders must be stored in a dark room, cool and dry. They should not be
located near electrically operated machines (ozone formation). Hang up the bladders
filled with air on the gas valve (no greater that atmospheric pressure) and use them in the
order of manufacturing dates (stamped on to the gas valve).

PAGE 15 OF 17
 HAB00018 ACCUMULATOR

Notes For Sealing

The valve guard can be sealed to protect against unauthorized modification of the pre-
charge pressure.
Fitting
Take both wire ends through the hole in the valve guard. fit seal (resting directly
on the valve guard). Firmly tighten both wire ends, wind them together and then
seal.
The lower wire end must always be in the angle greater than 0° referred to the
valve guard direction of rotation 'slack'.

FIGURE 30

Transportation Of Hydraulic Accumulators

The valve guard can be sealed to protect against unauthorized modification of the pre-
charge pressure.

PAGE 16 OF 17
 HAB00018 ACCUMULATOR

Troubleshooting
Type of damage: Cause: Repair:

Charge pressure drop due to:

• External leaks: Seal under the screw plug is Fit new seal.
defective
Gas can escape through the screw
plug.
• Internal leaks: • Charge pressure too small, The causes to the left are
Gas mixes with the hydraulic Diaphragm is punched Maintenance or layout faults
oil. Through on the gas side. Eliminate causes, install new
• Discharge velocity is >8m/sec. Diaphragm-type accumulator.
This results in the diaphragm being
pierced on the liquid side
mushroom unbuttons.
• Intake velocity is >8m/sec. The
button in the diaphragm is
unbuttoned.

PAGE 17 OF 17
HAB00036 ACCUMULATOR

HAB00036

ACCUMULATOR

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HAB00036 ACCUMULATOR

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HAB00036 ACCUMULATOR

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HAB00036 ACCUMULATOR

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HAB00036 ACCUMULATOR

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HAB00036 ACCUMULATOR

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HAB00036 ACCUMULATOR

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HAB00036 ACCUMULATOR

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 HMP00116 HYDRAULIC MOTOR

HMP00116
HYDRAULIC MOTOR

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HMP00116 HYDRAULIC MOTOR

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HMP00116 HYDRAULIC MOTOR

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HMP00116 HYDRAULIC MOTOR

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HMP00116 HYDRAULIC MOTOR

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HMP00116 HYDRAULIC MOTOR

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HMP00116 HYDRAULIC MOTOR

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HMP00116 HYDRAULIC MOTOR

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HMP00116 HYDRAULIC MOTOR

PAGE 17 OF 17
 HPG00072 FIXED DISPLACMENT GEAR PUMP

HPG00072

FIXED DISPLACEMENT GEAR PUMP

FEATURES

• Pressure Loaded Design

• Efficient, Simple Design - Few Moving Parts

• Exceptionally Compact and Lightweight for Their Capacity

• Efficient At High Pressure Operation

• Resistant to Cavitation Effects

• High Tolerance to System Contamination

• Reliable Under Cold Weather Operation

• Sleeve Bearing Construction

• Multi-Fluid Compatibility

CONTROLS

• Optional Built In Relief Valve

• Optional Built In Relief Valve and Flow Divider

SPECIFICATIONS
Flow Ratings ........................ 2.5 GPM (9.5 LPM) to 9.3 GPM (35.2 LPM) (at 1000 RPM)
Pressure Ratings..................................................................................... 1500 PSI (103 Bar)
Speed Ratings....................................................................................................... 3600 RPM
Mountings ..... SAE-A - 2 Bolt Flange (Optional SAE-A - 2 Bolt Flange Ext. Front Cover)
Housing Material .................................................................................. Die Cast Aluminum

PAGE 1 OF 5
 HPG00072 FIXED DISPLACMENT GEAR PUMP

INLET CONDITIONS

• 10 In. Hg. Maximum Vacuum Condition (At 1800 RPM)

• 5 In. Hg. Maximum Vacuum Condition (At Maximum RPM)

• 20 PSI (1.4 Bar) Maximum Positive Pressure

OPERATING TEMPERATURE
-40°F to 185°F (-40°C to 85°C)

FILTRATION
Maintain SAE Class 4

PERFORMANCE DATA
Data Based on 100 SSU

Flow In Gallons Per Minute - GPM (LPM) Viscosity Fluids at 120°F (49°C)

Displacement RPM 100 PSI 1000 PSI 1500 PSI

IN³ (CC/REV) (6.9 Bar) (69 Bar) (103 Bar)

1200 11.20 10.90 10.80

(42.45) (41.31) (40.93)
2.227 (36.50) 1800 16.70 16.50 16.30
(63.29) (62.54) (61.78)
3600 33.50 33.20 33.10
(125.97) (125.63) (125.45)

PAGE 2 OF 5
 HPG00072 FIXED DISPLACMENT GEAR PUMP

INSTALLATION INFORMATION
Filtration

For maximum pump and system component life, the system should be protected
from contamination at a level not to exceed 125 particles greater than 10 microns
per milliliter of fluid (SAE Class 4).

Fluid Compatibility

• Petroleum based fluid

• Water glycols

• Water emulsions

• Transmission fluid

• Mineral oil fluid

NOTE: All data in catalog are based on petroleum based fluid. Pump
pressure reduced by 1/2 of specified rating, pump speed rating reduced
by 1000 RPM from specified rating and “DU” bushings must be used
when pump operates on water glycols and water emulsions. Consult
factory for special fluids.
Start-Up

On any start-up where the pump suction line is empty of fluid, the circuit should be
open to permit priming.

Inlet Conditions

Not to exceed 10 in. Hg. at 1800 RPM or 5 in. Hg. at pump maximum rated RPM.
Inlet positive pressure not to exceed 20 PSI (1.4 Bar) maximum.

Shaft Rotation And Line Up

Pump and motor shaft alignment must be within .007 inches total indicator
reading. Please follow coupling manufacturer's recommended installation
instructions to prevent end thrust on pump shaft. Turn pump by hand to assure
freedom of rotation. Pump and motor must be on a rigid base.

The coupling should be sized to absorb the peak horsepower developed.

PAGE 3 OF 5
 HPG00072 FIXED DISPLACMENT GEAR PUMP

Instructions for Reversing Gear Pump Rotation

• The basic tools needed are a vise, preferably with soft jaws, a torque wrench, a thin
screwdriver, a small hone stone, a ratchet, a paper clip and an additional 1/4" hex
head driver. It is also recommended that you have on hand a few extra heat shields
and gaskets.

• To change rotation, hold the pump by the rear cover with the drive shaft pointing up.
Remove all the bolts (six hex and two allen head). At this time, it would be helpful to
scribe a line down the outlet side of the pump. If not marked, the outlet port is usually
the smallest.

• If the pump has a key type shaft, remove the key and hone down any burrs that may
be on the shaft. This is important as the next step will be to lift off the front cover and
any sharp edges could possibly damage the front seal or bearing.

• After the front cover is off, note the position of the little vent hole in the bronze wear
plate, which should have come off with the front cover. The parts underneath also
have a similar vent hole.

• Remove in order, the wear plate, the heat shield, gasket and V-seal. To facilitate this,
make a little hook with a paper clip and lift up the part high enough to slip a
screwdriver under and carefully pry up. Please note, the heat shield, in particular, is
very brittle and may crack if bent.

• After removing these four parts, reinstall the V-seal with the lips down in the front
cover so that the vent hole is on the opposite side across from the reference mark. Use
the screwdriver to seat it completely. Next, install the gasket, heat shield, and wear
plate; again with the vent hole in line with that of the V-seal. The wear plate should
be almost flush with the surface of the front cover. You may have to go back and tuck
in, here or there, so that it is flush.

• Remove the center section and note the notch cut on the inside. This will be installed
in line and next to the vent hole in the wear plate. The dowel pins used to locate the
center section may be removed temporarily to facilitate sliding the center section over
the gear assemblies. Be careful not to pinch the o-ring between the front cover and
center section. If it doesn't want to stay in place, it can be "glued" using heavy grease.

• Install the thrust plate into the center section orienting the side with the bar in line
with the vent hole, ensuring that the bronze side faces the gears.

• The rear cover is installed with the outlet side in line with the vent hole. The outlet
side will be marked or can be identified by the smaller cavity internally. As when
installing the center section, be careful not to pinch the o-ring seal.

PAGE 4 OF 5
 HPG00072 FIXED DISPLACMENT GEAR PUMP

• To check your work, the line that was originally scribed on the side should now be
located 180° on the rear cover and center section from that on the front cover.

• Install the bolts and snug them down by hand. Then torque to the proper setting,
alternating from side to side. The correct torque specifications are 190-210" lbs.
Reverse or remove the rotation arrow originally stamped on the mounting flange.

Testing Procedure

After pump has been reinstalled, run for 2-3 minutes before pressurizing.
Try to apply pressure gradually for an additional five minutes, but do not
pressurize for longer than 5 seconds at a time.

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 HPG00085 HYDRAULIC GEAR PUMP

HPG00085

HYDRAULIC GEAR PUMP

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HPG00085 HYDRAULIC GEAR PUMP

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HPG00085 HYDRAULIC GEAR PUMP

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HPG00085 HYDRAULIC GEAR PUMP

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HPG00085 HYDRAULIC GEAR PUMP

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HPG00085 HYDRAULIC GEAR PUMP

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HPG00085 HYDRAULIC GEAR PUMP

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HPG00085 HYDRAULIC GEAR PUMP

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HPG00085 HYDRAULIC GEAR PUMP

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 HPG00085 HYDRAULIC GEAR PUMP

WEAR GUIDE

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HPG00085 HYDRAULIC GEAR PUMP

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HPG00085 HYDRAULIC GEAR PUMP

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HPG00085 HYDRAULIC GEAR PUMP

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 GEAR PUMP (HPG00099)
TO BE PROVIDED AT A LATER DATE
 HPP00134 / HPP00135 PISTON PUMP

HPP00134 / HPP00135
PISTON PUMP
SERVICE LITERATURE
GENERAL

The HPP00134 / HPP00135 are variable displacement open circuit axial piston pumps with
advance pumping and control concepts.

MOUNTING

This pump is designed to operate in any position. The pump shaft must be in alignment with the
shaft of the prime mover and should be checked with a dial indicator. The mounting pad or
adapter into which the pump pilots must be concentric with the pump shaft to prevent bearing
failure. This concentricity is particularly important if the shaft is rigidly connected to the driven
load without a flexible coupling.

SHAFT INFORMATION

Splined: The shafts will accept a maximum misalignment of .006”, 0.15 mm TIR. Angular
misalignment at the male and female spline axis must be less than 0.001” per inch radius, 0.001
mm per mm. The coupling interface must be lubricated. Hydra Rig recommends lithium
molydisulfide or similar grease. The female coupling should be hardened to 27-34 Rc.

Keyed: High strength heat treated keys must be used. Replacement keys must be hardened 27-
34 Rc. The key corners must be chamfered .030”-.040”, 0.75-1.00 mm at 45° to clear radii that
exist in the keyway.

PORTING INFORMATION

The maximum case pressure is 25 psi., 1.7 bar continuous, 50 psi, 3.4 bar intermittent. Case
pressures must never exceed inlet pressure by more than 25 psi., 1.7 bar. When connecting case
drain line, make certain that drain plumbing passes above highest point of the pump before
returning to the reservoir. If it does not, install a 5 psi, 0.3 bar case pressure check valve to be
certain the case is filled with oil at all times.

The case leakage line must be of sufficient size to prevent back pressure in excess of 25 psi, 1.7
bar and returned to the reservoir below the surface of the oil as far from the supply suction as
possible. All fluid lines, whether pipe, tubing, or hose, must of adequate size and strength to

PAGE 1 OF 26
 HPP00134 / HPP00135 PISTON PUMP
assure free flow through the pump. An undersize inlet line will prevent the pump from reaching
full speed and torque. An undersized outlet line will create back pressure and cause improper
operation. Flexible hose lines are recommended. If rigid piping is used, the workmanship must
be accurate to eliminate strain on the pump port block or to the fluid connections. Sharp bends in
the lines must be eliminated wherever possible. All system piping must be cleaned with solvent
or equivalent before installing pump. Make sure the entire hydraulic system is free of dirt, lint,
scale, or other foreign material.

CAUTION
DO NOT USE GALVANIZED PIPE. GALVANIZED COATING CAN FLAKE OFF WITH
CONTINUED USE.

INLET CONDITIONS AT SEA LEVEL:

SPEED GAGE PRESSURE ABS. PRESSURE
RPM PSIG BAR IN. HG MM HG PSI BAR
1200 -3 -0.2 -6.1 -155 11.7 0.8
1500 -3 -0.2 -6.1 -155 11.7 0.8
1800 -0.8 -0.05 -1.6 -41 13.9 0.95
1850 0 0 0 0 14.7 1.01
*2100 4.3 0.30 8.8 224 19.0 1.30
*2500 12.2 0.82 24.8 630 26.9 1.89

NOTE: Inlet conditions apply for petroleum base fluids. Contact Hydra Rig for inlet
conditions with other fluids.

MAINTENANCE

This pump is self-lubricating and preventable maintenance is limited to keeping system fluid
clean by changing filters frequently. Keep all fittings and screws tight. DO NOT operate at
pressures and speeds in excess of the recommended limit. If the pump does not operate properly,
check the troubleshooting chart before attempting to overhaul the unit. Overhauling is relatively
simple and may be accomplished by referring to the disassembly rework limits of wear parts and
assembly procedures.

FLUID CLEANLINESS

Fluid must be cleaned before adding to the system, and continuously during operation by filters
maintain a cleanliness level of NAS 1638 class 8. This approximately corresponds to ISO 17/14.

PAGE 2 OF 26
 HPP00134 / HPP00135 PISTON PUMP

TROUBLESHOOTING
EFFECT OF POSSIBLE FAULT WHICH NEEDS REMEDY
TROUBLE CAUSE
Pump noisy Air in system • Leak in suction line
• low fluid level
• turbulent fluid
• return lines above fluid lines
• gas leak from accumulator
• excessive pressure drop in the inlet line from a
pressurized reservoir
• suction line strainer acting as air trap
Cavitation in • fluid too cold, too viscous, or too heavy
rotating group • shaft speed too high
• suction line strainer too small or strainer too dirty
• operating attitude too high
• boost pressure too low
• inlet flow too small for dynamic conditions
Misaligned shaft • Faulty installation
• distortion in mounting
• axial interference
• faulty coupling
• excessive overhung loads
Mechanical fault in • Piston and shoe looseness or failure
pump • bearing failure
• incorrect port plate selection or index
• eroded or worn parts in the displacement control
Erosion on barrel Air in fluid See noisy pump above
ports and port plate
cavitation See noisy pump above
High wear in pump Excessive loads • Reduce pressure settings
• reduce speeds
Contaminant • improper filter maintenance
particles in fluid • filters too coarse
• introduction of dirty fluid to system
• reservoir openings
• improper reservoir breather
• improper line replacement

PAGE 3 OF 26
 HPP00134 / HPP00135 PISTON PUMP
High wear in pump Improper fluid • fluid too thin or thick for operating temperature range
• breakdown of fluid with time/temperature shearing
effects
• incorrect additives in new fluid
• destruction of additive effectiveness with chemical
aging
Improper repair Incorrect parts, procedures, dimensions, finishes
EFFECT OF POSSIBLE FAULT WHICH NEEDS REMEDY
TROUBLE CAUSE
High wear in pump Unwanted water in • condensation
(continued) fluid • faulty breather/strainer
• heat exchanger leakage
• faulty clean-up practice
• water in makeup fluid
Pressure shocks Cogging load Mechanical considerations
Worn relief valve Needed repairs
Worn compensator Needed repairs
Slow response in Replace or relocate
check valve
Excessive Improve decompression control
decompression
energy rates
Excessive line • Reduce line size or lengths
capacitance (line • eliminate hose
volume, line
stretch,
accumulator
effects)
Barrel blow-off Re-check pump holddown rotating group, drain pressure
Heating of fluid Excessive pump • re-check case drain flow and repair as required
leakage • fluid too thin
• improper assembly, port timing
Relief valve • set too low (compared to load or to compensator)
• instability caused by back pressure, worn parts
Compensator • Set too high (compared to relief)
• worn parts
Pump too large for Select smaller pump displacement
fluid needs
Heat exchanger • water turned off, too hot or too little flow
• fan clogged or restricted
• efficiency reduced by mud or scale deposits
• intermittent hydraulic fluid flow

PAGE 4 OF 26
 HPP00134 / HPP00135 PISTON PUMP
Heating of fluid Reservoir • too little fluid
• improper baffles
• insulating air blanket that prevents heat rejection
• heat pickup from adjacent equipment
EFFECT OF TROUBLE POSSIBLE CAUSE FAULT WHICH NEEDS REMEDY
Compensator,
Compensator Override
Low system pressure Compensator malfunction • dirt in spool orifice
• damaged cone or seat
• broken differential spring
• improperly adjusted differential spring
Failure to compensate Differential adjustment Differential set too high
Sluggish response • Differential adjustment Differential set too low
• modulating valve
Wide pressure fluctuations • Excessive line Install check valve near pump outlet
(hunting) capacitance
• modulating valve
Load Sensing Control
Low system pressure Compensator malfunction • dirt in spool orifice
• damaged cone or seat
• broken differential spring
• improperly adjusted differential spring
Failure to compensate Differential adjustment Differential set too high
Sluggish response • Differential adjustment • Differential set too low
• modulating valve • air in load sensing line
Wide pressure fluctuations • Excessive line • Install check valve near pump outlet
(hunting) capacitance
• modulating valve • air in load sensing line
Excessive pressure drop Differential adjustment Differential set too high
across control valve
Poor control of flow Differential adjustment Differential set too low
Torque Limiter, Torque
Limiter Override
Torque setting erratic Torque limiter cap Sticking pin
malfunction
Torque incorrect at high Incorrect torque setting Outer adjustment screw
flows
Torque incorrect at low Incorrect torque setting Inner adjustment screw
flows
Too much torque variation Wrong torque limiter for Replace inner/outer springs with correct
range springs

PAGE 5 OF 26
 HPP00134 / HPP00135 PISTON PUMP
Low system pressure Compensator malfunction • dirt in spool orifice
• damaged cone or seat
• broken differential spring
• improperly adjusted differential spring
EFFECT OF TROUBLE POSSIBLE CAUSE FAULT WHICH NEEDS REMEDY
Torque Limiter, Torque
Limiter Override (cont.)
Failure to compensate Differential adjustment Differential set too high
Sluggish response Differential adjustment Differential set too low
Wide pressure fluctuations • Excessive line Install check valve near pump outlet
(hunting) capacitance
Wide pressure fluctuations • Excessive line Install check valve near pump outlet
(hunting) capacitance
Rotary Servo
Failure to stroke Differential adjustment Differential set too low
Goes to full Differential adjustment Differential set too high
Sluggish response Low servo pressure Check servo pressure
Stokes in steps Servo cap malfunction • sticking pin
• wear on linkages or input com surface
Hydraulic Stroker
Failure to stroke Differential adjustment Differential set too low
Goes to full Differential adjustment Differential set too high
Stokes in steps Servo cap malfunction Wear on linkages, sticking stroker piston
Electric Stroker
Failure to stroke Differential adjustment Differential set too low
Goes to full • Differential adjustment • Differential set too high
Excessive hysteresis • Electric proportional • change dither on electrical signal
valve
No response Electric proportional valve Faulty wiring, filter screen plugged
Stokes in steps Servo cap malfunction • sticking stroker piston
• wear on linkages
Instability Air in control • bleed air from control
• check for air in servo supply

PAGE 6 OF 26
HPP00134 / HPP00135 PISTON PUMP

PAGE 7 OF 26
 HPP00134 / HPP00135 PISTON PUMP
DISASSEMBLY INSTRUCTIONS

Disassembly

Disassemble ONLY as far as necessary to replace or repair worn parts.

If the pump has a rear drive, the mounting adapter and coupling must be removed prior to pump
disassembly.

Clean outside surface of the pomp before disassembly. Disassembly area should be clean. A
suitable surface should be used capable of supporting the pump weight of 325 lbs., 147.5 Kg.

Refer to Figure 1:

1. Remove plug (49) and drain oil from pump. Position pump with shaft up.

2. Wind maximum volume screw (ref. item (50), CW so that piston (44) bottoms out. This
positions the cam at approximately zero stroke allowing removal of the drive shaft.

3. Remove socket head cap screws (9). If disassembling PQ control version, remove tubing and
pass thru fitting (56).

4. Remove cradle assembly (6) from the housing. The M-10 threaded hole in end of the shaft is
provided for lifting this assembly.

5. Remove snap ring (4).

6. Remove screws (21) and (47) to remove cam bearings (29) and (42) as applicable.

7. Remove shaft (1), and bearing, and seal retainer. Support flat face of the rocker cradle and
press end of shaft opposite the bearing end.

8. Remove the shaft seal (1c) from the retainer (1e) if necessary.

9. Remove retaining ring (20).

10. Press bearing off shaft if necessary. Press against bearing inner race.

11. If pump contains a volume indicator assembly, remove indicator pointer, retaining ring, and
pivot nut from pump housing. Remove pivot shaft and fork assembly (3) and (4) through the
hole.

12. Remove two screws (34), two washers (25), clearance bearing (24), and two washers (23)
from retainer (28).

13. Wind maximum volume screw CCW until piston (44) bottoms out.

PAGE 8 OF 26
 HPP00134 / HPP00135 PISTON PUMP
14. Remove control cap (50) and control cap (31).

15. Insert two tools into housing supporting each end of the control piston. The piston must be
moved outward (away from pump center) to remove cam assembly.

16. Lift cam assembly (10) from pump. [Link (43), pistons and shoes and retainer plate (17),
wear plate (22), and holddown (45 and 46) are part of the cam assembly.]

17. Remove slide link (43), retaining ring (45), thrust washer (46), pistons, shoes & retainer
assembly (17) and wear plate (22). The pins for the slide link and for the indicator have been
pressed into the rocker cam and should not be removed.

18. Remove two screws (34), two screws (26), and two retainers (28).

19. Remove Belleville washers (18) and barrel stop (19).

20. Attach tool to barrel assembly. (Two M6 screws are required.) Lift barrel from port plate and
housing.

21. The inner race bearing (11) has a light press fit with barrel. DO NOT remove the inner race
unless bearing needs to be replaced. If replacement is necessary, remove seven socket head
cap screws (12). Replace with 5/16-18UNC x 6-1/2 in. long cap screws. Rest assembly on the
extended screws. Press barrel from inner race. Care must be taken to avoid damage to barrel
face.

22. Remove port plate (ref. Item (14), and alignment pin (16), from port block.

The barrel bearing outer race (11) should only be removed from housing if worn, damaged or
closer inspection is needed. A bearing puller should be used for removal.

PAGE 9 OF 26
 HPP00134 / HPP00135 PISTON PUMP

REWORK LIMITS OF WEAR PARTS

ITEM MAXIMUM REWORK FROM MINIMUM DIMENSION
ORIGINAL DIMENSION AFTER REWORK
WEAR PLATE 0.10* (0.254mm) .240” (6.096mm)
PISTON SHOE FACE (pocket) * .4175” (10.605mm)

* Shoe face pocket depth must be .004” (0.010mm) minimum.

