Am804uu0164 dual20galaccum n2backup electronic version

20 GALLON VALVE CONTROL ACCUMULATOR ASSEMBLY NUMBER: AM804UU0164

USERS GUIDE

Revision Information

DisclaimerLee Specialties has made every effort to ensure that this document contains accurate and current information. This document is intended to be used in conjunction with a complete training program and on-site supervision. Lee Specialties does not warrant or guarantee that the information contained herein is either complete or accurate in every respect. The reader hereby protects, indemnifies and holds harmless Lee Specialties together with its officers, employees and agents from and against all liability for personal injury, death or property damage to any person arising directly or indirectly from the use by the reader of the information contained in the document.

Contact InformationIf you have any questions that are not covered by the contents of this manual please let us know:

Copyright InformationCopyright Lee Specialties. All rights reserved.

Revision Date Released Description of Changes SME(s)/Reviewer(s)/Approver(s)Rev 0 March 2016 First release Ryan Corbett

Head Office & Manufacturing - CANADA7883 Edgar Industrial Way, Red Deer, Alberta, Canada T4P 3R2Telephone: 1.403.346.4487Fax: 1.403.347.3312Business Hours: Monday to Friday, 08:00 - 16:00 (Mountain Standard Time - MST)General information: [email protected] (24-hour service)website: www.leespecialties.com

Main Office & Manufacturing - USA5119 Hiltonview Drive. P.O. Box 691693, Houston TX 77086 USATelephone: 1.281.519.1719Fax: 1.281.587.0865Business Hours: Monday to Friday, 08:00 - 16:00 (Central Daylight Time - CDT)General information: [email protected] (24-hour service)website: www.leespecialties.com

ConfidentialThis document and the proprietary information herein are the property of Lee Specialties. It shall not be disclosed nor copied, in whole or in part, without the written consent of Lee Specialties.Unauthorized transmission, reproduction, transcription, or retrieval system storage in any form is prohibited.

USERS GUIDE TABLE OF CONTENTS

LEE SPECIALTIES, 2016 REV 0III

Table of ContentsSection 1: About This Document ...................................................................................11.1 Video Tutorial for the 3D Toolbar ...........................................................................................2Section 2: Safety ..............................................................................................................3Section 3: Description & Specifications ........................................................................53.1 Overview ...................................................................................................................................5

3.1.1 Interactive 3D Model.........................................................................................................63.2 Control Panel Hood................................................................................................................103.3 Control Panel..........................................................................................................................123.4 EMERGENCY SHUTDOWN Control ......................................................................................143.5 Hydraulic Tank .......................................................................................................................153.6 Diesel Fuel Tank.....................................................................................................................163.7 Specifications.........................................................................................................................17Section 4: Operations....................................................................................................204.1 Pre-Operation Checklist ........................................................................................................204.2 Maintenance During Operation.............................................................................................214.3 Set Up Procedures .................................................................................................................22

4.3.1 Engine Start Up ..............................................................................................................224.3.2 Un-Spool and Connect the Hydraulic Hoses ..................................................................26

4.4 Charge the Accumulator System..........................................................................................284.5 Actuate the Hydraulic Valves................................................................................................30

4.5.1 From the Operators Control Panel.................................................................................304.5.2 Actuate Valves Using the Nitrogen Back-Up ..................................................................32

4.6 Shut Down Procedures..........