WEAR PLATE

The wear plate finish must be 10 µin., 0.25 µm min., flat within .0005” , 0.0127 mm and parallel
to the backside within .001”, 0.0254 mm total indicator reading.

PISTON SHOE

The piston shoe wear face finish must be 45µin., 1.143 µm min, and must be lapped in a set with
the retainer plate. All shoe sole thickness’ to be within .001”, 0.0254 mm lapping. The maximum
permissible shoe and piston axial looseness is .010”, 0.254 mm.

PAGE 10 OF 26
 HPP00134 / HPP00135 PISTON PUMP

PUMP PARTS LISTS

ITEM DESCRIPTION QTY.
1 SHAFT ASSEMBLY 1
KEYED, NO REAR DRIVE
A (SHAFT)
B (BEARING)
C (SEAL)
D (KEY)
E (SEAL RETAINER)
KEYED, WITH REAR DRIVE
A (SHAFT)
B (BEARING)
C (SEAL)
D (KEY)
E (SEAL RETAINER)
SPLINED, NO REAR DRIVE
A (SHAFT)
B (BEARING)
C (SEAL)
E (SEAL RETAINER)
SPLINED, WITH REAR DRIVE (STANDARD)
A (SHAFT)
B (BEARING)
C (SEAL)
E (SEAL RETAINER)
SPLINED, WITH REAR DRIVE (HI-TORQUE – SAE-F)
A (SHAFT)
B (BEARING)
C (SEAL)
E (SEAL RETAINER)
4 RETAINER 1
5 O-RING 1
6 CRADLE 1
CRADLE, PQ CONTROL
7 HOUSING, NO REAR DRIVE 1
HOUSING, NO REAR DRIVE, PQ CONTROL
HOUSING WITH REAR DRIVE
HOUSING WITH REAR DRIVE, PQ CONTROL
8 O-RING 1
9 SCREW, SHC 12-16

PAGE 11 OF 26
 HPP00134 / HPP00135 PISTON PUMP
ITEM DESCRIPTION QTY.
10 CAM ASSEMBLY 1
CAM ASSEMBLY, PQ CONTROL
11 BEARING 1
12 SCREW, SHC 7
14 BARREL & PORT PLATE ASSEMBLY, CW, H* 1
BARREL & PORT PLATE ASSEMBLY, CCW, H*
BARREL & PORT PLATE ASSEMBLY, CW, Q*
BARREL & PORT PLATE ASSEMBLY, CCW, Q*
BARREL & PORT PLATE ASSEMBLY, CW, PQ CONTROL
BARREL & PORT PLATE ASSEMBLY, CCW, PQ CONTROL
16 DOWEL PIN 1
17 HEAVY PISTONS, SHOES, RETAINER ASSY (Q ,PQ CONTROL)* 1
(17-1) RETAINER PLATE (1 REQ’D)
(17-2) HEAVY PISTONS AND SHOES (7 REQ’D) 18
18 BELLEVILLE WASHERS 3
19 STOP 1
20 RETAINING RING 1
21 SCREW, BUTTON HEAD (PQ CONTROL) 2
22 WEAR PLATE 1
23 LOCKWASHER 2
24 BEARING 1
25 WASHER 2
26 SCREW, SHC 2
27 O-RING, 90 6
28 CAM/BEARING RETAINER 2
29 BEARING, HYDROSTATIC CAM (PQ CONTROL) 1
30 0-RING, 70 2
31 OFF STROKE CONTROL SIDE (SEE FIG. 4) 1
BUCK-UP CAP (COMP, TORQUE LIMITER, LOAD SENSING)
ELECTRIC STROKER
HYDRAULIC STROKER
ROTARY SERVO
PQ CONTROL
32 PLUG, SAE-4, ¼ BSPP 2
33 O-RING, 90 2
34 SCREW, SHC 4

PAGE 12 OF 26
HPP00134 / HPP00135 PISTON PUMP

PAGE 13 OF 26
 HPP00134 / HPP00135 PISTON PUMP
CONVERSION

PAGE 14 OF 26
 HPP00134 / HPP00135 PISTON PUMP

PUMP REASSEMBLY INSTRUCTIONS

SHAFT SEAL REPLACEMENT

Remove worn or damaged seal from retainer. Clean Loctite® “Master Gasket” from retainer.
Install new seal by applying “Master Gasket” to retainer and pressing seal in retainer.

The shaft seal and all “O” rings necessary for total seal replacement may be obtained by ordering
the Seal Kit. These seals are suitable for petroleum base fluids. For fire resistant fluids, contact
Hydra Rig to obtain the appropriate seal kit number.

PRE-ASSEMBLY

Depending on the repairs, many steps in this section may not be applicable.

The assembly area should be clean and the environment such that foreign matter will not be
introduced to the pump during assembly. All parts must be absolutely clean and free from rust,
contamination, lint, or any other foreign matter. Critical surfaces must be free of dings or
scratches. All “O” ring seals must be clean and carefully examined for cuts or other damage
before installation.

During assembly, occasional reference will be made to the use of lubricating oil for proper
assembly. It is important that any oil used be compatible with the seal and fluid to be used in
operation. Compatibility is also necessary for grease that should be used on all “O” rings to
ensure proper assembly without damage.

Several screws require a thread lock liquid for locking in position. When required, use Loctite®
#242 unless otherwise specified.

PAGE 15 OF 26
 HPP00134 / HPP00135 PISTON PUMP

ASSEMBLY

Refer to Figure 1

1. Place the port block end of the housing (7) on a suitable surface capable of supporting the
pump weight of 325 lbs, 147.5 Kg.

2. Install plugs (41) with “O” rings into port block. Install plugs (32) with “O” rings into port
block.

3. Install pin (16) in port block. Position port plate (14) on port block and over pin. To view
correct port plate for shaft rotation specified, see illustration below:

4. Press bearing outer race (11) into housing (7).

PAGE 16 OF 26
 HPP00134 / HPP00135 PISTON PUMP
BARREL AND INNER RACE ASSEMBLY

5. Thread seven 5/16-18 studs into bearing inner race. Lower barrel (14) over studs and seal. If
the inner race is heated to 150°F, 65°C, barrel will slide into position without force. If race is
not heated, longer screws (12) can be used to draw the race and barrel together. Insert screws
(12) and torque to 30 lbs ft, 40 Nm.

6. Apply oil to face of port plate and inner bearing race. Attach tool to barrel with two M6
screws. Carefully lower barrel assembly into housing engaging inner race into roller of outer
bearing race; barrel may then be lowered until it has seated on port plate.

7. Insert two “O” rings (27) into each retainer (28). Apply Loctite® #271 to two screws (26)
and secure retainer to housing. Torque to 84 lbs-in., 9.5 Nm.

8. Apply Loctite® #271 to two screws (34) and assemble the other retainer on opposite side of
housing. Torque to 84 lbs-in., 9.5 Nm.

9. Assemble the two piston rings (39) on control piston (44). Insert control piston (44) into
housing bore that is used with the control caps. For CW shaft rotation, the long end of the
piston must be positioned to the right. (See Figure 1) For CCW rotation, the long end of the
piston is to the left. Insert tools (two required) into housing bores; support each end of the
control piston. The piston must be moved outward (away from pump center) so that
clearance is provided for installing the rocker cam assembly.

PAGE 17 OF 26
 HPP00134 / HPP00135 PISTON PUMP

10. Position Belleville washers (18) on barrel (See illustration). To insure proper pump operation
and correct barrel holddown force, they must be assembled exactly as shown. Place barrel
stop (19) on Belleville washers and center the washers and stop on barrel.

CAM ASSEMBLY

11. Set cam assembly (10) on suitable surface protecting cam surfaces from damage during
assembly (See illustration).

12. Place wear plate (22) on cam.

13. Position pistons-shoes-retainer assembly (17) over center post and against wear plate.

14. Install thrust washer (45) over center post.

15. Six different retainers (46) are available for setting the shoe holddown. Each retainer is
marked; white dot .073”, 1.85 mm thick, yellow dot .071”, 1.80 mm thick, green dot .069”,
1.70 mm thick, blue dot .065”, 1.65 mm thick, and orange dot .063”, 1.60 mm thick. Install
the thickest retainer with t dot side up; that will fit in the groove on the center post and allow
a clearance of .003”-.005”, 0.076-0.127 mm between the shoe and wear plate. A .003”, 0.076
mm feeler gage must go completely under any shoe, and a .005”, 0.127 mm feeler gage
must not go under any shoe while holding a piston and lifting against the shoe retainer. The
piston and shoe assembly must be free to rotate easily by hand. Rotate 360° to confirm there
is no binding and that each shoe is free in the retainer plate. Oil the assembly thoroughly.

16. Install slide link (43) on rocker cam pin as shown.

PAGE 18 OF 26
 HPP00134 / HPP00135 PISTON PUMP

17. Oil barrel bores before installing cam assembly. Lower cam assembly into the housing with
the slide link positioned so it will engage into the control piston (44). The seven pistons (17)
must first be engaged into the barrel bores.

Next, the slide link (43) must engage into the control piston (44). Continue lowering rocker
cam assembly until it is seated on cam/bearing retainers (28).

18. Apply Loctite® 242 to two screws (34) and assemble clearance-bearing (24) to cam/bearing
retainer (28) using the screws (34), two washers (25), and two washers (23). Move rocker
cam to the right until it is against stop. Set clearance between clearance bearing (24) and
cam at .006”, 0.152 mm. Torque screws to 6 lbs-ft, 8.1 Nm maintaining the .006”, 0.152 mm
clearance.

19. Adjust piston (44) toward the off stroke control side (31). This will place the cam at
approximately zero stroke and provide clearance for the shaft installation.

PAGE 19 OF 26
 HPP00134 / HPP00135 PISTON PUMP

Rocker Cradle Assembly

20. AppIy Loctite® 242 to the screws (47) and assemble two cam bearings (42) to cradle (6). Torque to 33 lbs-in.,
3.8 Nm.

Note: Pumps with PQ control: A special cam, cradle and cam bearing provides a
pressure balance to the bearing interface on the control side of the cam. Install plugs
(54) and (55) to cradle as shown. Install “O” ring (36) in cradle. Apply Loctite® 242 to
two scres (21) and attach cam bearing (29). Torque to 33 in-lbs, 38 Nm.

21. Press bearing (1b) on shaft (1a). Press on inner race only.

22. Apply over 360° bead of Loctite® 44 “Master Gasket” to seal retainer (1a) per following illustration. Press shaft
seal (1c) into seal retainer (1a).

23 Install shaft seal and retainer on shaft using tool to protect seal.

24 Install “O” ring (5) in cradle (6).

25 Press seal retainer and bearing and shaft assembly into bore of cradle (6) using tool.

26 Install snap ring (4) to cradle.

PAGE 20 OF 26
 HPP00134 / HPP00135 PISTON PUMP
27 Install “O” ring (8) to rocker cradle.

28 Install retaining ring (20) on shaft.

29 Center Belleville washers and barrel stop. Lower rocker cradle assembly into pump housing with the step in -10
threaded hole in the end of shaft should be used to support the assembly. The shaft spline must first engage the
splined barrel stop (19), thru the Belleville washers (18) and engage the barrel spline. The assembly will then
rest on the cam.

30 Install socket head cap screws (9) as shown. Torque evenly to 75 ft-lb (102 Nm). Install case drain plug (49)
and shipping plug (51). If pump does not contain stroke indicator, install plug (52) and “O” ring (53) in
indicator hole.

31 If assembling “X” model pump, install pass thru fitting (56) into housing, being careful that “O” ring enters hole
in cradle without damage.

Indicator Assembly Option

(See following figure) To install Indicator assembly, loosen setscrew (6), remove indicator (2) and slide shaft out of
nut (1). Guide fork into indicator hole in housing to engage the pin on the hanger. A ¼-20 SHCS or threaded rod
maybe used to hold the shaft. Slide nut (1) over shaft and tighten nut in threaded hole. Pull shaft out to slip retaining
ring (9) into groove in shaft. Use maximum volume stop to set pump or zero stroke (10.2 turns from full). Install
indicator, set pointer on “0” and lock in position.

PAGE 21 OF 26
 HPP00134 / HPP00135 PISTON PUMP
CONTROLS

Description Of Operation

A pilot operated valve spool and sleeve combination is the core of the control function. For the compensator, torque
limiter and load sensing controls, system pressure is applied to the input port of a three-way valve, and to one end of
the valve spool. A small orifice feeds this pressure to the other end of the spool and limits pilot flow to
approximately 115in3/min., 1.9 lpm. A spring on this end biases the spool to normally port the control piston to
pump case. This control piston links to the pump cam. On the opposite end of the control piston a small buck-up
piston connects to system pressure. This force, pump timing forces, and a spring combine to put the pump on stroke.

Pressure Compensator

A spring-loaded core cone seal connected to the spring end of the three-way spool establishes an adjustable pressure
limit on this end of the spool. When system pressure reaches this value, flow through the spool creates a pressure
difference across the spool. At approximately 250 psi, 17.2 bar difference, the spool shifts toward the spring, re-
directing the control piston port to a system pressure. The pressure applied to the control piston overcomes the
forces putting the pump on stroke, causing the pump to reduce displacement. When the pump pressure drops, the
spool meters to maintain the pump pressure at approximately 250 psi, 17.2 bar above the controlled pressure to the
spring side. The spring end of this three-way spool may also be connected to a remote pressure control, through the
vent port “V”.

Compensator With Load Sensing Configuration

To use the compensator for load sensing, the “V” port is connected to the load downstream of a metering valve. The
pump will supply approximately 250 psi, 17.2 bar difference in pressure across the metering valve, and thus controls
flow independent of operating pressure. Adjustment of spring load on the three-way spool allows precise control of
the differential pressure.

Load Sensing Control

To eliminate the pilot flow, and to control multiple loads, a control designed for load sensing is available. In the load
sensing control, the vent flow is modulated by a valve which senses load pressure and establishes the pump
compensator pressure at approximately 250 psi to 435 psi, 24.1 to 30 bar above load pressrue. There is essentially no
flow in the sensing line and the pump supplies the flow required to develop 350 psi to 435 psi, 24.1 to 30 bar across
the metering valve to the load.

PAGE 22 OF 26
 HPP00134 / HPP00135 PISTON PUMP

Torque Limiter

The product of system pressure and pump displacement must be kept constant for torque limiting. As pressure
increases, displacement must reduce, and vice versa. A linkage to the pump control piston slides a sleeve over a pin.
The sleeve and pin act as a metering valve. The pin contains a cross drilled hole, and a connecting drilling to one
end which is ported to the vent port of the compensator. The pressure in the vent port applies a force on the pin,
which is resisted on the other end by a two spring combination.

The pin positions itself to where the vent pressure force on the one end is balanced by the spring force on the other
end. When the cross drilled hole opens, it causes the three-way spool to shift to direct system pressure into the con-
trol piston, reducing stroke. The linkage to the control piston causes the sleeve to move in the direction to close the
cross drilled hole. Thus, for every position of the pin, there is a corresponding position for the control piston where
balance is achieved. At low pressure, high flow, only the outer spring contacts the pin. As pressure increases, the
second spring also makes contact. Thus the rate of change of pressure starts at a low initial rate when the pump is at
full stroke and changes to a high rate at reduced stroke, to approximate a constant product of pressure times
displacement. The normal compensator function is retained to provide a maximum pressure limit.

Torque Limiter With Load Sensing

A modulating valve is mounted to a torque limiter body to provide a load sensing control with torque limiting and
pressure compensator override.

Rotary Servo Control

The rotary servo is mounted on the off-stroke side of the control piston. Servo pressure is connected to the input port
of a four-way valve, and to the end of this valve spool. A drilling and orifice connects to the opposite end of the
spool. One cylinder port connects to the “off stroke” end of the control piston, while the other cylinder port connects
to the “on stroke” end of the control piston, through the control no the opposite side.

A rotatable shaft converts to a linear motion on a pin. A sleeve over the pin is driven by a linkage to the control
piston. The sleeve/pin combination meters pilot flow from the four-way valve controlling the shifting of the four-
way valve, in such a manner that the fout-way valve shifts to hold the cylinder position to the corresponding position
for the input rotation.

Hydraulic Stroker

In the hydraulic stroker, a spring loaded piston is attached to the pin. A control pressure of 50 psi 3.45 bar causes the
piston to commence to move against the spring, to position the pin in proportion to the control pressure, and, thus,
cause the pump to stroke in proportion to the control pressure. Full stroke is achieved at 275 psi, 19 bar.

Electric Stroker

By mounting an electrically modulated pressure control valve on the hydraulic stroker to establish the control
pressure, pump stroke is controlled by an electrical signal. For a 24 volt coil, the pump commences to stroke at
approximately 175 mA electrical signal, and will be at full stroke at approximately 320 mA.

Pressure Compensator And Torque Limiter Override

An override pressure compensator or a torque limiter control mounts on the smaller diameter of the control piston,
opposite the servo, hydraulic or electric stroker. In the normal position, the spool in the override control connects
this piston to the control valve on the opposite side, allowing control by the stroker. When system pressure or torque
exceed the override setting, this spool connects system pressure to the smaller diameter control piston, to to override

PAGE 23 OF 26
 HPP00134 / HPP00135 PISTON PUMP
the rotary servo, hydraulic or electric stroker command and reduce stroke according to the compensator or torque
limiter setting. Override pressure must be sufficient to overcome servo pressure acting on the larger diameter piston.

TIGHTENING TORQUE FOR HYDRAULIC PUMPS

PORT SIZE FT/LB Nm
SAE - 4 11 15
SAE – 6 18 24
SAE – 8 46 62
SAE – 10 75 102
SAE – 14 130 175
SAE - 24 250 339
¼ BSPP 18 24
3/8 BSPP 18 24
½ BSPP 93 126
1-1/2 BSP 288 390

PAGE 24 OF 26
 HPP00134 / HPP00135 PISTON PUMP

PORT SIZES DESCRIPTION

PORT C1 OFF-STROKE CYL. GAGE SAE-4
PORT C2 ON-STROKE CYL. GAGE SAE-4
PORT D CASE DRAIN SAE-24
PORT D1 CASE DRAIN SAE-24
PORT DG DRAIN GAGE, AIR BLEED PORT SAE-4
PORT AG INLET GAGE SAE-4
PORT BG SYSTEM GAGE SAE-4
PORT BG1 ALT. SYSTEM GAGE SAE-6
PORT E ELECTROHYDRAULIC STROKER SERVO SUPPLY SAE-4
PORT H HYDRAULIC STROKER SIGNAL SAE-4
PORT LS LOAD SENSING LINE SAE-4
PORT V COMPENSATOR, TORQUE LIMITER, LOAD SENSING VENT SAE-8
PORT V OVERRIDE COMPENSATOR, OVERRIDE TORQUE LIMITER SAE-4
VENT
PORT V1 SERVO VENT SAE-4
PORT X SERVO SUPPLY SAE-8
PORT XG SERVO GAGE SAE-10

PAGE 25 OF 26
 HPP00134 / HPP00135 PISTON PUMP

SPECIFICATION TERM
Displacement at max. Angle in³/rev. 16
1
cm /rev. 262.2
Pressure continuous psi 6000
bar 420
Pressure intermittent (not to exceed 6 sec./minute) psi 7250
bar 500
Speed, @ atmospheric inlet rpm 1850
Max. With boost rpm 2500
2
Rotating inertia lb/in. 349
2
kg/m 0.012
Compensator response off-stroke sec. 0.100
On stroke sec. 0.150
Compensator adjustment psi/turn 2000
bar/turn 138
Minimum compensating pressure (comp, torque limiter) psi 200*
bar 13.6*
Minimum compensating pressure (override controls) (at 700 psi/48.3 psi 1350*
bar servo) bar 93*
Typ. Servo & stroker response @ 700 psi/48.3 bar servo pressure, sec. <0.35
zero to full stroke and vice versa
Servo flow required for this response Gpm 5
L/min 19
Minimum servo pressure psi 700
bar 48
Maximum servo pressure psi 1500
bar 103
PQ control response (10% to 90% & 90% to 10% flow) sec. <0.09
Electric stroker nominal coil resistance (24V coil) ohms 41
Electric stroker nominal coil resistance (12V coil) ohms 10
Handwheel turns, full to zero stroke turns 10
Torque to turn handwheel @ 1000 psi/70 bar in./lb 150
Nm 17
Torque to turn handwheel @ 7250 psi/500 bar in./lb 350
Nm 40
Rotary servo shaft rotation, 0 to full stroke degrees 65-70
Torque to turn rotary servo shaft in./lb 20
Nm 2.3

PAGE 26 OF 26
 IPP00001 DEBOOSTER

IPP00001
DEBOOSTER

FUNCTION
The pressure debooster, Figure 1, is an instrument used to step down fluid pressures
through a known ratio, typically for the purpose of measurement. The debooster consists
of two pistons connected on a single rod but with surface areas differing by a desired
ratio, i.e. 4:1. A pressure vessel in the form of a sealed cylinder encloses the two pistons.
High pressure fluid acting on the surface of the small piston results in a lower pressure in
the fluid acted on by the larger piston.
INSTALLATION
The pressure debooster comes fitted with two external connections:
• One 1/4 low pressure signal pressure outlet.

• One 9/16-18UNF female connection-high pressure inlet.

Low pressure system charge procedure:

1. Remove plastic protection plug from cross atop cap.
2. Install hydraulic gauge line into cross.
3. Remove check valve cap and install hand pump, Figure 2, to check valve, leaving
connection loose.
4. Fill hand pump reservoir with appropriate hydraulic fluid.
5. Stroke hand pump until all air is bled from line; tighten fitting and replenish
reservoir with hydraulic fluid.
6. Stoke hand pump until gauge or recorder shows a slight preload.
7. Bleed air from upper cylinder through the 1/4 NPT plug atop cross.
8. Repeat steps 4 to 7 two additional times while keeping reservoir at least one-half
full at all times.

PAGE 1 OF 4
 IPP00001 DEBOOSTER

High pressure system charge:

1. Connect high pressure line to inlet, leaving nut loose.
2. Prime system with the appropriate hydraulic fluid until all air bubbles no longer
emerge from the fitting nut.
3. Tighten fitting nut.
4. Mount debooster in vertical position using mounting flange furnished with unit.

SEAL REPLACEMENT
Debooster assembly (Figure 1)
1. To determine whether the seal needs replacement, the debooster has been fitted
with a tell-tale vent hole located approximately mid-distance on the body. As the
seals become worn, hydraulic fluid will bypass the seals and exit the tell-tale hole
indicating seal replacement is necessary.
2. Remove debooster from service.
3. Remove cap (Item 1) from body.
4. Remove o-ring (Item 2) from inside cap.
5. With spanner wrench, remove access plug (Item 9) and seals from end of
debooster.
6. Push piston (Item 5) out of cylinder from small end until large piston is
disengaged from large cylinder.
7. Pull piston free from body.
8. Clean and inspect cylinder bore for damage.
9. Remove hex screw (Item 4), washer (Items 7 and 11) from either end of piston.
10. Remove seals (Item 6 and 8) from piston.
11. Replace seals on both ends of piston insuring that lips of each seal face out from
each other.
12. Replace washers (Items 11 and 7) and hex screw (Item 4) to ends of piston. It is
recommended that a thread sealant be used on the screw threads during assem-
bly.
13. Replace seal (Item 8) on access plug (Item 9) insuring that seal lip faces outward.
14. Replace o-ring (Item 2) in cap (Item 1).
15. Liberally grease seals on piston and insert piston into body until piston seats at
bottom of bore.
16. Replace cap (Item 1) and tighten.
17. Grease seal and replace access plug (Item 9); tighten securely.
18. Replace flange (Item 10).
19. Lubricate piston with water resistant grease through fitting (Item 12). All excess
grease will exit through tell-tale vent hole.

PAGE 2 OF 4
 IPP00001 DEBOOSTER

20. Return debooster to service.

FIG. 1, DEBOOSTER ASSEMBLY

ITEM QTY DESCRIPTION

1 1 Plug, 1/4 MPT S/S

2 2 Plug, 1/4 MPT, Nylon

3 1 Check Valve

4 1 Cross, Hex, 1/4 NPT S/S

5 1 Cap, 4:1 Debooster

6 1 Seal, O-ring

7 3 Washer, Splitlock, S/S

8 3 Screw, Hex Head, S/S

9 1 Body, 4:1 Debooster

10 1 Washer, Retainer

11 1 Piston, 4:1 Debooster

12 1 Seal, Standard

13 1 Grease Zerk, 1/4-28 Taper Thread

PAGE 3 OF 4
 IPP00001 DEBOOSTER

ITEM QTY DESCRIPTION

14 1 Hole Plug, Modified

15 2 Seal, Standard

16 2 Washer, Retainer

17 1 Plug, Retaining, Access

18 1 Flange, Mounting

19 4 Screw, Flange Mounting

FIGURE 1

FIGURE 2

PAGE 4 OF 4
 REHS0871-01
March 2001

Special Instruction
i01482017 “PM1 Interval” ................................................ 15
“Aux Press Enable” ........................................ 15
Electronic Installation Guide “Aux Temp Enable” ........................................ 15
“Ether Enable” ............................................... 15
SMCS Code: 1000 “Oil Grade” ..................................................... 15
Programmable Monitoring System (PMS) ......... 15
Industrial Engines Required Tools ...................................................... 17
3126B (S/N: BEJ1-Up) Electronic Technician (ET) ................................ 17
C-9 (S/N: CLJ1-Up) Connecting ET and the Communication
C-10 (S/N: BCX1-Up) Adapter ........................................................ 18
ET Support .................................................... 18
C-12 (S/N: BDL1-Up) Switches ............................................................... 19
C-15 (S/N: BEM1-Up) Measuring Voltage in Switch Circuits ................ 19
C-16 (S/N: BFM1-Up) Measuring Current in Switch Circuits ................ 19
Measuring Resistance in Switch Circuits .......... 20
Table of Contents Mounting Dimensions for Switches ................... 20
Switch Specifications ........................................ 20
Introduction ........................................................... 2 Voltage Thresholds at the ECM ........................ 21
System Overview .................................................. 2 Connectors ........................................................... 22
Electronic Controls ............................................ 2 Pull Test ............................................................. 22
System Component Diagrams .......................... 3 Installation of Terminals and Seal Plugs ........... 23
3126B Engines .............................................. 3 J61/P61 Customer Connector ........................... 23
C-9 Engines ................................................... 4 Deutsch DT Connectors .................................... 23
C-10, C-12, C-15, and C-16 Engines ............ 5 Deutsch HD Connectors ................................... 24
Component Locations ....................................... 6 Wiring Considerations ........................................... 24
3126B Engines .............................................. 6 Wire Size Requirements ................................... 24
C-9 Engines ................................................... 7 Harness Routing ............................................... 25
C-10 and C-12 Engines ................................. 8 Battery Circuit Requirements ................................ 25
C-15 and C-16 Engines ................................. 9 Grounding ......................................................... 25
System Configuration Parameters ........................ 10 Negative Battery Connection ......................... 25
Customer Passwords ........................................ 10 Welding on a Machine that is Equipped with an
Parameter Lockout ............................................ 10 Electronic Engine ......................................... 26
Parameters Table .............................................. 11 Switched Positive Battery and Unswitched Positive
Parameters Worksheet ...................................... 12 Battery ............................................................. 27
Parameter Descriptions ..................................... 13 Suppression of Voltage Transients .................... 27
“Equipment ID” .............................................. 13 Customer Installed Components .......................... 28
“Engine Serial Number” ................................. 13 P61 Customer Connector .................................. 28
“Rating Number” ............................................ 13 Sensor Return Connections .............................. 28
“Top Engine Limit” (TEL) ................................ 13 J66 Customer Supplied Service Tool
“Engine Accel. Rate” ...................................... 13 Connector ........................................................ 29
“Low Idle Speed” ........................................... 13 Air Shutoff System ............................................ 29
“PTO Mode” ................................................... 13 Alarm Lamps (Diagnostic and Warning) ........... 30
“High Idle Speed” ........................................... 14 Lamp Driver Electrical Specifications ............ 30
“Intermediate Engine Speed” ......................... 14 Diagnostic Lamp Operation ........................... 30
“Engine Power Trim” ...................................... 14 Warning Lamp Operation .............................. 30
“Engine Torque Limit” .................................... 14 Auxiliary Pressure Sensor ................................. 31
“FLS” (Full Load Setting) ............................... 14 Auxiliary Temperature Sensor ........................... 31
“FTS” (Full Torque Setting) ............................ 14 Coolant Level Sensor ........................................ 32
“Air Shutoff” ................................................... 14 Ether Injection System ...................................... 32
“Maintenance Indicator Mode” ....................... 15 Inlet Air Heater (3126B and C-9 Engines) ......... 33

1
 Intermediate Engine Speed Switch ................... 33 Introduction
Maintenance Due Lamp and Maintenance Due
Reset Switch ................................................... 34 This document is intended to provide the information
Overspeed Verify Switch ................................... 34 that is necessary to properly wire and program the
PTO Switches .................................................... 35 engine electronics.
“Ramp Up/Ramp Down” Mode ...................... 35
“Set/Resume” Mode ...................................... 36
Remote Shutdown Switch ................................. 37
System Overview
Throttle Position Sensor .................................... 38
Note: The 3126B and C-9 Industrial Engines have
Mounting Dimensions .................................... 38
hydraulically actuated, electronically controlled
PWM Input Requirements ............................. 39
unit injectors (HEUI). The other Industrial Engines
Torque Limit Switch ........................................... 40
covered in this document have mechanically
J1939 (CAN) Data Link ......................................... 41
actuated, electronically controlled unit injectors
CAN Data Link Broadcast Parameters .............. 41
(MEUI).
Connecting Modules to the CAN Data Link ....... 42
Engine Monitoring System (EMS) Display ............ 46
This engine was designed for electronic control.
Overview ........................................................... 46
The injection pump, the fuel lines, and the nozzles
Mounting Dimensions for EMS Display
that are used in mechanical engines have been
Modules ........................................................... 47
replaced with a unit injector in each cylinder. A
Front Mount ................................................... 47
solenoid on each injector controls the amount of
Rear Mount .................................................... 47
fuel that is delivered by the injector. An electronic
Required Parts .................................................. 48
control module (ECM) sends a signal to each
Schematic ......................................................... 49
injector solenoid in order to provide complete
Power Requirements for the EMS Display ........ 50
control of the engine.
Connecting the EMS Display ............................. 50
Connecting the Harness to the Main EMS
Module, the Tachometer, and the Quad Electronic Controls
Gauge .......................................................... 50
Battery Connections for 12 Volt Systems ...... 50 The electronic system consists of the following
Battery Connections for 24 Volt Systems ...... 51 components: electronic control module (ECM), unit
Connecting the CAT Data Link ...................... 51 injectors, wiring harness, switches, and sensors.
Optional Switches ............................................. 51 The ECM is the computer. The personality module
Scroll Switch .................................................. 52 (flash file) is the software for the computer. The
US/Metric Display Switch .............................. 52 personality module (flash file) contains the operating
Optional Warning Lamp/Alarm Outputs ............ 52 maps. The operating maps define the following
Warning Lamp ............................................... 52 characteristics of the engine:
Warning Alarm ............................................... 53
Optional Alarm Enable/Disable Switch .......... 53 • Horsepower
Connecting Gauge Backlighting ........................ 53
Installing a Backlight Dimmer • Torque curves
(Potentiometer) ............................................ 54
Connecting an Optional Remote Module .......... 54 The ECM determines the timing and the amount
Connecting Multiple EMS Displays ................... 56 of fuel that is delivered to the cylinders. These
Reference Materials .............................................. 57 decisions are based on the actual conditions and
the desired conditions at any given time.

The ECM compares the desired engine speed to

the actual engine speed. The actual engine speed
is determined through the engine speed/timing
sensor. The desired engine speed is determined by
monitoring the following inputs to the ECM:

• Sensors (throttle position, etc)

• Diagnostic codes
• Event codes (derates)
If the desired engine speed is greater than the
actual engine speed, the ECM injects more fuel in
order to increase the actual engine speed.

2
System Component Diagrams
3126B Engines

g00776480
Illustration 1

3
C-9 Engines

g00775775
Illustration 2

4
C-10, C-12, C-15, and C-16 Engines

g00725379
Illustration 3

5
Component Locations
3126B Engines

g00776531
Illustration 4

6
C-9 Engines

g00775609
Illustration 5

7
C-10 and C-12 Engines

g00725713
Illustration 6

8
C-15 and C-16 Engines

g00725712
Illustration 7

9
System Configuration Parameters • “High Idle Speed”
System configuration parameters are parameters • “Monitoring System Configuration Access”
that affect emissions and power of the engine
applications. Default values for the parameters • “Rating Number”
are programmed at the factory. Some parameters
may be changed by the customer in order • “Top Engine Limit”
to suit the needs of the specific application.
System configuration parameters consist of ECM When an attempt to change a locked out parameter
Identification Parameters and Selected Engine occurs, the factory password screen will come up.
Rating Parameters. You must reprogram the ECM If changing the parameter is required, follow the
Identification Parameters if the ECM is replaced instructions on ET.
and/or you reprogram the engine rating. You do
not need to reprogram the ECM Identification
Parameters if you reflash the ECM. Proper values
for these parameters are available on ET. Certain
configuration parameters are also stamped on the
engine information plate.

Note: If the parameters that are protected with the

factory passwords are changed, the Caterpillar
warranty may be voided.

Customer Passwords
Customer passwords may be programmed in
order to limit access to the customer specified
parameters. A maximum of eight alphanumeric
characters may be entered for each of the two
available customer passwords. These passwords
are case sensitive. Both customer passwords do
not need to be programmed in order to provide
protection.

Parameter Lockout
Parameter Lockout is available to restrict access to
changing some of the available parameters. Locking
out a parameter requires customer passwords (if
used). Once a parameter is locked out, factory
passwords are required to unlock the parameter.

If a lockable parameter is not locked out, factory

passwords are not required. A locked out parameter
restricts the parameter from being changed
directly by the customer or unauthorized personnel.
This helps engine owners that are encountering
problems with operators that are obtaining customer
passwords and altering parameters.

A locked out parameter also provides an audit

trail. The audit trail can be used to determine the
following information:

• Time of change
• Operator during change
The following parameters can be locked out:

• “Engine Power Trim”

10
Parameters Table
Table 1
System Configuration Parameters
Required
Parameter Available Range or Options Default
Password
ECM Identification Parameters
“Equipment ID” 17 alphanumeric characters blank None
“Engine Serial Number” 0XX00000 or XXXX00000 blank None
“ECM Serial Number” Read Only (1)

“Software Gp Release Date” Software Dependent Read Only (1)

Selected Engine Rating
“Rating Number” Software Dependent Customer
“Rated Power” Software Dependent Read Only (1)
“Rated Peak Torque” Software Dependent Read Only (1)
“Top Engine Speed Range” Software Dependent Read Only (1)
“Test Spec” Software Dependent Read Only (1)
“Top Engine Limit” Software Dependent Customer
“Engine Accel. Rate” 50 to 1000 500 None
“Low Idle Speed” 600 to 1400 1400 None
“PTO Mode” “Ramp Up/Ramp Down” or “Set/Resume” “Ramp Up/Ramp Down” None
“High Idle Speed” Software Dependent Customer
“Intermediate Engine Speed” Programmed “Low Idle” to “TEL” Programmed “Low Idle” None
“Engine Power Trim” -3.0 to 3.0 0 Customer
“Engine Torque Limit” Software Dependent None
“FLS” (Full Load Setting) “Factory Programmed” Factory
“FTS” (Full Torque Setting) “Factory Programmed” Factory
“Fuel Air Ratio Control Adjust” N/A at this time None
“Air Shutoff” “Enabled” or “Disabled” “Disabled” None
“OFF”
“Auto Fuel”
“Maintenance Indicator Mode” “Auto Hour” “OFF” None
“Man Fuel”
“Man Hour”
100 to 750 Hours 250 Hours
“PM1 Interval” or or None
3785 to 28390 L (1000 to 7500 US gal) 9463 L (2500 US gal)
“Total Tattletale” Read Only (1)

“Aux Press Enable” “Enabled” or “Disabled” “Disabled” None

“Aux Temp Enable” “Enabled” or “Disabled” “Disabled” None
“Ether Enable” (2) “Enabled” or “Disabled” “Disabled” None
“Oil Grade” (C-9 Only) (3) “0W20”, “10W30”, or “15W40” “15W40” None
(1) The parameter can be viewed only. No changes are allowed.
(2) This feature is not available on 3126B Engines.
(3) The “15W40” oil grade plug must be installed for the parameter to become effective. Refer to Operation and Maintenance Manual,
“Engine Oil and Filter - Change” for more information.

11
Parameters Worksheet Table 3
Information from Engine Information Plate
Note: A mistake in recording this information will
result in incorrect passwords. “Engine Serial Number”

Table 2
“FLS”

Engine Parameters “FTS”

“Equipment ID”
Note: Compare the FLS and the FTS from the
“Engine Serial Number” ECM with the values that are listed on the Engine
“ECM Serial Number” Information Plate. The FLS and the FTS should only
be changed because of a mechanical change in
“Software Gp Release the engine. The use of the wrong parameters could
Date” cause damage to the engine. The use of the wrong
“Rating Number” parameters may also void the Caterpillar warranty.
“Rated Power”
“Rated Peak Torque”
“Top Engine Speed Range”
“Test Spec”
“Top Engine Limit”
“Engine Accel Rate”
“Low Idle Speed”
“PTO Mode”
“High Idle Speed”
“Intermediate Engine
Speed”
“Engine Power Trim”
“Engine Torque Limit”
“FLS”
“FTS”
“Air Shutoff”
“Maintenance Indicator
Mode”
“PM1 Interval”
“Total Tattletale”
“Aux Press Enable”
“Aux Temp Enable”
“Ether Enable” (1)

“Oil Grade”
(1) This feature is not available on 3126B Engines.

12
Parameter Descriptions TEL is a customer programmable parameter that
defines the maximum allowable engine speed for
“Equipment ID” maximum power delivery up to the maximum rated
engine speed. TEL is defined along the engine’s
“Equipment ID” allows the customer to enter a lug curve instead of “High Idle Speed” which is at
description into the ECM in order to identify the no load.
machine. A maximum of 17 characters may be
entered in the field. This parameter is only for “Engine Accel. Rate”
reference by the customer. This parameter is not
required. “Engine Accel. Rate” determines the rate of change
of the engine speed (acceleration or deceleration)
“Engine Serial Number” during PTO operation. This rate of change is also
used to achieve intermediate engine speed. This
“Engine Serial Number” should be programmed to parameter can be programmed between 5 and
match the engine serial number that is stamped 1000 rpm/sec.
on the engine information plate. If the ECM is
replaced, the engine serial number from the Engine “Low Idle Speed”
Information Plate should be programmed into the
new ECM. “Low Idle Speed” is the minimum allowable
operating speed for the engine. This parameter can
Note: When you are requesting factory passwords, be programmed between 600 and 1400 rpm.
always use the engine serial number that is resident
in the ECM. “PTO Mode”

“Rating Number” “PTO Mode” allows the ECM to be programmed

to either one of the two PTO configurations that
“Rating Number” is a reference number that are available.
corresponds to the rating map that is resident in
the flash file. Flash files may contain more than one “Ramp Up/Ramp Down”
rating. Flash files may also include more than one
rating tier (A through E). When “PTO Mode” is programmed to “Ramp
Up/Ramp Down”, the ECM allows PTO operation
“Top Engine Limit” (TEL) with traditional features. Refer to “PTO Switches”
for more details.

“Set/Resume”

When “PTO Mode” is programmed to “Set/Resume”,

the ECM allows PTO operation with enhanced
features (set/resume). Refer to “PTO Switches” for
more details.

g00763900
Illustration 8

13
“High Idle Speed” “Engine Torque Limit”

g00763900 g00764728
Illustration 9 Illustration 10

“High Idle Speed” is the maximum no load engine “Engine Torque Limit” can be used to limit torque
speed when the throttle or the PTO switch is in the output to the programmed value when the torque
maximum position. The maximum programmable limit switch is activated.
value for “High Idle Speed” is generally 10 percent
above the rated engine speed. This allows the “FLS” (Full Load Setting)
overrun to be programmed from 0 percent up to 10
percent, depending on the application. “FLS” is a number that represents the adjustment to
the fuel system that was made at the factory in order
Note: “High Idle Speed” cannot be programmed to fine tune the fuel system. The correct value for
lower than TEL. this parameter is stamped on the engine information
plate. This value should only be changed if the
“Intermediate Engine Speed” engine is rerated or a new ECM is installed. Factory
passwords are required.
“Intermediate Engine Speed” defines the speed
for the engine when the intermediate engine “FTS” (Full Torque Setting)
speed switch is activated. This parameter can be
programmed to any engine speed between “Low “FTS” is similar to “FLS”. This value should only be
Idle Speed” and “TEL”. Engine speed will ramp at changed if the engine is rerated or a new ECM is
the rate that is defined by the programmed value installed. Factory passwords are required.
for “Engine Accel. Rate”.
“Air Shutoff”
“Engine Power Trim”
“Air Shutoff” allows the ECM to be programmed for
“Engine Power Trim” allows small adjustments to operation of an air shutoff system. If this parameter
be made to engine power within a selected rating. is programmed to “Installed”, the ECM will activate
This parameter is expressed as a percentage and the air shutoff solenoid in the event of an engine
is used to move the engine’s lug curve up or down overspeed condition.
by the programmed value.
Note: If an engine overspeed event occurs and “Air
Shutoff” is programmed to “Enabled”, switched
power to the ECM must be cycled and the air
shutoff solenoid must be manually reset before the
engine will restart.

14
“Maintenance Indicator Mode” Programmable Monitoring System (PMS)
The ECM records data that is related to equipment The Programmable Monitoring System (PMS)
maintenance. The ECM will activate the maintenance determines the level of action that is taken by the
due lamp when scheduled maintenance is due. The ECM in response to a condition that can damage
maintenance due lamp can be reset by actuating the engine. These conditions are identified by the
the maintenance due reset switch. The maintenance ECM from the signals that are produced from the
interval may be based on operating hours or fuel following sensors.
consumption. The ECM provides information that
pertains to maintenance intervals and the last • Coolant level sensor
maintenance that was performed.
• Engine coolant temperature sensor
“PM1 Interval”
• Engine oil pressure sensor
“PM1 Interval” allows the customer to define the
maintenance interval if “Maintenance Indicator • Engine speed/timing sensors
Mode” is programmed to one of the manual options.
• Fuel pressure sensor
“Aux Press Enable”
• Fuel temperature sensor
“Aux Press Enable” should be programmed to
“Enabled” if an auxiliary pressure sensor is installed. • Intake manifold air temperature sensor
This will allow the Engine Monitoring System (EMS)
display to monitor the pressure of another system.

“Aux Temp Enable”

“Aux Temp Enable” should be programmed to

“Enabled” if an auxiliary temperature sensor is
installed. This will allow the Engine Monitoring
System (EMS) display to monitor the temperature
of another system.

“Ether Enable”

“Ether Enable” should be programmed to “Enabled”

if an ether injection system is installed on the engine.
This allows the ECM to control ether injection.

“Oil Grade”

“Oil Grade” should be programmed to match the

grade of oil that is installed in the engine in order to
aid in cold weather starting.

Note: The “15W40” plug must be installed for the

programmed parameter to become effective. Refer
to Operation and Maintenance Manual, “Engine Oil
and Filter - Change” for more information.

15
Table 4
Programmable Monitoring System Parameters
Time Delay in
Default Set Points
Parameter Action Seconds “Disable”
Value
Range Default Range Default
75 C
Warning None YES
“High Engine Air Inlet (167 F)
ON 4 None
Temperature” 0 to 79 C
Derate YES
120 (174 F)
85 C (185 F)
105 C
Warning None to YES
(221 F)
105 C (221 F)
ON
86 C (187 F)
“High Engine Coolant 106 C
Derate 4 to YES
Temperature” (223 F)
0 to 106 C (223 F)
120 87 C (189 F)
107 C
Shutdown OFF to YES
(224 F)
107 C (224 F)
Warning YES
“Low Engine Oil ON 2
Derate None Maps are not programmable. YES
Pressure”
Shutdown OFF 10 YES
Warning None 0.6 (1) 1800 to 2800 2800 YES
or or
“Engine Overspeed” ON
Shutdown None 1.0 1800 to 3100 3100 YES
(3126B) (3126B)
Warning ON YES
“High Fuel Filter
Derate None 10 Maps are not programmable. YES
Pressure Restriction” OFF
Shutdown YES
“High Fuel Pressure” Warning ON None 2 Maps are not programmable. YES

Warning YES
ON 0 to
“Low Coolant Level” Derate 10 Not Applicable YES
120
Shutdown OFF YES
 
70 C (158 F)
80 C
Warning 4 to YES
(176 F)
ON
0 to 80 C (176 F)
“High Fuel Temperature”
Derate 120 81 C (178 F) YES
91 C
3 to
(196 F)
Shutdown OFF 91 C (196 F) YES
(1) The time delay on the ET screen for the programmable monitoring system will be represented as zero “0”. This is necessary because
ET cannot display decimal numbers such as 0.6. The Warning for the engine overspeed will be activated when the engine speed has
reached the set point for the warning for 0.6 seconds.

16
Required Tools Table 6

Table 5
Required Electronic Service Tools for the Use of ET

Required Service Tools Part Number Description

Part Number Description Required

IBM compatible PC with
1U-7563 Hex Key Wrench (4 mm) 100 MHz Pentium processor
1U-5804 Crimp Tool (12−26 AWG) 32 MB of RAM
N/A 200 MB of available hard drive space
7X-1710 Multimeter Probes
CD-ROM drive
9U-7330 Digital Multimeter 3.5" 1.44 MB floppy disk drive
Windows NT, 2000, or 9x
147-6456(1) Wedge Removal Tool (Deutsch DT) RS232 port with 16550AF UART
VGA monitor or display
1U-5805 Wire Removal Tool (14 AWG)
Recommended
151-6320(1)(2) Wire Removal Tool (14-18 AWG) IBM compatible PC with
175-3700 Connector Repair Kit (Deutsch DT) 450 MHz Pentium III processor
N/A
190-8900 Connector Repair Kit (Deutsch HD) 128 MB of RAM
1 GB of available hard drive space
140-9944 Terminal Repair Kit 24X speed CD-ROM drive
(1) Included in 175-3700 Connector Repair Kit
(2) Included in 190-8900 Connector Repair Kit JERD2124 “Electronic Technician Program” (ET)

“Data Subscription for All Engines and

There are other tools that are required to JERD2129
Machines”
troubleshoot the engine electronics. Refer to the
appropriate Troubleshooting module for your engine 171-4400(1) Communication Adapter II Gp
for more information. (1) 7X-1700 Communication Adapter Gp may also be used.

Electronic Technician (ET)

ET can display the following information:

• Parameters
• Event codes
• Diagnostic codes
• Engine configuration
ET can be used by the technician to perform the
following functions:

• Diagnostic tests
• Sensor calibrations
• Flash programming
• Set parameters
The following components are required to use ET to
service the engine.

17
Connecting ET and the Communication Adapter

g00758025
Illustration 12
g00647144 Communication Adapter I
Illustration 11
Communication Adapter II (1) Personal computer (PC)
(2) 7X-1425 Data Link Cable As (PC Serial)
(1) Personal computer (PC)
(3) 7X-1701 Communication Adapter I
(2) 160-0141 Adapter Cable (PC Serial)
(4) 139-4166 Data Link Cable As
(3) 171-4401 Communication Adapter II
(4) 160-0133 Adapter Cable (Data Link)
Note: Item (2) is part of the 7X-1700 Communication
Note: Items (2), (3), and (4) are part of the Adapter Gp.
171-4400 Communication Adapter II Gp.
Use the following procedure to connect ET and the
Communication Adapter.

1. Turn off all switched power to the ECM.

2. Connect cable (2) between the “COMPUTER”

(“Service Tool”) port of communication adapter
(3) and the RS232 serial port of PC (1).

3. Connect cable (4) between the “DATA LINK”

(“Control”) end of communication adapter (3)
and the service tool connector.

4. Turn on the switched power to the ECM. The

ECM must be powered in order for ET to operate.
ET will operate while the engine is running or
stopped.

ET Support

For authorization and ordering information, contact

Caterpillar Media and Product Information Logistics.
You can call between 7:00 AM and 5:00 PM Central
Standard Time.

18
 Phone: (800) 566-7782, (309) 266-0942

Facsimile: (309) 266-4394

E-mail: [email protected]

If you are having problems with the software,

you can contact the SIS Help Desk. You can call
between 6:00 AM and 9:00 PM Central Standard
Time.

Phone: (800) 765-0999, (309) 675-0999

Facsimile: (309) 675-0725

E-mail: [email protected]

Switches
Measuring Voltage in Switch Circuits

g00763648
Illustration 13
Voltage measurement

Measuring Current in Switch Circuits

g00763649
Illustration 14
Current measurement

19
Measuring Resistance in Switch Circuits

g00763650
Illustration 15
Resistance measurement

Mounting Dimensions for Switches Switch Specifications

All switches that are provided by the OEM and
connected to the Electronic Control Module (ECM)
must be of a two wire design. These switches must
be externally connected to the negative battery.
Switches which are grounded internally to the case
must not be used.

Supplied voltage from the ECM to the switches

will not normally exceed 12 VDC. Normal current
through the switches will not exceed 5.0 mA.

Momentary opening or closing of the switches and

contact chatter should not exceed 100 milliseconds
in duration. Vibration or shock that is normally found
g00766635
Illustration 16 in the application should not cause opening or
Toggle Switch closing of the switches.

The plating on the contacts should not be

susceptible to corrosion or oxidation. Gold plated
switch contacts are recommended.

When a switch contact is opened or the wiring

harness has an open circuit, the internal pull up
voltages of the ECM force the respective input to
12 VDC. Closing an OEM installed switch must
short circuit the switch input to the negative battery
ground stud that is located near the J61/P61
Customer Connector. Refer to “Battery Circuit
Requirements”.

All switches are supplied by the OEM. If a problem

occurs with an undetermined cause, connect ET
and observe the status of the switch.

g00766842
Illustration 17
Rocker Switch

20
Voltage Thresholds at the ECM
When any of the switch contacts are closed, the
voltage drop through the switch circuit must be less
than 0.9 VDC. This measurement should be taken at
the respective control input and the negative battery
input to the ECM. This measurement includes the
following values:

• Ground potential differences

• Voltage drop across the switch
• Voltage drop across the wiring harness
When any of the switch contacts are open, the
resistance between the respective control input and
the negative battery input to the ECM should not be
less than 5,000 Ohms. Potential paths for leakage
may exist within the following components:

• Connectors
• Harnesses
• Switches
Note: OEM installed switches must be connected
to negative battery.

21
Connectors

g00732050
Illustration 18

Pull Test Perform the pull test on each wire. Each terminal
(socket or pin) and each connector should easily
The pull test is used to verify that the wire is properly withstand 45 N (10 lb) of pull and each wire should
crimped in the terminal and the terminal is properly remain in the connector body.
inserted in the connector.

22
Installation of Terminals and Seal Plugs • All unused cavities for sockets and pins must be
filled with 8T-8737 Seal Plugs in order to ensure
that the connector is sealed. The seal plugs must
be installed from the wire insertion side of the
plug or receptacle. The seal plugs must seal
correctly. The head of the seal plug should rest
against the seal. Do not insert the head of the
seal plug into the seal. Refer to Illustration 19 for
correct installation of plugs.

J61/P61 Customer Connector

g00690571
Illustration 19
Installation of seal plugs

g00735800
Illustration 21

Ensure that the allen head screw in the customer

connector is tightened to a torque of 2.25 ± 0.25 N·m
(20 ± 2 lb in). All unused cavities for sockets and
pins must be filled with 8T-8737 Seal Plugs in
order to ensure that the connector is sealed.
g00738352
Illustration 20
Terminal connections The acceptable diameter of the insulation for a
wire that is connected to the customer connector is
The following requirements ensure the correct 2.54 to 3.43 mm (0.100 to 0.135 inch).
installation of terminals in the connectors:
Deutsch DT Connectors
• Do not solder the sockets and pins to the wires.
A DT connector has a wedge that locks the pins
• Never crimp more than one wire into a socket and the sockets in place. The wedge can be
or a pin. The 186-3735 Connector Pin and removed and replaced without cutting the wires. The
the 186-3736 Connector Socket are designed 147-6456 Wedge Removal Tool (DT Connector)
to accept only one 16 or 18 AWG wire. The aids in the removal of the wedges. When the
9W-0844 Connector Socket and the 9W-0852 receptacle is inserted into the plug, a click should
Connector Pin are designed to accept only one be heard as the two halves lock together. The
14 AWG wire. Do NOT insert multiple wires of a connector should not be able to be pulled apart.
smaller gauge.
The acceptable range for the diameter of the
• All sockets and pins should be crimped on the insulation on the wire that is used with the DT
wires. Use the 1U-5804 Crimp Tool for 12 to 26 connectors is 2.24 to 3.81 mm (0.088 to 0.150 inch).
AWG wire.
Inspect the plug and the receptacle in order to
ensure that the following conditions are met:

23
• The connector seals are seated. Table 7
Heat Shrink Tubing (Adhesive Lined)
• The pins and sockets are not damaged.
Part Number I.D. Before Shrink I.D. After Shrink
• The pins and the sockets are securely installed 3.20 mm 1.58 mm
on the wires. Perform the 10 pound pull test. 8T-6342
(0.126 inch) (0.062 inch)

• The correct number of pins and sockets exist on 4.70 mm 1.78 mm

3E-9553
both halves of the connector. (0.185 inch) (0.070 inch)
5.72 mm 1.27 mm
125-7874
• The pins align correctly with the sockets. (0.225 inch) (0.050 inch)
6.40 mm 3.20 mm
• The locking tabs are not damaged. Replace the 9X-2109
(0.252 inch) (0.126 inch)
connector if the tab is damaged.
7.44 mm 1.65 mm
125-7585
• The wedges are not damaged. (0.293 inch) (0.065 inch)
10.85 mm 2.41 mm
Deutsch HD Connectors 119-3662
(0.427 inch) (0.095 inch)

Ensure that the wires in the plug align with the 17.78 mm 4.45 mm
125-7876
(0.700 inch) (0.175 inch)
corresponding wires in the receptacle. Ensure
that the index markings on the plug and the 68.00 mm 22.00 mm
8C-3423
receptacle are aligned. Rotate the plug until the (2.678 inch) (0.866 inch)
plug slips into the receptacle. Rotate the coupling
by approximately 90 degrees until a click is heard.
Ensure that the plug and the receptacle cannot be Wire Size Requirements
pulled apart.
The size of the wire that is used to connect all
The acceptable range for the diameter of the electrical components must be of adequate size
insulation of the wire that is used with the connectors for the maximum current in the circuit. Observe the
is 2.54 to 3.94 mm (0.100 to 0.155 inch). requirements in Table 8.
Table 8
Wiring Considerations Wire Size Requirements
The Caterpillar supplied engine wiring harness must Circuit Location Size Part Number
not be spliced into or modified in any way that may
Electronics
affect the engine operation Negative
Ground 4 AWG -
Battery
Stud
Caterpillar recommends sealing all ring terminals
and splices on the customer side of the J61/P61 Switched 14 -
J61:1
customer connector with Raychem ES2000 Positive Battery AWG
adhesive lined heat shrink tubing, or an equivalent J61:48
substitute. Refer to Table 7. Unswitched 14 -
J61:52
Positive Battery AWG
J61:53
18
CAT Data Link+ J61:7 143-5018 (1)
AWG
18
CAT Data Link− J61:6 143-5018 (1)
AWG
J1939 (CAN) 19
J61:16 153-2707 (2)
Data Link+ AWG
J1939 (CAN) 19
J61:17 153-2707 (2)
Data Link− AWG
J1939 (CAN) 19
J61:18 153-2707 (2)
Data Link Shield AWG

- 16 -
All Other
AWG
(1) 143-5018 Cable (Twisted Pair)
(2) 153-2707 Cable (Shielded Twisted Pair)

24
Table 9 Battery Circuit Requirements
Metric Equivalents for AWG Wire Numbers
Grounding
AWG 20 18 16 14 12 4
Diameter (mm) 0.8 1.0 1.3 1.6 2.0 3.2 NOTICE
Improper grounding can cause uncontrolled or
Harness Routing unreliable circuit paths and electrical noise. This can
result in damage to the engine bearings, and other
engine components.

Proper grounding of the unit and the engine

electrical systems is necessary for proper
performance and reliability. Improper grounding
results in unreliable electrical circuit paths that may
damage main bearings, crankshaft bearing journal
surfaces, and aluminum components. This may
also cause electrical noise, which may degrade the
performance of the control system. Diagnosing and
repairing these problems is often very difficult.

Negative Battery Connection

NOTICE
The customer must provide a 4 AWG or larger ground
cable from the electronics ground stud on the engine
to negative battery.

Illustration 22
g00690568 All ground paths must be capable of carrying any
likely fault currents. On units that are equipped with
Harness Routing
an air starting motor, a cable of at least 4 AWG is
required between the electronics ground stud on
The routing of the OEM wiring harness should be
the engine and the negative battery bus. On units
designed so that the radius of any bend is greater
that are equipped with an electric starting motor, a
than two times the diameter of the wiring harness.
cable of at least 4 AWG is required between the
Curvatures should be avoided within 25 mm
electronics ground stud on the engine and the
(1.0 inch) of any connector in order to avoid seal
negative post on the starting motor. The electronics
distortion (moisture entry path).
ground stud is located on the bracket for the
J61/P61 customer connector.

A cable of at least 4 AWG is recommended in order

to handle alternator currents. The alternator and
other electrical loads should be grounded at the
same point in order to avoid unwanted electrical
currents.

Note: Grounding through frame members is not

recommended.

A maximum of three ring terminals should be

connected to the electronics ground stud in order
to ensure integrity of the ground connection. The
use of more than three terminals at the electronics
ground stud can cause the connection to become
loose.

25
Welding on a Machine that is Equipped with an
Electronic Engine

Proper welding procedures are necessary in order

to avoid damage to the engine’s ECM, sensors,
and associated components. If at all possible, the
component that is to be welded should be removed
from the machine for welding. If removal of the
component is not possible, the following procedure
must be followed when welding on a machine that
is equipped with a Caterpillar Electronic Engine.
This procedure is considered the safest and should
provide minimum risk of electronic component
damage.

NOTICE
Do not ground the welder to electrical components
such as the ECM or sensors. Improper grounding
can cause damage to the drive train bearings,
hydraulic components, electrical components, and
other components.
g00762464
Illustration 23
Clamp the ground cable from the welder to the In the example above, the current flow from the welder to the
component that will be welded. Place the clamp as welder ground clamp will not cause damage to any associated
close as possible to the weld. This will help reduce components.
the possibility of damage.
4. Connect the welding ground cable directly to
the part that will be welded. Place the ground
1. Stop the engine. Turn the switched power to the cable as close as possible to the weld in order to
OFF position. reduce the possibility of welding current damage
to bearings, hydraulic components, electrical
2. Disconnect the negative battery cable from components, and ground straps.
the battery. If a battery disconnect switch is
provided, open the switch. Note: If electrical/electronic components are used
as a ground for the welder, or electrical/electronic
3. Disconnect the J1/P1 and J2/P2 connectors from components are located between the welder ground
the ECM. Move the harness to a position that will and the weld, current flow from the welder could
not allow the harness to accidentally move back severely damage the component.
and make contact with any of the ECM pins.
5. Protect the wiring harness from welding debris
and spatter.

6. Use standard welding techniques to weld the

materials.

26
Switched Positive Battery and Suppression of Voltage Transients
Unswitched Positive Battery
The installation of transient suppression at the
source of the transient is recommended. Caterpillar
follows a stringent electrical environment standard
that is similar to SAE recommended practices.

The use of inductive devices such as relays

and solenoids can result in the generation of
voltage transients in electrical circuits. Voltage
transients that are not suppressed can exceed
SAE specifications and lead to the degradation of
electronic control system performance.

g00737195
Illustration 24

Note: All battery connections to the ECM are

required for the engine to operate.

The electronic control system can operate on either

a 12 V electrical system or a 24 V electrical system.
Switched positive battery and unswitched positive
battery connections to the ECM are made at the
P61 customer connector.
g00737516
The ECM receives electrical power through the Illustration 25
switched positive battery input. Protection for this Using a diode in a relay as a voltage transient suppressor
circuit must be rated at 15 Amp (12 V or 24 V
system). The OEM should specify relays and solenoids
with built-in voltage transient suppression. Refer
The unswitched positive battery input is used to to Illustration 25 for ways to minimize voltage
power ECM memory that contains maintenance transients from relays and solenoids without built-in
information and certain logged diagnostics. voltage transient suppression. Techniques include
Protection for the unswitched positive battery circuit the installation of a diode or resistor of the proper
is specified as 15 Amp. size in parallel with the solenoid or the relay coil.
Other techniques may also be used.
Powering the electronic control system through
dedicated circuits with circuit breakers reduces Inductive devices such as relays or solenoids
the possibility of degradation of electronic control should be located as far as possible from the
system performance. This also minimizes the components of the electronic control system. Wiring
chance of an engine shutdown due to a short in harnesses that are installed by the OEM should be
the electrical system. Additional loads should not routed as far as possible from the wiring harness
be connected between the ECM and the circuit of the electronic control system in order to avoid
protection for the ECM. problems that are associated with electrical noise.

Note: DO NOT use in-line fuses for circuit protection.

Caterpillar recommends using circuit breakers for
circuit protection. Circuit breakers should be located
with other circuit protection devices in a centrally
located, dedicated panel. If circuit breakers that
automatically reset are used, consideration of the
environment of the location of the breaker is critical
and the effect on the trip point is critical. The trip
point of some circuit breakers can be significantly
reduced below the rated trip point if the circuit
breaker is exposed to high temperatures. This
can cause intermittent shutdowns that result with
needless replacement of electronic components.

27
Customer Installed Components
Note: Refer to the appropriate Parts Manual for your
engine for further details on parts information.

P61 Customer Connector

The P61 customer connector utilizes a 8T-9834
Connector Plug. All circuits that are connected to
the P61 customer connector require a 186-3736
Connector Socket. Any unused cavities in the
connector must be filled with 8T-8737 Seal
Plugs. The torque for the allen head screw is
2.25 ± 0.25 N·m (20 ± 2 lb in).
Table 10
Customer Connector Pin-Outs
J61/P61 Circuit Function J61/P61 Circuit Function
1 Unswitched Positive Battery 21 -

2 Torque Limit Switch 22 Ether Start Valve Relay +

3 - 23 -

4 Air Shutoff Solenoid Relay + 24 Diagnostic Lamp

5 Air Shutoff Solenoid Relay Common 25 Warning Lamp
6 CAT Data Link − 26 Switched Positive Battery
7 CAT Data Link + 27 Remote Shutdown Switch
8 Digital Sensor Power (+8 VDC) 28 Intermediate Engine Speed Switch
9 Digital Sensor Return 29 PTO Enable Switch
10 Throttle Position Sensor Signal 30 PTO Ramp Up/Set Switch
11 Auxiliary Temperature Sensor Signal 31 Unswitched Positive Battery
12 Maintenance Due Reset Switch 32 Unswitched Positive Battery
13 Maintenance Due Lamp 33 Auxiliary Pressure Sensor Signal
14 Analog Sensor Power (+5 VDC) 34 -

15 Analog Sensor Return 35 -

16 J1939 (CAN) Data Link Shield 36 Coolant Level Sensor Signal

17 J1939 (CAN) Data Link + 37 -

18 J1939 (CAN) Data Link − 38 Starting Aid Override Switch

19 PTO Interrupt Switch 39 PTO Ramp Down/Resume Switch
20 - 40 Overspeed Verify Switch

Sensor Return Connections Connecting switches and/or the throttle position

sensor to the sensor returns at the P61 customer
Certain components that interface directly with the connector can degrade the performance of the
ECM are connected to the dedicated sensor returns electronic control system. These components must
at the P61 customer connector. Separate sensor be connected to negative battery. Any relays or
returns are provided for analog signal and digital solenoids that are driven by the ECM must not be
signals. Refer to the Electrical System Schematic. connected to the sensor returns at the P61 customer
connector. These components must be connected
to negative battery. Refer to the Electrical System
Schematic for details.

28
J66 Customer Supplied Service Tool Air Shutoff System
Connector
The engine may be equipped with an air shutoff
An additional service tool connector is system. The parameter for “Air Shutoff” must be
recommended in applications that have limited programmed to “Enabled” for the ECM to operate
accessibility to the J63 engine service tool this feature in the event of an engine overspeed
connector. Proper wiring of the J66 customer condition.
supplied service tool connector is essential for
reliable communication of data. Use 143-5018 Note: If an engine overspeed event occurs and “Air
Cable (Twisted Pair) and dedicated terminal strips Shutoff” is programmed to “Enabled”, switched
for all data connections. Mount the terminal strips power to the ECM must be cycled and the air
in a central location in order to minimize the overall shutoff solenoid must be manually reset before the
length of the data link cable. The total length of the engine will start.
data link cable should not exceed 30 m (100 ft).
Table 12
Required Parts
Part Number Description Qty
(1)
Air Shutoff Group 1
155-2270 Connecting Plug Kit 1
186-3736 Connector Socket 4
2L-8065 Terminal (Relay) 1
2L-8067 Terminal (Solenoid ) 1
(1)
N/A 10 AWG Wire
(1)
N/A 16 AWG Wire
g00739919 (1) Refer to the appropriate Parts Manual for your engine.
Illustration 26 (1) Fabricated to length
Table 11
Required Parts
Part Number Description Qty
8T-8736
or
9W-1951 Connector Receptacle 1
(flanged
mounting)
186-3736 Connector Socket 2
8C-6354 Receptacle Cap 1
186-3735 Connector Pin 4
8T-8737 Seal Plug 5 g00765297
Illustration 27
(1)
143-5018 Cable (Twisted Pair) Schematic
(1)
N/A 16 AWG Wire
(1) Fabricated to length

29
Alarm Lamps (Diagnostic and Warning) Diagnostic Lamp Operation

Installation of both a warning lamp and a diagnostic Installation of a diagnostic lamp is strongly
lamp is strongly recommended in order to alert the recommended. The diagnostic lamp is used to
operator of problems that may be detected by the alert the operator of an electronic control system
ECM. malfunction (active diagnostic code).

Caterpillar’s proprietary two digit flash codes can

be viewed from the diagnostic lamp. A sequence
of flashes represents the system diagnostic
message (flash code). The first sequence of flashes
represents the first digit of the flash code. After a
two second pause, a second sequence of flashes
which represent the second digit of the flash code
will occur. Any additional flash codes will follow after
a pause. These flash codes will be displayed in the
same manner.

Note: Flash codes should only be used to indicate

the nature of a diagnostic condition. Do not use
g00739656
flash codes to perform detailed troubleshooting.
Illustration 28
Schematic Warning Lamp Operation
Table 13 Installation of a warning lamp is strongly
Required Parts recommended. The warning lamp is used to alert
the operator of an engine operating condition which
Part Number Description Qty has the potential to cause engine damage (event
186-3736 Connector Socket 2 code).
Lamp 2 The warning lamp will come ON for five seconds
Circuit Protection (1 Amp) 1 when the ECM is first turned ON in order to indicate
(1)
that the lamp circuit is functional.
N/A 16 AWG Wire
(1) Fabricated to length

Lamp Driver Electrical Specifications

Electrical specifications for the ECM low side

drivers that are used for the diagnostic lamp and
the warning lamp allow a maximum current load
of 0.30 Amp (300 mA). The ECM does not provide
diagnostic codes for either lamp circuit.

Low side ECM drivers provide a path to negative

battery in order to activate the device (lamp,
etc) that is connected to the circuit. While circuit
protection is recommended for the lamp driver
circuits, Caterpillar does not require dedicated
circuit protection.

30
Auxiliary Pressure Sensor Auxiliary Temperature Sensor
An additional pressure sensor input is provided in An additional temperature sensor input is provided
order to allow an auxiliary pressure to be displayed in order to allow an auxiliary temperature to be
on ET, EMS display modules, and J1939 (CAN) displayed on ET, EMS display modules, and J1939
display modules. (CAN) display modules.

To utilize this feature, the Caterpillar supplied To utilize this feature, the Caterpillar supplied
pressure sensor must be used and the parameter temperature sensor must be used and the
“Aux Press Enable” must be programmed to parameter “Aux Temp Enable” must be programmed
“Enabled”. This pressure sensor is an analog to “Enabled”. This temperature sensor is a digital
sensor with an operating range of 0 to 2900 kPa PWM sensor with an operating range of 0 to 120 C
(0 to 420 psi). (32 to 216 F).

g00738821 g00738819
Illustration 29 Illustration 30
Schematic Schematic

Table 14 Table 15
Required Parts Required Parts
Part Number Description Qty Part Number Description Qty
161-9932 Pressure Sensor (Auxiliary) 1 131-0427 Temperature Sensor (Auxiliary) 1
155-2260 Connecting Plug Kit 1 8T-8731 Connector Plug 1
186-3736 Connector Socket 6 186-3736 Connector Socket 6
(1) (1)
N/A 16 AWG Wire N/A 16 AWG Wire
(1) Fabricated to length (1) Fabricated to length

31
Coolant Level Sensor Ether Injection System
An optional coolant level sensor allows the ECM to The ECM can drive an ether control relay in order
monitor the coolant level in order to have the ability to aid in cold weather starting and operation. In
to warn the operator of a low coolant level. automatic mode, ether injection is controlled by the
ECM. A starting aid switch allows the operator to
The sensor output voltage is approximately 0 VDC manually inject additional ether.
(negative battery) when coolant is present. The
sensor output voltage is approximately 5 VDC when Note: Do not connect the ether valve directly to the
coolant is not present. The ECM supplies the sensor ECM output. Install a relay between the ether valve
with 8 VDC. and the ECM.

Note: The sensor must be mounted in a position

which keeps the sensing element immersed under
all operating conditions. The sensor is normally
installed in the radiator top tank. The sensor is
supplied with thread sealant on the threads, so it
is not necessary to apply thread sealant on a new
sensor. Although, if the sensor has been removed,
apply 5P-3413 Pipe Sealant to the threads before
reinstallation.

g00739426
Illustration 32
Schematic

Table 17
Required Parts
Part Number Description Qty
(1)
Ether Starting Aid Gp 1
7N-8001 Toggle Switch (SPST, Momentary) 1
g00738292
Illustration 31
186-3736 Connector Socket 2
Schematic
2L-8074 Terminal (for Switch) 2
Table 16 (2)
N/A 16 AWG Wire
Required Parts (1) Refer to the appropriate Parts Manual for your engine.
(2) Fabricated to length
Part Number Description Qty
165-6634 Coolant Level Sensor 1
155-2260 Connecting Plug Kit 1
186-3736 Connector Socket 6
(1)
N/A 16 AWG Wire
(1) Fabricated to length

32
Inlet Air Heater (3126B and C-9 Engines) Intermediate Engine Speed Switch
3126B and C-9 Industrial Engines come equipped The intermediate engine speed switch allows the
with an inlet air heater to aid in cold weather operator to change the desired engine speed from
starting. The heater has a ground strap that bolts the current engine speed to the programmed value
to the cylinder head. The control circuit from the for “Intermediate Engine Speed”. Engine speed will
ECM is included in the engine wiring harness. The ramp at the rate that is defined by the programmed
positive battery circuit must be connected to the value for “Engine Accel. Rate”.
inlet air heater relay through a 100 Amp (130 Amp
peak) circuit breaker.
Table 18
Required Parts
Part Number Description Qty
N/A Circuit Breaker (100 Amp) 1
g00739238
Illustration 34
9G-4343 Terminal 3
Schematic
(1)
N/A 4 AWG Wire
(1) Fabricated to length Table 19
Required Parts
Part Number Description Qty
8D-2676 Toggle Switch (SPST) 1
186-3736 Connector Socket 1
2L-8074 Terminal 2
(1)
N/A 16 AWG Wire
(1) Fabricated to length

g00779826
Illustration 33
Schematic

33
Maintenance Due Lamp and Maintenance Overspeed Verify Switch
Due Reset Switch
NOTICE
The maintenance due lamp illuminates in order to Activating the overspeed verify switch will result in
alert the operator when scheduled maintenance is an engine shutdown when engine speed reaches 75
due. When the maintenance due reset switch is percent of the overspeed set point.
activated, the maintenance interval values (fuel or
hours) in the ECM are reset to zero.
An overspeed shutdown feature is provided in order
to help prevent damage to the engine or driven
equipment in the event of an overspeed condition.
The overspeed verify switch allows the operator
or a service technician to quickly verify that the
overspeed protection system is operating correctly.
When the overspeed verify switch is activated, the
engine will shut down when engine speed reaches
75 percent of the overspeed setpoint. The ECM
shuts down the engine by disabling fuel injection
and activating the relay for the air shutoff solenoid.

Note: The air shutoff solenoid must be manually

reset in order to restart the engine.
g00739280
Illustration 35
Schematic

Table 20
Required Parts
Part Number Description Qty
g00739255
7N-8001 Toggle Switch (SPST, Momentary) 1 Illustration 36
Schematic
186-3736 Connector Socket 2
2L-8074 Terminal 2 Table 21

Lamp 1 Required Parts

Circuit Protection (1 Amp) 1 Part Number Description Qty

N/A 16 AWG Wire (1) 7N-8001 Toggle Switch (SPST, Momentary) 1

(1) Fabricated to length 186-3736 Connector Socket 1
2L-8074 Terminal 2
(1)
N/A 16 AWG Wire
(1) Fabricated to length

34
PTO Switches PTO Enable Switch

The ECM can be programmed to operate in either The PTO enable switch is used to determine
one of the two PTO configurations that are available. whether the ECM should acknowledge the PTO
When “PTO Mode” is programmed to “Ramp ramp up/down switch.
Up/Ramp Down”, the ECM allows PTO operation
with traditional features. When “PTO Mode” is PTO Ramp Up/Down Switch
programmed to “Set/Resume”, the ECM allows PTO
operation with enhanced features. When the PTO enable switch is in the ON position,
the throttle position sensor is disabled and the
“Ramp Up/Ramp Down” Mode desired engine speed is controlled by the PTO
ramp up/down switch. The Ramp Up input and the
Ramp Down input cannot be connected to negative
battery at the same time. If this occurs, the ECM will
generate a diagnostic code and the ECM will make
no adjustments to the desired engine speed when
the unit is in the PTO mode.

Note: The ECM will use the selected speed that

is higher when the ECM chooses between the
throttle input or the PTO input. When the switch is
toggled, the engine will respond according to the
programmed value for “Engine Accel. Rate”. When
the switch is open (center position), the engine will
maintain the current desired engine rpm. “Opened”
in this case means that the switch is in the center
g00741240
Illustration 37 position.
Schematic

Note: If PTO is the only means of controlling engine

speed, the PTO enable circuit may be wired directly
to negative battery.
Table 22
Required Parts
Part Number Description Qty
8D-2676 Toggle Switch (SPST) 1
9G-0011 Toggle Switch (SPDT Momentary) 1
186-3736 Connector Socket 3
2L-8074 Terminal 5
(1)
N/A 16 AWG Wire
(1) Fabricated to length

Switch inputs:

• PTO Enable
• Ramp Up
• Ramp Down

35
“Set/Resume” Mode PTO Enable Switch

The PTO enable switch is used to determine

whether the ECM should acknowledge the PTO
ramp up/down switch.

Set (Ramp Up) Switch

• If the input is momentarily connected to negative

battery, the desired engine speed will be set to
the current engine speed.

• If the input is connected to negative battery and

held in that position, the desired engine speed
will increase according to the programmed value
g00739133
for “Engine Accel. Rate”.
Illustration 38
Schematic • After the desired engine speed is set, momentarily
connecting this input to negative battery will
Note: If PTO is the only means of controlling engine increase the engine speed in increments of 20
speed, the PTO enable circuit can be wired directly rpm.
to negative battery.
Resume (Ramp Down) Switch
Table 23
Required Parts • If this input is momentarily connected to negative
battery, the desired engine speed will be set to
Part Number Description Qty the last known value that was used during PTO
8D-2676 Toggle Switch (SPST) 2 operation.
9G-0011 Toggle Switch (SPDT Momentary) 1
• If this input is connected to negative battery and
186-3736 Connector Socket 4 held in that position, the desired engine speed
will decrease at the rate that is programmed for
2L-8074 Terminal 7 “Engine Accel. Rate”.
(1)
N/A 16 AWG Wire
(1) Fabricated to length
• After the desired engine speed is set, momentarily
connecting this input to negative battery will
decrease the engine speed in increments of 20
Switch inputs: rpm.
• PTO Enable PTO Interrupt Switch
• Set (Ramp up) When this input is open, the ECM uses the throttle
position sensor as the source for determining the
• Resume (Ramp down) desired engine speed. When this input is connected
to negative battery, the ECM returns control of the
• PTO Interrupt desired engine speed to the PTO.

When control of the desired engine speed is

transferred from the throttle position sensor to the
PTO, engine speed will change at the rate that is
programmed for “Engine Accel. Rate”. The PTO
set speed will be lost whenever the keyswitch is
turned OFF.

36
Remote Shutdown Switch
When the remote shutdown switch is activated
(closed), the ECM disables fuel injection in order to
stop the engine. To restart the engine, the remote
shutdown switch must be deactivated (opened) and
switched power to the ECM must be cycled.

Note: The air shutoff solenoid is not activated and

the ECM remains energized.

g00739640
Illustration 39
Schematic

Table 24
Required Parts
Part Number Description Qty
8D-2676 Toggle Switch (SPST) 1
186-3736 Connector Socket 1
2L-8074 Terminal 2
(1)
N/A 16 AWG Wire
(1) Fabricated to length

37
Throttle Position Sensor Mounting Dimensions

The throttle position sensor (TPS) eliminates the

mechanical throttle and governor linkages. The TPS
interprets the position of the throttle lever into an
electrical signal that is sent to the ECM. The throttle
position signal and the engine speed/timing signal
are processed by the ECM in order to precisely
control engine speed.

g00766664
Illustration 41
9X-9647 Throttle Position Sensor

g00738140
Illustration 40
Schematic

Table 25
Required Parts
Part Number Description Qty
9X-9647
or g00766531
134-0597 Illustration 42
or Throttle Position Sensor 1 134-0597 Throttle Position Sensor
134-0670
or
161-8906
8T-8732 Connector Receptacle 1
186-3735 Connector Pin 3
186-3736 Connector Socket 1
(1)
N/A 16 AWG Wire
(1) Fabricated to length

g00766523
Illustration 43
134-0670 Throttle Position Sensor

38
PWM Input Requirements

• Open collector sinking PWM output with a pull

up resistor

• Sensor stops
Low sensor stop ............................... 7.5 ± 2.5%
High sensor stop ............................ 92.5 ± 2.5%

• Output frequency
Minimum .................................................. 300 Hz
Nominal ................................................... 500 Hz
Maximum ................................................. 700 Hz

• Output voltage high

Minimum ................................................ 4.0 VDC
Nominal ................................................. 5.0 VDC

• Output voltage low Illustration 45

g00766798

Speed control with PWM input

1.0 mA sink current
Nominal ............................................... 0.23 VDC
Maximum ............................................. 0.25 VDC
10.0 mA sink current
Nominal ............................................... 0.65 VDC
Maximum ............................................... 0.7 VDC

• Output linearity
Duty cycle versus throttle lever position .. ± 2.5%

g00766342
Illustration 44
PWM input requirements

39
Torque Limit Switch
Torque output is limited to the programmed value
for “Engine Torque Limit” when the torque limit
switch is activated.

g00739775
Illustration 46
Schematic

Table 26
Required Parts
Part Number Description Qty
7N-8001 Toggle Switch (SPST, Momentary)
or 1
8D-2676 Toggle Switch (SPST)
186-3736 Connector Socket 2
2L-8074 Terminal 2
(1)
N/A 16 AWG Wire
(1) Fabricated to length

40
J1939 (CAN) Data Link
The SAE J1939 (CAN) data link is used to
communicate engine information to a J1939
receiving device. The CAN data link is limited to
broadcast only.

CAN Data Link Broadcast Parameters

Table 27
Parameters for Data Link Broadcast
Resolution Byte Order in Transmission
Parameter PGN Bytes (Offset) Message Rate
Active Diagnostic 65226 (1) (1) (1) (1)

Broadcast Announcement Message 60416 (1) (1) (1) (1)

Multi-packet Transfer Message 65227 (1) (1) (1) (1)

Previously Active Diagnostic Codes 65227 (1) (1) (1) (1)

1%/bit
Percent Load 61443 1 3 50 ms
(0%)
4 kPa/bit
Oil Pressure 65263 1 4 500 ms
(0 kPa)
0.05 V/bit
Battery Voltage 65271 2 5, 6 1.0 s
(0 V)
2 kPa/bit
Boost Pressure 65270 1 2 500 ms
(0 kPa)
1 C/bit
Coolant Temperature 65262 1 1 1.0 s
(-40 C)
4 kPa/bit
Fuel Pressure 65263 1 1 500 ms
(0 kPa)
1 C/bit
Fuel Temperature 65262 1 2 1.0 s
(-40 C)
0.05L/hr/bit
Fuel Rate 65266 2 1, 2 100 ms
(0Lhr)
0.125 rpm/bit
Engine Speed 61444 2 4, 5 15 ms
(0 rpm)
1 C/bit
Inlet Manifold Temperature 65270 1 3 500 ms
(-40 C)
1 C/bit
Auxiliary Temperature 65164 1 1 1.0 s
(−40 C)
16 kPa/bit
Auxiliary Pressure 65164 1 3 1.0 s
(0 kPa)
0.05 hr/bit
Engine Hours 65253 4 1, 2, 3, 4 50 ms
(0 hr)
(1) Refer to the SAE J1939 Diagnostic layer for more details.

41
Connecting Modules to the CAN Data
Link
Table 28
Required Parts
Installation of a Single Module
Part Number Description Qty
6 cm
5P-6001 Heat Shrink Tubing (2.4
inch)
15 cm
125-7876 Heat Shrink Tubing
(6 inch)
133-0969 Connector Socket (Extended) 2
133-0970 Receptacle As (Tee) 1
Receptacle As
134-2540 1
(Termination Resistor)
153-2707 Cable (Shielded Twisted Pair) (1)

165-0200 Cable As 1
165-0201 Cable As 1
174-0503 Connecting Plug Kit (2) 1
186-3736 Connector Socket 4
(1) Fabricated to length
(2) Use the blue wedge.

Table 29
Required Parts
Installation of Each Additional Module
Part Number Description Qty
6 cm
5P-6001 Heat Shrink Tubing (2.4
inch)
15 cm
125-7876 Heat Shrink Tubing
(6 inch)
133-0969 Connector Socket (Extended) 2 g00745029
Illustration 47
133-0970 Receptacle As (Tee) 1
Illustration 47 shows the connection of modules to
153-2707 Cable (Shielded Twisted Pair) (1)
the CAN data link. The following requirements must
165-0200 Cable As 1
be met for installation of modules on the CAN data
link:
174-0503 Connecting Plug Kit (2) 2
186-3736 Connector Socket 4 • 153-2707 Cable (Shielded Twisted Pair) must be
used for all CAN data link runs.
(1) Fabricated to length
(2) Use the blue wedge. • The total length of the data link run must not
exceed 40 m (130 ft).

• All splices into the data link require a 133-0970

Receptacle As (Tee).

• A 134-2540 Receptacle As (Termination

Resistor) must be installed at the end of the data
link in order to ensure proper operation.

42
Note: A termination resistor for the CAN data link is f. Cut two 3 cm (1.2 inch) pieces of 5P-6001
included in the Caterpillar supplied wiring harness Heat Shrink Tubing. Slide a piece of the heat
to the J61 customer connector. Only one additional shrink tubing over the shield at each end of
termination resistor needs to be installed at the end the cable. Position the heat shrink tubing so
of the data link run. that 1 cm (0.4 inch) of the socket is covered
and the remaining tubing is covering the
Use the following procedure to connect modules to shield. Apply heat until a complete seal is
the CAN data link: formed around the shield and the socket. Be
careful to avoid skin contact with any hot glue
that may seep from the heat shrink tubing.

g. Cut two 5 cm (2 inch) pieces of 125-7876

Heat Shrink Tubing. Slide a piece of the heat
shrink tubing over each end of the cable.

h. Insert the wires from one end of the data link

into the P61 customer connector. See Table
30.

Table 30
Terminal Locations in P61 Customer Connector
Wire Color Location in P61
g00783780
Illustration 48
Shield 16
Yellow 17
Green 18

i. Position the 125-7876 Heat Shrink Tubing

so that 2 cm (0.8 inch) of the exposed wires
are covered and the rest of the heat shrink
g00779822 tubing is over the cable. Apply heat until a
Illustration 49
complete seal is formed. Be careful to avoid
1. Run the CAN data link from the customer skin contact with any hot glue that may seep
connector to a module. from the heat shrink tubing.

Note: The end of the data link must be within j. Insert the sockets at the opposite end of the
approximately 15 cm (6 inch) of the module. The CAN data link into a 174-0503 Connecting
total length of the data link run must not exceed Plug Kit. See Table 31. Insert the blue wedge
40 m (130 ft). into the connector in order to secure the
terminals in place.
a. Run 153-2707 Cable (Shielded Twisted
Pair) from the P61 customer connector to the
location of the first module. Cut the cable to
length.

b. Remove 25 mm (1.0 inch) of insulation from

both ends of the cable.

c. Remove 7 mm (0.28 inch) of insulation from

each end of the green wire and the yellow
wire.

d. Crimp a 186-3736 Connector Socket on

each end of the green wire and the yellow
wire with a 1U-5804 Crimp Tool.

e. Crimp a 133-0969 Connector Socket

(Extended) on each end of the shield with a
1U-5804 Crimp Tool.

43
Table 31 e. Crimp a 133-0969 Connector Socket
Terminal Locations in the Plug (Extended) on each end of the shield with a
1U-5804 Crimp Tool.
Wire Color Location in the Plug
Shield C
f. Cut two 3 cm (1.2 inch) pieces of 5P-6001
Heat Shrink Tubing. Slide a piece of the heat
Yellow A shrink tubing over the shield at each end of
the cable. Position the heat shrink tubing so
Green B
that 1 cm (0.4 inch) of the socket is covered
and the remaining tubing is covering the
k. Position the 125-7876 Heat Shrink Tubing so shield. Apply heat until a complete seal is
that 1 cm (0.4 inch) of the plug is covered formed around the shield and the socket. Be
and the rest of the heat shrink tubing is over careful to avoid skin contact with any hot glue
the cable. Apply heat until a complete seal is that may seep from the heat shrink tubing.
formed around both the plug and the cable.
Be careful to avoid skin contact with any g. Cut two 5 cm (2 inch) pieces of 125-7876
hot glue that may seep from the heat shrink Heat Shrink Tubing. Slide a piece of the heat
tubing. shrink tubing over each end of the cable.

l. Plug the end of the data link into the single h. Install a 174-0503 Connecting Plug Kit on
end of a 133-0970 Receptacle As (Tee). each end of the cable. See Table 32. Insert
the blue wedge into the connector in order to
secure the terminals in place.

Table 32
Terminal Locations in the Plug
Wire Color Location in Plug
Shield C
Yellow A
Green B

i. Position the 125-7876 Heat Shrink Tubing so

that 1 cm (0.4 inch) of the plug is covered
g00746640 and the rest of the heat shrink tubing is over
Illustration 50
the cable. Apply heat until a complete seal is
2. Run the data link from the tee to another tee for formed around both the plug and the cable.
an additional module. Be careful to avoid skin contact with any
hot glue that may seep from the heat shrink
Note: For single module installations, proceed to tubing. Perform this process on both ends
Step 3. of the cable.

Note: The end of the data link must be within j. Plug one end of the new cable into one of
approximately 15 cm (6 inch) of the module. The the openings in the existing tee. Plug the
total length of the data link run must not exceed other end of the new cable into the single end
40 m (130 ft). of a 133-0970 Receptacle As (Tee) for the
additional module.
a. Run 153-2707 Cable (Shielded Twisted
Pair) from the tee to the location of the next k. If you are installing additional modules, repeat
module. Cut the cable to length. Step 2 for each module.

b. Remove 25 mm (1.0 inch) of insulation from

both ends of the cable.

c. Remove 7 mm (0.28 inch) of insulation from

each end of the green wire and the yellow
wire.

d. Crimp a 186-3736 Connector Socket on

each end of the green wire and the yellow
wire with a 1U-5804 Crimp Tool.

44
 a. Plug one end of a 165-0201 Cable As into
the open tee at the end of the data link.

b. Connect a 134-2540 Receptacle As

(Termination Resistor) to the other end of the
cable assembly.

g00746601
Illustration 51

3. Connect a receiving module to the tee.

a. Plug a 165-0200 Cable As into the

133-0970 Receptacle As (Tee).

b. Cut a 5 cm (2 inch) piece of 125-7876 Heat

Shrink Tubing. Slide the heat shrink tubing
over the module end of the cable assembly.

Note: Do not connect the shield to the receiving

module.

c. Connect the green wire (J1939 Data−) and

the yellow wire (J1939 Data+) on the module
end of the cable assembly to the appropriate
terminals in the module plug.

d. Trim the shield back to the existing heat shrink

tubing on the cable assembly. Position the
125-7876 Heat Shrink Tubing so that the
shield is completely insulated and a proper
seal can be obtained. Apply heat until a
complete seal is formed. Be careful to avoid
skin contact with any hot glue that may seep
from the heat shrink tubing.

e. Repeat Step 3 for each module.

g00746639
Illustration 52

4. Connect a termination resistor to the tee at the

end of the data link.

45
Engine Monitoring System (EMS) The main gauge module has ten indicators (two
rows of five) that are used to display the system
Display diagnostics. A digital LCD readout displays the
parameters that are monitored. When metric values
Overview are displayed, the units of measurement are
also displayed. When US values are displayed,
the units of measurement are not displayed. For
example, if metric values are being displayed, the
readout would be “35 kPa”. If US values are being
displayed, the readout would be “5”. (The unit of
measurement “psi” is NOT displayed.)

The following parameters are monitored:

• Auxiliary pressure
• Auxiliary temperature
• Battery voltage
• Coolant temperature
• Engine hours
• Engine load (percent)
g00746960
Illustration 53 • Engine oil pressure
The EMS display is used to display various engine • Engine speed
parameters. The EMS display supports backlighting
in order to provide excellent visibility in various light • Fuel pressure
conditions.
• Fuel rate
The engine ECM processes the operating
parameters and diagnostic information before • Fuel temperature
sending this information to the EMS display via the
CAT data link. The main gauge module displays • Inlet air temperature
the information that is received from the ECM. Only
two wires are required from the ECM to the display • Turbocharger outlet pressure (boost)
for communication of all of the engine operating
parameters. The quad gauge module has graduated warning
zones that display information in an analog format.
The EMS display incorporates three individual The quad gauge module displays the following
gauge modules which can be installed in various information:
locations in order to enhance operation. One main
gauge module is required for each desired operator • Battery voltage
station. The tachometer module and the quad
gauge module are optional. These optional modules • Coolant temperature
will NOT operate without being connected to a main
gauge module. • Engine oil pressure
The following information describes the function • Fuel pressure
and the requirements for installation of each gauge
module: The tachometer module displays engine speed
(rpm) on an analog gauge.

46
Mounting Dimensions for EMS Display
Modules

g00748502
Illustration 54

Note: Each module has identical dimensions. The Rear Mount

mounting options with bezels are described below.
A U-shaped bracket is required for applications
Each module can be mounted from either the front which are rear mounted. The bracket should push
or rear. Each module has a 5 mm tapped hole in up against the inside of the dash panel in order to
each corner (four holes), a 4 mm clearance hole in pull the module tightly against the outside of the
each corner, and four 6 mm tapped holes in the dash panel. Use 8T-3992 Screws (M6) to attach
back of the housing. the bracket to the holes in the rear of the module.

Front Mount Note: The bracket that is shown is a reference. The

length of the bracket legs must be adjusted in order
The fabricated gauge bracket is NOT required for to fit your dash panel.
applications that have a front mount.
The bezel can be attached to the gauge module
Bezels must be installed over the front of the with 7Y-7388 Screws (M5). Install the screws
module. Install 7Y-7388 Screws in the four corners through the bezel and into the tapped holes in the
of the bezel, through the dash panel, and into the flange of the module.
tapped holes in the gauge module.
Note: The bezel screws must not exceed 12 mm
(0.47 inch) in length. If a longer screw is used, the
screw will protrude through the module and into the
dash panel.

47
Required Parts (Table 33, contd)
155-2274 Connecting Plug Kit 1
Use the following tables for ordering the parts that
186-3736 Connector Socket (1)
are required for the installation of an EMS Display.
Refer to the individual topics for the specific parts 113-5183 Lamp Socket (Backlight) 2
that are required for each particular installation. The
required parts will vary according to the installation 113-5184 Lamp Terminal (Backlight) 4
options that are chosen. 118-5075 Miniature Lamp (Backlight) 2
N/A 16 AWG Wire (2)
Note: Customer (OEM) wiring and optional features
are recommended. NO additional connections are (3)Remote Quad Gauge Module (Optional)
allowed to any of the circuits that are detailed in this
publication without Caterpillar’s approval. 166-6936 Quad Gauge Module Gp 1

Table 33
117-6601 Bezel 1

Required Parts 7Y-7388 Screw (M5) 4

Part Number Description Qty 8T-3992 Screw (M6) 4

Main EMS Module 155-2265 Connecting Plug Kit 1

186-3736 Connector Socket (1)
149-1148 Engine Monitoring Control Gp 1
117-6601 Bezel 1 113-5183 Lamp Socket (Backlight) 2

133-4860 Film 1 113-5184 Lamp Terminal (Backlight) 4

N/A 16 AWG Wire (2)
7Y-7388 Screw (M5) 4
8T-3992 Screw (M6) 3 Miscellaneous Parts

Tachometer Module 127-8853 Electrical Converter (12/24) 1

153-8059 Tachometer Module Gp 1 Switch (SPDT Momentary)

3E-8775 1
(Scroll Switch)
117-6601 Bezel 1
Rocker Actuator
155-2705 1
7Y-7388 Screw (M5) 4 (for Scroll Switch)
8T-3992 Screw (M6) 3 Switch (SPST Momentary)
3E-8768 (US/Metric Display and Alarm 2
118-5075 Miniature Lamp (Backlight) 2 Enable/Disable Switches)
Quad Gauge Module Rocker Actuator
166-6936 Quad Gauge Module Gp 1 155-2706 (US/Metric Display and Alarm 2
Enable/Disable Switches)
117-6601 Bezel 1
3E-7996 Connector Plug (Switches) 3
7Y-7388 Screw (M5) 4 (2)
065-7187 Female Terminal (Switches)
8T-3992 Screw (M6) 4
2N-2371 Indicator Lamp (Warning) 1
118-5075 Miniature Lamp (Backlight) 2
7N-5876 Lamp (Warning) 1
Wiring Harness
9G-9813 Alarm Gp
160-1050 Harness (EMS) 1 or 1
123-9694 Horn
143-5018 Cable (Twisted Pair) (1)

(2)
Terminal
186-3736 Connector Socket 2L-8074 (Warning Lamp and (2)

8T-8737 Seal Plug (2) Alarm)

N/A 16 AWG Wire (2) Rheostat (Backlight Dimmer)

N/A 1
(75 Ohm, 10 Watt)
(3)Remote Tachometer Module (Optional) (1) Fabricated to length
(2) Quantity depends on application.
153-8059 Tachometer Module Gp 1
(3) Only one remote module may be installed, either a tachometer
117-6601 Bezel 1 or a quad gauge.
7Y-7388 Screw (M5) 4
8T-3992 Screw (M6) 3
(continued)

48
Schematic

g00748526
Illustration 55

49
Power Requirements for the EMS Display Battery Connections for 12 Volt Systems

The EMS display requires a 24 VDC power supply. If Table 35

a 12 VDC electrical system is used, a 12 VDC to 24 Required Parts
VDC (12/24) converter is required. The 127-8853
Electrical Converter (12/24) is capable of supplying Part Number Description Qty
5 Amp at 24 VDC. This converter can be used in 127-8853 Electrical Converter (12/24) 1
installations that have a 12 VDC electrical system.
186-3736 Connector Socket 2
Dimensions of the 127-8853 Electrical Converter N/A 16 AWG Wire (1)

Length .................................. 140 mm (5.5 inch) (1) Fabricated to length

Width ............................. 88.9 mm (3.5000 inch)
Height ................................ 67.9 mm (2.67 inch)

Note: Avoid splicing or soldering wire connections.

All connections should be terminated at terminal
strips in order to ensure reliability of the engine and
communication systems.

Note: Use 5 Amp circuit protection on the 24 VDC

positive battery supply to the display.

Connecting the EMS Display

Connecting the Harness to the Main EMS Module,
the Tachometer, and the Quad Gauge
Table 34
Required Parts
Part Number Description Qty
160-1050 Harness (EMS) 1
g00750943
Illustration 56

1. Connect the P1 connector to the main EMS 1. Run a wire from the “RUN” terminal of the Engine
module. Control Switch (ECS) to the “+V IN” terminal of
the 12/24 converter.
2. Torque the allen head screw to 2.25 ± 0.25 N·m
(20 ± 2 lb in). 2. Run a wire from negative battery to the “−V IN”
terminal of the 12/24 converter.
3. Plug the tachometer into the P2 connector.
3. Run a wire from the “+V OUT” terminal of the
4. Plug the quad gauge into the P3 connector. 12/24 converter to terminal 1 of the J1 EMS
customer connector.

4. Install a jumper wire between the “−V IN” and the

“−V OUT” terminals on the 12/24 converter.

5. Run a wire from the “−V OUT” terminal on the

12/24 converter to J1 EMS customer connector
terminal 2.

50
Battery Connections for 24 Volt Systems Connecting the CAT Data Link

Table 36 Table 37
Required Parts Required Parts
Part Number Description Qty Part Number Description Qty
186-3736 Connector Socket 2 143-5018 Cable (Twisted Pair) (1)

N/A 16 AWG Wire (1) 186-3736 Connector Socket 4

(1) Fabricated to length (1) Fabricated to length

1. Route 143-5018 Cable (Twisted Pair) from the

J1 EMS customer connector to the P61 engine
customer connector.

Note: The total length of the cable should not

exceed 30 m (100 ft).

2. Install 186-3736 Connector Sockets on each

wire end.

3. Connect the CAT Data Link+ (Pink) wire between

terminal 6 of the J1EMS customer connector and
terminal 7 of the P61engine customer connector.

4. Connect the CAT Data Link− (White) wire between

terminal 5 of the J1EMS customer connector and
terminal 6 of the P61engine customer connector.

Note: If another device which utilizes the CAT data

link (J66 customer supplied service tool connector)
g00750945 is connected to the P61 customer connector, use a
Illustration 57
dedicated terminal strip in order to splice the circuit.
1. Run a wire from the “RUN” terminal of the Engine
Control Switch (ECS) to terminal 1 of the J1 EMS
customer connector.

2. Run a wire from the negative battery to terminal

2 of the J1 EMS customer connector.
Optional Switches

g00748530
Illustration 58

51
Scroll Switch
Table 38
Required Parts
Part Number Description Qty
Switch (SPDT Momentary)
3E-8775 1
(Scroll Switch)
Rocker Actuator
155-2705 1
(Scroll Switch)
Connector Plug
3E-7996 1
(for Scroll Switch)
Female Terminal (1)
065-7187
(for Scroll Switch)
186-3736 Connector Socket (1)

N/A 16 AWG Wire (2)

(1) Quantity depends on application.

(2) Fabricated to length

Each time the scroll switch is actuated, the display

Optional Warning Lamp/Alarm Outputs
on the main EMS module will scroll through the
Note: Maximum current draw on the outputs is 0.3
parameters. Connect a 3E-8775 Switch (SPDT
Amp.
Momentary) as indicated in Illustration 58.
Diagnostic outputs are provided at the J1 EMS
US/Metric Display Switch
customer connector which may be used to drive a
Table 39 relay, an audible alarm, or an alarm lamp.
Required Parts The diagnostic outputs may be used to warn the
Part Number Description Qty operator of any engine diagnostics and/or engine
warnings that are present. An additional switch may
Switch (SPST Momentary) be installed in order to enable and/or disable the
3E-8768 1
(US/Metric Display Switch) alarm.
Rocker Actuator
155-2706 1 Warning Lamp
(US/Metric Display Switch)
Connector Plug Table 40
3E-7996 1
(US/Metric Display Switch)
Required Parts
Female Terminal (1)
065-7187 Part Number Description Qty
(US/Metric Display Switch)
186-3736 Connector Socket (1) 2N-2371 Indicator Lamp 1

N/A 16 AWG Wire (2) 7N-5876 Lamp 1

(1) Quantity depends on application. 2L-8074 Terminal 2
(2) Fabricated to length
186-3736 Connector Socket 1
The default setting for the EMS display is Metric (SI) N/A 16 AWG Wire (1)

units. If Metric (SI) units are desired, no connection (1) Fabricated to length
is needed. If US units are desired, a permanent
connection to negative battery is required. If both 1. Connect a wire from terminal 8 (Warning Lamp)
US units and Metric units are desired, install a
of the J1 EMS customer connector to one of the
3E-8768 Switch (SPST) as indicated in Illustration
terminals on the lamp.
58.
2. Connect the other terminal on the lamp to
negative battery.

52
Warning Alarm
Table 41
Required Parts
Part Number Description Qty
9G-9813 Alarm Gp
or 1
123-9694 Horn
2L-8074 Terminal 2
186-3736 Connector Socket 1
N/A 16 AWG Wire (1) Connecting Gauge Backlighting
(1) Fabricated to length Table 43
Required Parts
1. Connect a wire from terminal 9 (Warning Alarm)
of the J1 EMS customer connector to the positive Part Number Description Qty
terminal on the alarm.
118-5075 Miniature Lamp (Backlight) 4
2. Connect the negative terminal on the alarm to 186-3736 Connector Socket 1
negative battery. (1)
N/A 16 AWG Wire
Optional Alarm Enable/Disable Switch (1) Fabricated to length

Table 42 1. Install a 118-5075 Miniature Lamp (Backlight) in

Required Parts each of the P4, P5, P6, and P7 lamp sockets.
Part Number Description Qty 2. Insert P4 and P5 into the tachometer module.
3E-8768 Switch (SPST) 1
3. Insert P6 and P7 into the quad gauge module.
155-2706 Rocker Actuator 1
3E-7996 Connector Plug 1 4. If you are installing a backlight dimmer,
proceed to “Installing a Backlight Dimmer
065-7187 Female Terminal (1)
(Potentiometer)”. Otherwise, connect terminal 10
N/A 16 AWG Wire (2) (Lamp Power) of the J1 EMS customer connector
to the switched +24 VDC circuit.
(1) Quantity depends on application.
(2) Fabricated to length

Connect the SPST switch between negative battery

and the negative terminal on the alarm.

53
 Connecting an Optional Remote Module
Table 45
Installing a Backlight Dimmer (Potentiometer) Required Parts
Table 44 Part Number Description Qty
Required Parts (1) Remote Tachometer Module
(Optional)
Part Number Description Qty
153-8059 Tachometer Module Gp 1
Rheostat (Backlight Dimmer)
N/A 1
(75 Ohm, 10 Watt) 117-6601 Bezel 1
186-3736 Connector Socket 1 7Y-7388 Screw (M5) 4
N/A 16 AWG Wire (1) 8T-3992 Screw (M6) 3
(1) Fabricated to length 155-2274 Connecting Plug Kit 1
186-3736 Connector Socket 12
113-5183 Lamp Socket (Backlight) 2
113-5184 Lamp Terminal (Backlight) 4
118-5075 Miniature Lamp (Backlight) 2
N/A 16 AWG Wire (2)

(1) Remote Quad Gauge Module

(Optional)
166-6936 Quad Gauge Module Gp 1
117-6601 Bezel 1
7Y-7388 Screw (M5) 4
g00748575
Illustration 59 8T-3992 Screw (M6) 4

1. Connect the wiper (output) of the potentiometer 155-2265 Connecting Plug Kit 1
to terminal 10 (Lamp Power) of the J1 EMS 186-3736 Connector Socket 12
customer connector.
113-5183 Lamp Socket (Backlight) 2
2. Connect the +V IN terminal of the potentiometer 113-5184 Lamp Terminal (Backlight) 4
to the switched +24 VDC circuit.
118-5075 Miniature Lamp (Backlight) 2
3. Connect the remaining terminal of the (2)
N/A 16 AWG Wire
potentiometer back into the wiper.
(1) Only one remote gauge may be installed, either a tachometer
or a quad gauge.
(2) Fabricated to length.

54
 g00748572
Illustration 60

1. Mount the remote module (tachometer or quad

gauge).

Note: The length of the wires between the J2 remote

module connector and the remote module should
NOT exceed 6 m (20 ft).

2. Remove the sealing plugs from the J2 remote

module connector.

3. Connect a wire from terminal 1 of the J2 remote

module connector to terminal 1 of the 155-2274
Connecting Plug Kit (Remote Tachometer) or
terminal 1 of the 155-2265 Connecting Plug Kit
(Remote Quad Gauge).

4. Continue connecting wires between the two

connectors at terminals 2, 3, 4, and 5.

5. Connect the backlight circuit as shown in

Illustration 2.

6. Install the sealing plugs that were removed in

Step 1 into any open cavities in the J2 remote
module connector and the connector at the
remote module.

7. Connect the remote module to the harness.

55
Connecting Multiple EMS Displays

g00750946
Illustration 61

Additional EMS displays can be installed for

a multiple station installation. The EMS display
for each station can be connected as shown in
Illustration 61. For additional stations, make multiple
connections to the CAT Data Link while keeping the
total combined cable length as short as possible.
The preferred method is through terminal strips.

Note: Use 143-5018 Cable (Twisted Pair) for all

connections to the CAT data link. The total length of
the cable should NOT exceed 30 m (100 ft).

56
Reference Materials
For additional information, use the following
publications:

• Electrical Schematic, SENR9590, “3126B

Industrial Engines”

• Electrical Schematic, SENR9592, “C-9 Industrial

Engines”

• Electrical Schematic, SENR9575, “C-10, C-12,

C-15, and C-16 Industrial Engines”

• Operation and Maintenance Manual, SEBU7457,

“3126B Industrial Engines”

• Operation and Maintenance Manual, SEBU7502,

“C-9 Industrial Engines”

• Operation and Maintenance Manual, SEBU7385,

“C-10 and C-12 Industrial Engines”

• Operation and Maintenance Manual, SEBU7517,

“C-15 and C-16 Industrial Engines”

• Troubleshooting, SENR9591, “3126B Industrial

Engines”

• Troubleshooting, SENR9593, “C-9 Industrial

Engines”

• Troubleshooting, SENR9576, “C-10, C-12, C-15,

and C-16 Industrial Engines”

• Pocket Guide, SEBD0402, “Guidelines for Routing

and Installing Wire Harness Assemblies”

• Special Publication, NEHS0685, “Caterpillar

Electronic Technician (ET)”

57
58
59
©2001 Caterpillar
All Rights Reserved Printed in U.S.A.
 C-15 and C-16 Industrial Engines C-10 and C-12 Industrial Engines
SENR9575-01
July 2001

Engine Coolant Customer Service Tool Fuel Fuel Atmospheric Electronic Control Module (ECM) Caterpillar Supplied
Customer J63
Service Tool Fuel Fuel Temperature Connector Connector Temperature Pressure Pressure Engine Service
Turbo Outlet Connector Connector Pressure Temperature Sensor J61 J63 Sensor Sensor Sensor Tool Connector
Pressure J61 J63 Sensor Sensor Electronics
Electronics
Sensor Ground 6 Electronic J2 J1 Termination
Ground
(Intake Stud Unit Injectors Resistor (J1939)
Stud
Manifold Air)
Electronics
Ground Stud
Intake Manifold
Air Temperature
Sensor
Customer
J61 Connector
J300/P300
Battery + -
P61 Disconnect Battery
Switch 12 or 24VDC
P400
Breaker
Secondary Timing Calibration SMMS
Speed/Timing Probe Connector
Sensor
ECM
(Camshaft) J401/P401
TC Probe Ground
Primary Keyswitch
Connector Strap Speed/Timing Sensor
P400
(Crankshaft) 15 Amp
J402/P402 Breaker 15 Amp
Secondary Breaker
Electronic Speed/Timing Sensor
Control (Camshaft)
Module
Electronic
(ECM) P209/J209
Control OEM Installed Switches:

C-10, C-12, C-15, and C-16

Fuel
Module Pressure Sensor PTO Enable
(ECM) PTO Ramp Up/Down
P203/J203 PTO Interrupt

Industrial Engine
ECM Remote Shutdown
Atmospheric
Ground Pressure Sensor Starting Aid Override
Strap Overspeed Verify

Electrical System
P201/J201 Intermediate Engine Speed
TC Probe Engine Oil ECM ECM
Connector Pressure Connector Connector Engine Oil Maintenance Due Reset
P400 Sensor J2/P2 J1/P1 Pressure Sensor Torque Limit
Primary
Speed/Timing Atmospheric Engine Oil ECM ECM J403/P403
P200/J200
Sensor Pressure
Sensor
Pressure Connector Connector LEFT SIDE VIEW BDL1-UP Turbo Outlet
Throttle
(Crankshaft) Sensor J2/P2 J1/P1 Position Sensor
BEM1-UP Pressure Sensor
(Intake Manifold Air)
LEFT SIDE VIEW
Secondary Turbo Outlet
Pressure
BFM1-UP Engine Coolant
J100/P100

Speed/Timing P800/J800
Sensor
Intake Manifold
Air Temperature
Sensor BCX1-UP Temperature Sensor Coolant
(Camshaft) (Intake Manifold Air) Level Sensor
Sensor J105/P105
Primary
Fuel
Speed/Timing P220/J220
Temperature Sensor
Sensor
Auxiliary
(Crankshaft) J103/P103 Pressure Sensor
Intake Manifold Air
Temperature Sensor
P142/J142
Engine Coolant
Auxiliary
Temperature
Temperature Sensor
Sensor
NOTE: Warning Lamp
Components within
this area are Inlet Air Shutoff
Diagnostic Lamp Solenoid
recommendations
Inlet Air Shutoff Relay
Maintenance
Due Lamp
Ether Start Valve
Termination Ether Start Valve Relay Solenoid
Resistor (J1939)

Customer Installed J66

15 Engine Monitoring
Service Tool
10

FRONT VIEW TOP VIEW System (EMS)

5 20

Connector
FRONT VIEW 0 25
Display Modules

© 2001 Caterpillar Printed in U.S.A.

All Rights Reserved
 P300/J300
L983/WH 12 L983/WH
ECM L984/OR 10 L984/OR
GROUND L985/YL 8 L985/YL
STRAP A706/GY 6 A706/GY
ECM
MOUNTING A705/BU 5 A705/BU
BOLT A704/GN 4 A704/GN
A703/BR 3 A703/BR
A702/PU 2 A702/PU
A701/GY 1 A701/GY J61 Customer Pin Out
J2/P2 11
INJECTOR COMMON 1 & 2 44 L983/WH 9
INJECTOR COMMON 3 & 4 45 L984/OR 7 CYL CYL CYL CYL CYL CYL
No. Function Wire Ident
INJECTOR COMMON 5 & 6 46 L985/YL NO.6 NO.5 NO.4 NO.3 NO.2 NO.1 1 +Bat. (Unswitched) 150/OR
INJECTOR 6 55 A706/GY
INJECTOR 5 54 A705/BU P400 TIMING 2 Torque Limit Switch M909/GN
INJECTOR 4 39 A704/GN G810/PU 2 CALIBRATION
INJECTOR 3 38 A703/BR G811/YL 1 PROBE 3 N/C¹ T936/GN
INJECTOR 2 37 A702/PU CONNECTOR
INJECTOR 1 36 A701/GY 4 Inlet Air Shutoff Solenoid Relay G971/BR
TIMING CALIBRATION PROBE - 23 G810/PU 5 Solenoid Common G969/YL
TIMING CALIBRATION PROBE + 22 G811/YL P401/J401 PRIMARY ENGINE
PRIMARY (CRANK) SP/TMG SIG - 49 P920/BR P920/BR 1 SIGNAL - SPEED/TIMING SENSOR 6 Cat Data Link - 892/BR
PRIMARY (CRANK) SP/TMG SIG + 48 F732/PK F732/PK 2 SIGNAL + (CRANKSHAFT)
SECONDARY (CAM) SP/TMG SIG - 59 998/BR (189-9266) 7 Cat Data Link + 893/GN
SECONDARY (CAM) SP/TMG SIG + 58 999/WH
ENGINE COOLANT TEMP. SNSR 32 995/BU P402 J402 SECONDARY ENGINE 8 Digital Sensor Power (+8V) 167/OR
PASSIVE SNSR COMMON 18 R993/BR 998/BR 1 1 SIGNAL - SPEED/TIMING SENSOR
HARNESS EXTENSION (CAMSHAFT) 9 Digital Sensor Return A274/BK
ANALOG SNSR POWER (+5V) 2 997/OR 999/WH 2 2 SIGNAL +
NOTE U (189-9801 NOTE N)
ANALOG SNSR COMMON 3 993/BR 10 Throttle Position Sensor A307/GY
TURBO OUTLET PRESS. SNSR 40 A746/PK (188-7513 NOTE P)
ATMOSPHERIC PRESS. SNSR 14 A747/GY P100/J100 11 Auxiliary Temperature Sensor G488/GN
ENG OIL PRESS. SNSR 24 994/GY 995/BU 1 SIGNAL ENGINE COOLANT
FUEL TEMP. SNSR 33 F421/YL R993/BR 2 COMMON TEMPERATURE SENSOR 12 Maintenance Due Reset Switch F426/BU
(130-9811)
FUEL PRESS. SNSR 16 413/BR 13 Maintenance Due Lamp F424/YL
INTAKE MANIF. AIR TEMP. SNSR 35 C967/BU J200/P200
UNUSED 1 997/OR A +5V TURBO OUTLET 14 Analog Sensor Power (+5V) 125/OR
UNUSED 4 A746/PK C SIGNAL PRESSURE SENSOR
UNUSED 5 993/BR B RETURN (INTAKE MANIFOLD AIR) 15 Analog Sensor Return T993/BR
UNUSED 6 (161-9929)
16 J1939 Shield A234/BK
UNUSED 7 J203/P203
ATMOSPHERIC PRESSURE
UNUSED 8 997/OR A +5V
SENSOR
17 J1939 Data + K900/YL
UNUSED 9 A747/GY C SIGNAL
UNUSED 10 993/BR B RETURN (161-9925 NOTE S) 18 J1939 Data - K990/GN
UNUSED 11 (163-8530 NOTE T)
UNUSED 12 J201/P201 19 PTO Interrupt Switch M904/OR
UNUSED 13 997/OR A +5V ENGINE OIL PRESSURE 20 N/C¹ 450/YL
UNUSED 15 994/GY C SIGNAL SENSOR
UNUSED 17 993/BR B RETURN (161-9931) 21 N/C¹ 451/BR
UNUSED 19
UNUSED 20 22 Ether Start Valve Relay 382/PK
UNUSED 21 P105/J105
UNUSED 25 F421/YL 1 SIGNAL FUEL TEMPERATURE 23 N/C¹ J983/YL
UNUSED 26 R993/BR 2 COMMON SENSOR
(130-9811) 24 Diagnostic Lamp F404/RD
UNUSED 27
UNUSED 28 J209/P209 25 Warning Lamp F420/GN
UNUSED 29 997/OR A +5V
FUEL PRESSURE SENSOR 26 +Bat. (Switched) 120/YL
UNUSED 30 413/BR C SIGNAL
(161-9931)
UNUSED 31 993/BR B RETURN
UNUSED 34
27 Remote Shutdown Switch F716/WH
UNUSED 41 P103/J103 28 Intermediate Engine Speed Switch G968/WH
INTAKE MANIFOLD AIR
UNUSED 42 C967/BU 1 SIGNAL
TEMPERATURE SENSOR
UNUSED 43 R993/BR 2 COMMON 29 PTO Enable Switch 381/PU
(130-9811)
UNUSED 47
UNUSED 50 30 PTO Ramp Up/Set Switch G955/GN
UNUSED 51
31 +Bat. (Unswitched) 150/OR
UNUSED 52
UNUSED 53 32 +Bat. (Unswitched) 150/OR
UNUSED 56
UNUSED 57 33 Auxiliary Pressure Sensor G469/BU
UNUSED 60
UNUSED 61 34 N/C¹ H407/YL
UNUSED 62 Customer Connector J61 35 N/C¹ E798/PK
UNUSED 63
UNUSED 64 36 Coolant Level Sensor E452/WH
UNUSED 65 Customer Connector P61
UNUSED 66 37 N/C¹ H405/BU
UNUSED 67
UNUSED 68
38 Starting Aid Override Switch M910/OR
1 2 3 4 5 6 7 8 9 10 10 9 8 7 6 5 4 3 2 1
UNUSED 69 39 PTO Ramp Down/Resume Switch G967/WH
UNUSED 70 11 12 13 14 15 16 17 18 19 20 20 19 18 17 16 15 14 13 12 11
40 75% Overspeed Verify Switch 387/PK
21 22 23 24 25 26 27 28 29 30 30 29 28 27 26 25 24 23 22 21

31 32 33 34 35 36 37 38 39 40 40 39 38 37 36 35 34 33 32 31
¹ This terminal is for future expansion. Install an 8T-8737 Seal Plug.

Terminal Side
Terminal Side

CIRCUITS WITHIN THIS AREA ARE RECOMMENDATIONS

C OFF (NOTE B)
SMMS ON B
S ST 1
2 INLET AIR SHUTOFF
SOLENOID RELAY
R INLET AIR SHUTOFF (NOTE V)
SOLENOID (NOTE V)
CB
KEYSWITCH 15A
J1/P1
14 AWG P142/J142
UNUSED 1 AUXILIARY
A +8V
UNUSED 6 CB 14 AWG TEMPERATURE
C SIGNAL
UNUSED 7 (NOTE D) SENSOR
B RETURN
UNUSED 12 (131-0427)
UNUSED 13 +
UNUSED 14
P800/J800
UNUSED 16 COOLANT LEVEL
ALTERNATOR A +8V
UNUSED 17 G S SENSOR
C SIGNAL
UNUSED 18 (165-6634)
GND B RETURN
UNUSED 19 MTR BAT OFF ENGINE
CB
UNUSED 20
(NOTE D)
UNUSED 24
STARTING P220/J220
UNUSED 25 AUXILIARY
MOTOR A +5V
UNUSED 26 PRESSURE
C SIGNAL
UNUSED 31 SENSOR
B RETURN
UNUSED 32 (161-9932)
UNUSED 33 15A
UNUSED 35 14 AWG
UNUSED 36 J403/P403
10 AWG C SIG THROTTLE
UNUSED 37 BATTERY
CB A + BAT. POSITION
UNUSED 51 DISCONNECT
+ - B - BAT. SENSOR
UNUSED 55 SWITCH
(161-8906)
UNUSED 57
4 AWG BATTERY
UNUSED 62
(NOTE B)
UNUSED 64
UNUSED 69
PWM OUTPUT 3 43 E798/PK
TACHOMETER - 39 451/BR J61/P61 ETHER START
14 AWG VALVE RELAY ETHER
+BAT.(UNSWITCHED) 48 150/OR 1 +BAT. (UNSWITCHED)
AIR SHUTOFF SOLENOID 11 G971/BR 4 INLET AIR SHUTOFF SOLENOID RELAY (NOTE V) 1 START
SOLENOID COMMON 67 G969/YL 5 SOLENOID COMMON 2 VALVE
AUXILIARY TEMP SNSR 68 G488/GN 11 AUXILIARY TEMP SNSR (NOTE V)
COOLANT LEVEL SNSR 46 E452/WH 36 COOLANT LEVEL SNSR STARTING AID OVERRIDE SW
DIG SNSR PWR (+8V) 4 167/OR 8 DIG SNSR PWR (+8V)
DIG SNSR RETURN 5 A274/BK 9 DIG SNSR RETURN MAINTENANCE DUE RESET SW
AUXILIARY PRESS. SNSR 15 G469/BU 33 AUXILIARY PRESS. SNSR
THROTTLE POSITION SNSR 66 A307/GY 10 THROTTLE POSITION SNSR TORQUE LIMIT SW
ANLG SNSR PWR (+5V) 2 125/OR 14 ANLG SNSR PWR (+5V)
ANLG SNSR RETURN 3 T993/BR 15 ANLG SNSR RETURN REMOTE SHUTDOWN SW (NOTE K)
ETHER START VALVE RELAY 21 382/PK 22 ETHER START VALVE RELAY
STARTING AID OVERRIDE SW 22 M910/OR 38 STARTING AID OVERRIDE SW INTERMEDIATE ENGINE SPEED SW
MAINTENANCE DUE RESET SW 23 F426/BU 12 MAINTENANCE DUE RESET SW
TORQUE LIMIT SW 40 M909/GN 2 TORQUE LIMIT SW OVERSPEED VERIFY SW
REMOTE SHUTDOWN SW 44 F716/WH 27 REMOTE SHUTDOWN SW
INTERMEDIATE ENG. SPEED SW 45 G968/WH 28 INTERMEDIATE ENGINE SPEED SW PTO INTERRUPT SW
OVERSPEED VERIFY SW 54 387/PK 40 75% OVERSPEED VERIFY SW
PTO INTERRUPT SW 41 M904/OR 19 PTO INTERRUPT SW PTO ENABLE SW
PTO ENABLE SW 56 381/PU 29 PTO ENABLE SW
1.5A DIGITAL OUT 4 HS 10 T936/GN 3 NC
PTO RAMP UP SW 58 G955/GN 30 PTO RAMP UP/SET SW
PTO RAMP DOWN SW 60 G967/WH 39 PTO RAMP DOWN/RESUME SW
MAINTENANCE DUE LAMP 30 F424/YL 13 MAINTENANCE DUE LAMP
PTO RAMP
DIAGNOSTIC LAMP 28 F404/RD 24 DIAGNOSTIC LAMP
UP/DOWN SWITCH
WARNING LAMP 29 F420/GN 25 WARNING LAMP
TACHOMETER + 38 450/YL 20 NC 14 AWG
+BAT. (SWITCHED) 70 120/YL 26 +BAT. (SWITCHED) MAINTENANCE
CB DUE LAMP
CAT DATA LINK - 9 892/BR 6 CAT DATA LINK -
CAT DATA LINK + 8 893/GN 7 CAT DATA LINK + 1A
-BAT. 65 229/BK 21 NC
PASSIVE/ACTIVE ANLG 8 27 J983/YL 23 NC
14 AWG
+BAT.(UNSWITCHED) 52 150/OR 31 +BAT. (UNSWITCHED) DIAGNOSTIC LAMP
14 AWG CB
+BAT.(UNSWITCHED) 53 150/OR 32 +BAT. (UNSWITCHED)
SWITCH INPUT 5 59 H407/YL 34 NC 1A
SWITCH INPUT 11 49 H406/GY 35 NC
SWITCH INPUT 10 47 H405/BU 37 NC
MAX LENGTH 40 METERS
J1939 SHIELD 42 A234/BK 16 J1939 SHIELD WARNING LAMP
CB
J1939 DATA + 50 K900/YL 17 J1939 DATA +
J1939 DATA - 34 K990/GN 18 J1939 DATA - 1A
-BAT. 61 229/BK
-BAT. 63 229/BK (153-2707) A + BAT.
(NOTES B & E) B - BAT.
C
MAX LENGTH 30 METERS
ELECTRONIC CONTROL MODULE (ECM) E CAT DATA LINK -
C B A D CAT DATA LINK +
J63 F
G
120/YL A
+BAT.
J
229/BK B
-BAT.
H
893/GN D
CAT DATA LINK +
892/BR E
CAT DATA LINK - (J66)
A234/BK C
J1939 SHIELD CUSTOMER INSTALLED
K990/GN F
J1939 DATA - SERVICE TOOL CONN
ELECTRONICS (165-0201)
K900/YL G
J1939 DATA + C B A B A C
GROUND STUD H
NC
(NOTE A) J
NC
CAT SUPPLIED
ENGINE SERVICE TOOL
C B A (165-0200)
C B A CONNECTOR
MAX LENGTH 1 METER
(NOTE B)
TERMINATION DEVICE
RESISTOR
(134-2540) 120
120
(NOTE B & C)
TERMINATION
RESISTOR
(134-2540)
(NOTE B & C)
CAT DATA LINK +
CAT DATA LINK -
-BAT.
+BAT. (SWITCHED)

MAIN EMS MODULE

(NOTE G)
OPTIONAL EMS DISPLAY MODULES
SCROLL BACKWARD

TACHOMETER MODULE QUAD GAUGE MODULE

SCROLL FORWARD

(NOTE G) (NOTE G)
CAT DATA LINK +
CAT DATA LINK -

MODULE CLOCK

WARNING LAMP
AUXILIARY CKT
MODULE LOAD

MODULE DATA
CAT DATA LINK +
CAT DATA LINK -
-BAT.
+BAT. (SWITCHED)

+V MODULE

US/METRIC

15
WARNING

10 20
OPTIONAL REMOTE
5 25 TACHOMETER MODULE OR
+24V
-BAT

-BAT

QUAD GAUGE MODULE

RPM X100
0 30 (NOTES G & B)
14
15
25
34
35
20
23
13

33

10
11
12
16
17
18
19
21
22
24
26
27
28
29
30
31
32
36
37
38
39
40
1
2
5

7
4

3
6
8
9

1
2
3
4
5
6

1
2
3
4
5
6
7
8

1
2
3
4
5
6
7
8

(NOTE F)

MODULE DATA
+V MODULE
MODULE CLOCK
MODULE LOAD
-BAT
BACKLIGHT LAMP PWR

+24V 1
- BAT. 2
US/METRIC 3
SCROLL FORWARD 4 (NOTE H)
CAT DATA LINK - 5
CAT DATA LINK + 6 -V OUT +V OUT
UNUSED 7
WARNING LAMP 8 DC/DC CONVERTER
WARNING 9 (127-8853)
BACKLIGHT LAMP PWR 10 (NOTES B & L)
(+) BATTERY SUPPLY WIRES
SCROLL BACKWARD 11
12 -V IN +V IN
INPUT SIGNAL WIRES TO ECM
(NOTE B)
OUTPUT SIGNAL WIRES FROM ECM

SENSOR SUPPLY VOLTAGE

CAT DATA LINK +
CAT DATA LINK - SIGNAL PLUS
-BAT.
(NOTES B & L)
+BAT. (SWITCHED) SIGNAL MINUS

(-) BATTERY / SENSOR RETURN

NOTE A: THE CUSTOMER CONNECTOR BRACKET GROUND STUD MUST NOTE G: ONE MAIN EMS MODULE IS REQUIRED FOR EACH DESIRED MONITORING NOTE S: USE THIS SENSOR FOR ALL INDUSTRIAL APPLICATIONS
HAVE A DIRECT WIRE CONNECTION TO BATTERY (-). THIS STATION. THE TACHOMETER AND/OR QUAD GAUGE UNITS ARE OTHER THAN UNDERGROUND MINING
CONNECTION CAN BE MADE AT THE STARTER (-) TERMINAL OPTIONAL AND WILL NOT OPERATE WITHOUT CONNECTION TO ABBREVIATION
A MAIN EMS MODULE NOTE T: USE THIS SENSOR FOR UNDERGROUND MINING APPLICATIONS ONLY
ALT ALTERNATOR
NOTE B: REFER TO THE INSTALLATION GUIDE FOR ADDITIONAL
NOTE H: THE DEFAULT SETTING FOR THE EMS IS METRIC UNITS. NOTE U: HARNESS EXTENSION NOT USED FOR C-10 OR C-12. P402 CONNECTS ATA AMERICAN TRUCKING ASSOCIATION
INSTALLATION DETAILS
IF METRIC UNITS ARE REQUIRED NO CONNECTION IS NEEDED. DIRECTLY TO J402 ON C-10 & C-12 ONLY. CB CIRCUIT BREAKER
IF U.S. UNITS ARE REQUIRED, A PERMANENT CONNECTION TO NOTE V: ARC SUPPRESSION DIODES ARE REQUIRED CIS CUSTOMER IGNITION SWITCH
NOTE C: MAXIMUM LENGTH OF DATA BUS (TERMINATION RESISTOR
BATTERY (-) IS REQUIRED ON RELAY COILS AND SOLENOID COILS. DIG DIGITAL
TO TERMINATION RESISTOR) IS 40 METERS
ECM ELECTRONIC CONTROL MODULE
NOTE D: PLACE APPROPRIATE CIRCUIT PROTECTION NOTE K: WHEN THE SHUTDOWN SWITCH IS CONNECTED TO BATTERY (-) N/C NO CONNECTION
PWM PULSE WIDTH MODULATION
NOTE E: USE RECOMMENDED CABLE OR EQUIVALENT PER SAE J1939 THE ECM DISABLES THE FUEL INJECTION SIGNAL. THIS SM STARTING MOTOR
SPECIFICATIONS FOR ALL J1939 DATA LINK CONNECTIONS ACTION CAUSES THE ENGINE TO SHUTDOWN WHILE LEAVING NO ADDITIONAL CONNECTIONS ARE ALLOWED TO ANY WIRES SMMS START MOTOR MAG SWITCH
NOTE F: PIN 22 ON THE EMS MAIN MODULE 40 PIN CONNECTOR THE ECM POWERED TO MONITOR ENGINE DIAGNOSTICS WITHOUT CATERPILLAR ENGINEERING APPROVAL
MUST BE CONNECTED TO BATTERY (-) FOR PROPER OPERATION NOTE L: 12 VOLT BATTERY SYSTEMS MUST USE THE DC/DC CONVERTER
UNLESS OTHERWISE SPECIFIED: WIRE CODE
FOR THE EMS TO OPERATE PROPERLY. 24 VOLT SYSTEMS ALL WIRES TO BE 16 AWG OR LARGER SAE J1128 TYPE SXL OR
CUSTOMER SUPPLIED WIRING
SHOULD CONNECT SWITCHED BATTERY DIRECT TO PINS EQUIVALENT. FOR TWISTED PAIR SPECIFICATION SEE SAE J1708
1 & 2 ON THE 12 PIN EMS HARNESS CUSTOMER CONNECTOR
NOTE N: USE THIS SENSOR FOR C-10 & C-12 ONLY ELIMINATION OF ANY COMPONENTS SHOWN WILL DISABLE CERTAIN
ENGINE FEATURES. CONTACT CATERPILLAR ENGINEERING WHEN
NOTE P: USE THIS SENSOR FOR C-15 & C-16 ONLY CONSIDERING COMPONENT REMOVAL
Receptacle Wedge

Receptacle Wedge

Receptacle Wedge
Speed/Timing Sensor Connectors

HD Connector Receptacle

DT Connector Receptacle
150 Series Receptacle

ECM Side

ECM Side
Pin Contact

ECM Connectors
ECM Connector P2

ECM Connector P1
Socket Contact

Plug Wedge

Plug Wedge

Plug Wedge
HD Connector Plug

DT Connector Plug
IAPCV Connector
150 Series Plug

Harness Side

Harness Side
Sealing Plug
 MDDM-00066N
Revised 03-02
Installation and Operation Manual for Section 78
00-02-0428

Murphy Display and Diagnostic Module (MDDM)

Please read the following information before installing. A visual inspection of this product for damage during shipping is recommended
before mounting. It is your responsibility to have a qualified person install this unit and make sure it conforms to NEC and local codes.
GENERAL INFORMATION

WARNING
BEFORE BEGINNING INSTALLATION OF THIS MURPHY PRODUCT
✔ Disconnect all electrical power to the machine.
✔ Make sure the machine cannot operate during installation.
✔ Follow all safety warnings of the machine manufacturer.
✔ Read and follow all installation instructions.

Description Engine Parameters

The Murphy Display and Diagnostic Module (MDDM) is the keystone in a The following are some of the engine parameters displayed by
line of components manufactured by FW Murphy as part of its J1939 the MDDM in English or Metric units (when applicable):
MurphyLinkTM System. The J1939 MurphyLinkTM System has been developed 1. Engine Hours.
to meet the needs for instrumentation and control on electronically controlled
2. Engine RPM.
engines communicating using the SAE J1939 Controller Area Network (CAN).
3. System Voltage.
The MDDM is a powerful, easy to use multifunction tool that enables the
4. % Engine Load at the current RPM.
operator to view many different engine parameters and engine service codes.
5. Coolant Temperature.
The MDDM includes a two line, eight character backlit LCD display. The
top line displays data labels, i.e. "OilPress". The bottom line displays appro- 6. Oil Pressure.
priate units information i.e "80 psi" for oil pressure. 7. Fuel Economy.
The MDDM has two push buttons (UP and DOWN) for scrolling through the 8. Throttle Position.
parameter list and viewing the menu list. Two LEDs (amber and red) are used 9. Manifold Air Temperature.
to annunciate active fault messages received by the MDDM. 10. Current Fuel Consumption.
Other components in the system are microprocessor-based analog gauges for 11. Active Service Codes.
displaying critical engine data broadcast by the ECM: engine RPM, oil pres- 12. Stored Service Codes from the engine.
sure, coolant temperature, system voltage, etc., and a combination audible 13. Set the Units for display.
alarm and relay unit for warning and shutdown annunciation. 14. View the Engine Configuration Parameters.
The MDDM can be connected up to 40 meters from the ECM (Engine
Control Module). Up to 32 components may be linked to the MDDM by an Specifications
RS485 daisy chained twisted pair cable up to 1,000 meters from the MDDM. Bezel: Stainless Steel (Black Optional).
The MDDM and all connected components can be powered by 12 or 24 volt Membrane Switch: Polyester.
systems, are back lit using LEDs, and are environmentally sealed.
Case/Clamp: Nickel Plated Steel, Aluminum Killed, QQ-S-698.
How to Order Maximum Panel Thickness: 0.30 inch. (8 mm).
To order the MDDM use the model number designation diagram below: Mounting Hole: 2.062 inch (52 mm) in diameter.
Dial: White on Black.
MDDM 20 – B – B Reversed Polarity: Withstands reversed battery terminal polarity
Bezel Type indefinitely within operating temperatures.
Blank = A-20 Type
Model A = A-20 Type Black CAN BUS: SAE J1939 Compliant.
MDDM = Murphy Display and B = SAE Type Low Profile Auxiliary Gage Communication: RS485.
Diagnostic Module
Operating Voltage: 8 VDC Minimum to 32 VDC Maximum.
Connector
B = DeutschTM (DT04-08PA) Operating Temperature: -4 to 158°F (-20 to 70°C).
Size
C = Metri-PackTM (12047931) Storage Temperature: -40 to 185°F (-40 to 85°C).
20 = 2-1/16 in. (52 mm) Mounting hole.
D = AMP/DeutschTM

MDDM-00066N page 1 of 8
 Typical Mounting Dimensions

WARNING: Disconnect negative battery cable before mounting. IMPORTANT: The MDDM display is best viewed
either straight on or at the 6 o’clock position

Panel Mounting
Remove the mounting bracket and insert the gage from the front side of the panel.
Replace bracket and secure it (12-16 in./lb. torque), do NOT overtighten. (See Figure below). Panel 0.30 in. (8 mm)
maximum thickness
Alarm (LED) Shutdown
Amber (LED) Red
Mounting
Ø2.03 in. Clamp
(52 mm)
Mounting MDDM
Clamp

Scroll Up Scroll Option “D” AMP/DeutschTM

Down P/N: MTA-156
2.13 in. Mounting Hole 5-Way Connector
(54 mm) Ø2.062 in. (52 mm) Dia. 0.656 in. (17 mm)
Option “C” Metri-Pack TM
Option “B” DeutschTM

Wires Length Wires Length

3 in. (76 mm) 3 in. (76 mm) Wires Length
P/N: 12047931 25 in. (635 mm)
P/N: DT04-08PA P/N: DT04-3P
8-Way Connector 8-Way Connector 3-Way Connector
1.88 in. (48 mm) 1.78 in. (45 mm) 1.78 in. (45 mm)

MDDM Typical Wiring Diagram

IMPORTANT: To eliminate external interference: RS485(+) and RS485(-) should be twisted pair cable or twist wires together, one twist
per inch minimum. CAN–L, CAN–H and CAN Shield should be approved J1939 CAN bus cable or twist wires, one twist per inch min.
Option “C” Option “B” Option “D” AMP/DEUTSCH TM
METRI-PACKTM DEUTSCH TM PIN 5 B.L.
PIN A PIN H PIN 8 PIN 1 PIN 3 V+
PIN 4 GRND.
DATA+ DATA– DATA+ DATA– PIN 2 DATA+
PIN B PIN G PIN 7 PIN 2 AMP MTA-156
CAN_L CAN_H CAN_L CAN_H PIN 1 DATA–
DEUTSCH
PIN C PIN F PIN 6 PIN 3 PIN A DT04-3P
B.L. CAN_SHLD B.L. CAN_SHLD CAN_H
PIN D PIN E PIN B
PIN 5 PIN 4 PIN C
GRND. V+ CAN_L
GRND. V+ CAN_SHLD

White RS485 (+) Data

MDDM
Module Orange RS485 (-) Data 120 Ω
(back See
view) 120 Ω MLA Gage Note 2
See Note 1 (rear view)
Pin A Pin H
Green-CAN_L
To Next
ENGINE CONTROL MODULE MLA Gage
Yellow-CAN_H (SAE J1939 Complaint)
Gray-CAN_SHLD

Red-Battery NOTE 2: Place resistor at end of

Black-Ground line on last MLA gage. (Included
for factory purchased panels.)
Brown-Back Light
Ignition IMPORTANT: Use Murphy back
NOTE 1: Place resistor between Switch light MLVC2412 voltage
CAN_H and CAN_L lines near MDDM. Illumination Battery regulator on 24 VDC systems.
(Included for factory purchased panels.) Control*(optional)

MDDM-00066N page 2 of 8
 MDDM Operating Instructions

Operating Instructions The following two rules are used for accessing the various items
The MDDM is simple to use and allows quick and easy navigation on the main menus:
through the menu structure to find the information needed. 1. To scroll through the parameter list, press either the UP or
The MDDM Main Menu Tree (below) first displays engine data Down push buttons.
parameters, followed by the sub-menu entry points. 2. To select or exit a sub-menu SIMULTANEOUSLY press
NOTE: When first powered up some unused parameters may be the UP and DOWN push buttons.
displayed by the MDDM. These parameters will be automatically
removed from the display after the initialization cycle is complete.

Parameters

LCD Display
Main Menu Tree
Eng Hrs
.....Hrs NOTE: The parameters displayed on the MDDM will vary
depending on the engine make and model

Eng RPM Keys

.....RPM
Both

Up
Sys Volt
..... V Down

Load@RPM
..... %
Sub-Menus
Cool Tmp
..... F
SrvcCode
Press
Oil Pres To
.....PSI Srvc
Codes
From
Srvc
Codes
StorCode
Press
FuelEcon To
.....GPH Stor From
Codes Stor
Codes
Units
Press
Throttle
..... % To
Units From
Units
Eng Conf
Press
Mani Tmp Parameters To
Continued Eng Conf From
Eng Conf

MDDM-00066N page 3 of 8
 MDDM Operating Instructions continued

Selecting Engine Data Parameters To select English or Metric, the Units Sub-Menu must be selected.
To select the Units Sub-Menu, press the UP or DOWN button until the
To read any of the engine parameters press either the UP or DOWN but- display shows the following label:
ton until the top line of the display shows the desired information.
Units
Selecting Sub-Menus
Press either the UP or DOWN button until the top line of the display
Press
shows the label of the desired Sub-Menu. Then press BOTH the UP and Press BOTH the UP and DOWN buttons SIMULTANEOUSLY to select
DOWN buttons SIMULTANEOUSLY. This action will select the Sub- the Units Sub-Menu. The Units Sub-Menu Figure (below) shows the steps
Menu and the next screen on the display will list the Sub-Menu items. for selecting the desired units of measure. Two options are available:
1. Press BOTH buttons to retain the current units designation.
Changing Units of Measure 2. Press either UP or DOWN button to toggle the units selection, then
The MDDM can display engine data in either English or Metric units. press BOTH buttons to select the desired unit of measure.

Line 1 shows the

current units Enter
Units Sub Menu
Units Current Units Screen,
designation M=Metric,
displays the current units
E=English
designation.

Line 2 shows the

current units
designation, full text
Units: E NewUnits Exit
Units
-English -English

Press BOTH keys to select

Line 1 shows the current units and exit sub menu.
current units
designation M=Metric,
E=English Units: E NewUnits Exit
Units
New: Met -Metric
Line 2 shows the
alternate units
selection

Units: E NewUnits Exit

Units
Line 1 shows the New: Eng -English
current units
designation M=Metric,
E=English

Line 2 shows the

alternate units
selection

MDDM-00066N page 4 of 8
 MDDM Operating Instructions continued

Viewing Engine Configuration Data Press BOTH the UP and DOWN buttons SIMULTANEOUSLY to
The MDDM can display the engine configuration data stored in select the Engine Configuration Sub-Menu. The MDDM will
the engine ECM. To select the Engine Configuration Sub-Menu display the engine configuration data as shown in Engine
(shown below), press the UP or DOWN button until the display Configuration Sub-Menu. If the Engine Configuration is not
shows the following label. available, the display will show:

Eng Conf Eng Conf

Press N/A
NOTE: The parameters displayed on the MDDM will vary
depending on the engine make and model
Engine Configuration
Enter
Sub-Menu
Eng Conf

Speed 1 Torque 5 Hi Limit

.....RPM .....% .....%

Torque 1 Speed 6
.....% .....RPM
Configuration
Data Continued

Speed 2 Gov Gain

.....RPM .....%

Torque 2 Ref Torq

.....% .....f/#

Speed 3 Speed 7
.....RPM .....RPM

Torque 3 TimeLimt
.....% .....sec
To exit the Eng Conf
Display sub menu:
Press BOTH keys at
Speed 4 Lo Limit ANY time.
.....RPM .....RPM

Torque 4 Hi Limit
.....% .....RPM

Speed 5 Lo Limit
.....RPM .....%

MDDM-00066N page 5 of 8
 MDDM Operating Instructions continued

Viewing Active Engine Service Codes Press both the UP and DOWN buttons SIMULTANEOUSLY to
The MDDM continuously monitors all messages broadcast over the select the Service Code Sub-Menu. The MDDM will display all
SAE J1939 Control Area Network (CAN) and displays all Active Active Service Codes as shown in the Service Codes Menu
Service Codes at the time the message is broadcast. When a fault schematic (below). If Service Codes are not available, the dis-
occurs the display will show the message "SrvcCode" every five play will show the following:
seconds interrupting the currently displayed parameter. In addition,
the amber LED will be illuminated during Active Service Code
warning faults, and the red LED will be illuminated during shut-
SrvcCode
down faults. These warnings will continue until the fault clears. No Codes
To view the Active Service Codes select the Service Code Sub-
Menu by pressing the UP or DOWN button until the display
shows the following label:
SrvcCode
Press

Service Codes Sub-Menu

Data Available
Enter
SrvcCodes

First SPN, FMI

combination

User may exit the

SPN..... Service Code
FMI..... Display routine by
pressing BOTH
keys Simultaneously
at any time.

SPN..... Exit
SrvcCodes
FMI.....

SPN....n
FMI....n
Last SPN, FMI
combination (n)

Explanation of SPN & FMI Diagnostic Codes

SPN refers to Suspect Parameter Number and FMI refers to Failure Mode Identifier.
Both the SPN and FMI are used in the J1939 standard for identification of faults and conditions.

MDDM-00066N page 6 of 8
 MDDM Operating Instructions continued

Viewing Service Codes in Press both the UP and DOWN buttons SIMULTANEOUSLY to
select the StorCodes Sub-Menu. The MDDM will display the
The Engine Control Module (ECM) Stored Service Codes according to the menus shown in the
The MDDM can request Stored Service Codes (DM2) from the schematic below.
engine. The Stored Service Codes may be used for diagnostic If Stored Service Codes are not available, the display will show:
and service needs. To view the Stored Service Codes it is neces-
sary to select the StorCode Sub-Menu by pressing the UP or
DOWN button until the display shows the following label. StorCode
StorCode No Data
Press

Stored Codes
Enter
StorCode
(Previously Active Codes)
Sub-Menu
if
No DM2 data is
available

Yes Lamp Status

LampStat First SPN, FMI

0x.. combination

SPN....1
FMI....1
Last SPN, FMI
combination (n)

SPN....n
FMI....n

Indication of NO
DM2 Data.

StorCode
No Data
User may exit the
Service Code
Display routine by
pressing BOTH
keys Simultaneously
at any time.

MDDM-00066N page 7 of 8
 SAE J1939 MurphyLink System Implementation of J1939 Parameters
Source: SAEJ1939-71 Surface Vehicle Recommended Practice

SAE J1939 Section Description PGN Parameter Display Value

5.3.6 Elec Eng Cont #2 - EEC2 61443 Accelerator Pedal Position Throttle
Percent Load at Current RPM Load@RPM
5.3.7 Elec Eng Cont #1 - EEC1 61444 Actual engine % torque Eng Torq
Engine Speed Eng RPM
5.3.14 Vehicle Distance 65248 Trip Distance TripDist
Total Vehicle Distance Veh Dist
5.3.19 Engine hours, Revolutions 65253 Total Engine Hours Eng Hrs
5.3.23 Fuel Consumption 65257 Trip Fuel TripFuel
Total Fuel Used FuelUsed
5.3.28 Engine Temperature 65262 Engine Coolant Temp Cool Tmp
Fuel Temperature Fuel Tmp
Engine Oil Temperature Oil Tmp
Engine Intercooler Temperature Intc Tmp
5.3.29 Engine Fluid Level/Pressure 65263 Fuel Delivery Pressure FuelPres
Engine Oil Level Oil Lvl
Engine Oil Pressure Oil Pres
Coolant Pressure CoolPres
Coolant Level Cool Lvl
5.3.31 Cruise Control /Vehicle Speed 65265 Wheel Based Vehicle Speed Veh Spd
5.3.32 Fuel Economy 65266 Fuel Rate FuelRate
Instantaneous Fuel Economy FuelEcon
Average Fuel Economy Avg Econ
5.3.35 Ambient Conditions 65269 Barometric Pressure BaroPres
Air Inlet Temperature AirInTmp
5.3.36 Inlet/Exhaust Conditions 65270 Boost Pressure Bst Pres
Intake Manifold Temp Mani Tmp
Air Filter Differential Pressure AirDifPr
Exhaust Gas Temperature Exh Tmp
5.3.37 Vehicle Electrical Power 65271 Electrical Potential (Voltage) Sys Volt
Battery Pot. Voltage (Switched) Bat Volt
5.3.38 Transmission Fluids 65272 Transmission Oil Pressure TranPres
Transmission Oil Temperature Tran Tmp
5.3.46 Engine Fluid Level/Pressure #2 65243 Injector Metering Rail 1 Pres InjPres1
Injector Metering Rail 2 Pres InjPres2
5.3.58 Fan Drive 65213 Fan Spd
65226 DM1 - Active Diagnostic SrvcCode
Diagnostic Messages 65227 DM2 - Previously Act Diag Codes StorCode
65228 DM3 - Diagnostic Clear
5.3.17 Engine Conf. 65251 Engine Configuration Eng Conf

Warranty
A two year limited warranty on materials and workmanship is provided with this Murphy product.
Details are available on request and are packed with each unit.

CONTROL SYSTEMS & SERVICES DIVISION FRANK W. MURPHY, LTD. MACQUARRIE CORPORATION
P.O. Box 1819; Rosenberg, Texas 77471; USA Church Rd.; Laverstock, Salisbury SP1 1QZ; U.K. 1620 Hume Highway
(281) 342-0297 fax (281) 341-6006 +44 1722 410055 fax +44 1722 410088 Campbellfield, Vic 3061; Australia
FWMurphy e-mail [email protected] e-mail [email protected] +61 3 9358-5555 fax +61 3 9358-5558
P.O. Box 470248 www.fwmurphy.co.uk e-mail [email protected]
Tulsa, Oklahoma 74147 USA MURPHY DE MEXICO, S.A. DE C.V. MURPHY SWITCH OF CALIFORNIA
(918) 317-4100 Blvd. Antonio Rocha Cordero 300, Fracción del Aguaje 41343 12th Street West
fax (918) 317-4266 San Luis Potosí, S.L.P.; México 78384 Palmdale, California 93551-1442; USA
+52-48-206264 fax +52-48-206336
D
RE

(661) 272-4700 fax (661) 947-7570 GI

E

e-mail [email protected] STER

e-mail [email protected] e-mail [email protected]

www.fwmurphy.com www.murphymex.com.mx www.murphyswitch.com
In order to consistently bring you the highest quality, full featured products, we reserve the right to change our specifications and designs at any time.
Printed in U.S.A.
MDDM-00066N page 8 of 8
 MDDM TROUBLESHOOTING
For the MDDM to display engine parameter information, the ECM (Engine Control Module) must be programmed to broadcast J1939 information
over the CAN (Controller Area Network). Most ECMs are pre-programmed from the factory to broadcast J1939 information. please verify that the
ECM is “J1939 Enabled”.
The MDDM must have a “Termination Resistor” across the CAN–L and CAN–H wires to read J1939 information, see page 2 “MDDM typical
Wiring Diagram”.

MDDM INTERNAL ERROR CODES

Address Claim Procedure Errors (ACP-Err):
As a part of the MDDM's boot up procedure, the MDDM must claim a network address for its use. If an error occurs during this procedure an
error code is displayed on the LCD.
Error Code 1.
Line 1: "ACP-Err"
Line 2: "No Addr"
This error occurs if the MDDM is NOT able to claim an address, either the default address or one of the addresses from its range of
addresses (43 - 127). If this error occurs the MDDM has tried EACH address in it's range and has lost arbitration with each. Therefore,
the MDDM has not claimed an address.

Error Code 2.
Line 1: "ACP-Err"
Line 2: "Bus EP"
This error occurs if the MDDM encounters a CAN bus error that has caused the MDDM's bus interface to transition into an error state
of operation. The "Bus EP " means that the MDDM is in a Error Passive (EP) mode. The Error Passive state is a result of the MDDM
not having a partner on the CAN bus, or the MDDM is attached to the CAN bus with the CAN_HI and CAN_LO reversed.

Error Code 3.
Line 1: "ACP-Err"
Line 2: "BusError"

This error occurs if the MDDM has transitioned through the Error Passive mode and has continued to encounter CAN bus errors. The
"BusError" mode is a result of catastrophic errors on the CAN bus, some possible causes:
- CAN_HI or CAN_LO or both are shorted to electrical ground or to the battery voltage
- One or more nodes on the CAN bus is transmitting at a non-standard baud rate.
This type of error is generally non-recoverable, and will require a skilled service person to help sort out the possible error causes.

Run Time Bus Errors:

After the MDDM has claimed a network address, it enters its run time mode of operation. If a bus error occurs during this mode, one of the fol-
lowing error codes will be displayed.
Error Code 1.
Line 1: "xxxxx EP"
Line 2: "No Data"

EP = Error Passive, for some reason the MDDM has lost contact with the network and no longer has a communications partner or part-
ners. This may have been caused by a connector separating, or the network wires being severed.
Error Code 2.
Line 1: "xxxxx BO"
Line 2: "No Data"
BO = Bus Off, see ACP Error Code #3.
Error Code 3.
Line 1: "xxxxx BR"
Line 2: "No Data"
BR = Bus Reset, this error code is similar to ACP error code #3. The MDDM has encountered CAN bus errors that have caused it to transi-
tion through EP, and BO, in this state the MDDM is resetting the CAN interface in an attempt to re-establish connection to the network.
 MLA-00012N

Installation Instructions for MurphyLink TM Revised 09-02

Section 78
00-02-0424

Analog Gages Series: MLA20 and MLA35

Please read the following information before installing. A visual inspection of this product for damage during ship-
ping is recommended before mounting. It is your responsibility to have a qualified person install this unit.
GENERAL INFORMATION

WARNING
BEFORE BEGINNING INSTALLATION OF THIS MURPHY PRODUCT
✔ Disconnect all electrical power to the machine.
✔ Make sure the machine cannot operate during installation.
✔ Follow all safety warnings of the machine manufacturer.
✔ Read and follow all installation instructions.

Description MLA20 Series MLA35 Series

The MurphyLinkTM gages are a series of instruments designed to display the
information transmitted by the Murphy Display and Diagnostic Module
(MDDM) in a traditional analog format. Communication from the MDDM to
these units is via an RS485 twisted pair proprietary serial link. These Basic 2 in. (51 mm) case models
MurphyLinkTM components are environmentally sealed, LED back lit (green) MLA20-A-100-A Engine Oil Pressure
and are available in a standard 2 in. (51 mm) diameter, plastic case. The MLA20-B-250-A Coolant Temperature
MLA35 Series models feature a 3-3/8 in. (86 mm) diameter, plastic case.
MLA20-C-12-A Voltmeter 12 VDC
Specifications MLA20-C-24-A Voltmeter 24 VDC
Power Supply: MLA20-D-100-A Percent Load @ Current Speed
Input Voltage: 12V (10-16 VDC min. & max. voltage). MLA20-E-400-A Gear Oil Pressure
24V (18-32 VDC min. & max. voltage).
MLA20-F-250-A Gear Oil Temperature
Operating Current: (@ 14 VDC) = MLA20: 27 mA min.; 50 mA max.
MLA35: 43 mA min.; 48 mA max. Basic 3-3/8 in. (86 mm) case models
Backlight:
MLA35-T-3000-A Tachometer
Voltage: 12 to 14 VDC (See NOTE below).
Maximum Current: 30 mA. MLA35-S-85-A Speedometer

NOTE: MLVC2412 Regulator required for 24 VDC Systems. NOTE: All basic models listed above are available with Amp mini
universal (standard), Deutsch or Metri-Pack connectors.
Input: RS485 data (MurphyLinkTM proprietary protocol).
Output: Analog Readout.
Operating Temperature: -40° to 185°F (-40° to 85°C).
Storage Temperature: -76° to 185°F (-60° to 85°C). CAUTION: These instruments are designed to be used ONLY
Dial: White numerals over black background: with the MurphyLinkTM Display and Diagnostic module (MDDM)
MLA20: 90° sweep; MLA35: 250° sweep. or other approved MurphyLinkTM products.
Gage Accuracy: MLA20: Better than ±1.5% of scale.
MLA35: Better than ±2% of scale.
Enclosure: Environmentally Sealed. Warranty
Material: A two year limited warranty on materials and workmanship is provided
Case and Clamp: Polyester (PBT). with this Murphy product. Details are available on request and are
Lens: Polycarbonate. packed with each unit.
Bezel: Stainless Steel (Black optional).
In order to consistently bring you the highest quality, full featured products, we reserve the right to change our specifications and designs at any time.

Installation MLA-00012N page 1 of 2

 MLA20 and MLA35 Dimensions and Mounting

MLA20 Series MLA35 Series 0.48 in. (12 mm) Push On Plug (Amp)
Connection
0.48 in. (12 mm) Push On Plug (Amp)
Connection

3.22 in.
1.94 in. (82 mm)
(49 mm)
For Panels up to 3/8 in.
For Panels up to 3/8 in. (9.5 mm) maximum thickness
(9.5 mm) maximum thickness

2.25 in. (57 mm) 1.94 in. (49 mm)

3.55 in. (90 mm) 2.0 in. (51 mm)
Mounting Hole
For Panels up to 3/4 in. (19 mm)
2.062 in. (52 mm) Dia. maximum thickness Mounting Hole
For Panels up to 3/4 in. (19 mm)
3.375 in. (86 mm) Dia. maximum thickness

Mounting Clamp

Mounting Clamp

MLA20 and MLA35 Typical Wirings For 12 and 24 VDC

WARNING: Disconnect battery negative cable before wiring or service. Devices containing solid state components can be damaged or caused to
malfunction when used in systems which incorporate inductive loads (e.g. relays, solenoids, etc.) that can generate voltage spikes. To reduce the
potential for this type of damage, install a fly back or clamping diode across all inductive loads. Use Murphy diode package 65-00-0343 or equivalent.
A typical diode is 1N4005 and is readily available from commercial sources. Failures of this type are not covered by our Limited Warranty.

Wiring for 12 VDC Systems Wiring for 24 VDC Systems

White RS485 (+) Data White RS485 (+) Data
Place Resistor at Place Resistor at
End of Line on Orange RS485 (-) Data End of Line on Orange RS485 (-) Data
Last MLA gage. Last MLA gage.
(included for factory MDDM Gage (included for factory MDDM Gage
purchased panels.) MLA Gage Rear View Pin A Pin H purchased panels.) MLA Gage Rear View Pin A Pin H
Rear View Rear View
Illumination Illumination
120 Ω Control* 120 Ω Control*
(optional) (optional)

To Next To Next
MLA Gage MLA Gage Ignition Switch

Back Back
Light Blue Light
Ignition
Blue Ground Switch Ground
Black Battery Black Battery
Red Battery Red Battery
Back Light
C (V Out)
B (Ground)
A (V in)

* Electronic Dimmer switch recommended with 4 A, capacity * Electronic Dimmer switch recommended with 4 A, capacity Voltage
or heavy duty rheostat switch, 25 ohm, 5 watt. or heavy duty rheostat switch, 25 ohm, 5 watt.
For more than 6 MLA gages, contact factory for rheostat sizing. Regulator
For more than 6 MLA gages, contact factory for rheostat sizing.
(MLVC2412)

CONTROL SYSTEMS & SERVICES DIVISION FRANK W. MURPHY, LTD. MACQUARRIE CORPORATION
P.O. Box 1819; Rosenberg, Texas 77471; USA Church Rd.; Laverstock, Salisbury SP1 1QZ; U.K. 1620 Hume Highway
(281) 342-0297 fax (281) 341-6006 +44 1722 410055 fax +44 1722 410088 Campbellfield, Vic 3061; Australia
FWMurphy e-mail [email protected] e-mail [email protected] +61 3 9358-5555 fax +61 3 9358-5558
P.O. Box 470248 www.fwmurphy.co.uk e-mail [email protected]
Tulsa, Oklahoma 74147 USA MURPHY DE MEXICO, S.A. DE C.V. MURPHY SWITCH OF CALIFORNIA
(918) 317-4100 Blvd. Antonio Rocha Cordero 300, Fracción del Aguaje 41343 12th Street West
fax (918) 317-4266 San Luis Potosí, S.L.P.; México 78384 Palmdale, California 93551-1442; USA
+52-444-8206264 fax +52-444-8206336
D
RE

(661) 272-4700 fax (661) 947-7570 GI

E

e-mail [email protected] STER

e-mail [email protected] e-mail [email protected]

www.fwmurphy.com www.murphymex.com.mx www.murphyswitch.com
In order to consistently bring you the highest quality, full featured products, we reserve the right to change our specifications and designs at any time.
Printed in U.S.A.
Installation MLA-00012N page 2 of 2
HGGGH

HR JOB
#12328

NITROGEN TANK MANUAL

(Refer to Hard Copy of this Manual)

TP-1
 HYDRA RIG

PARTS ORDER FORM

CUSTOMER:_______________________________________________________DATE:____________

PROJECT:__________________________________________________________________________

COMPANY:_________________________________________________________________________

CONTACT:__________________________________________________________________________

When ordering parts, refer to the drawings in this manual for part numbers and descriptions. Provide Hydra
Rig with the drawing number, quantity, part number and description.

Drawing No.: .......................................................................................................Quantity ..........................................

Part No.: .........................................................................................................................................................................
Description......................................................................................................................................................................

Drawing No.: .......................................................................................................Quantity ..........................................

Part No.: .........................................................................................................................................................................
Description......................................................................................................................................................................

Drawing No.: .......................................................................................................Quantity ..........................................

Part No.: .........................................................................................................................................................................
Description......................................................................................................................................................................

Drawing No.: .......................................................................................................Quantity ..........................................

Part No.: .........................................................................................................................................................................
Description......................................................................................................................................................................

Drawing No.: .......................................................................................................Quantity ..........................................

Part No.: .........................................................................................................................................................................
Description......................................................................................................................................................................

Drawing No.: .......................................................................................................Quantity ..........................................

Part No.: .........................................................................................................................................................................
Description......................................................................................................................................................................

Drawing No.: .......................................................................................................Quantity ..........................................

Part No.: .........................................................................................................................................................................
Description......................................................................................................................................................................

Drawing No.: .......................................................................................................Quantity ..........................................

Part No.: .........................................................................................................................................................................
Description......................................................................................................................................................................

HYDRA RIG, INCORPORATED PHONE: (817) 457-3825 FAX: (817) 457-3897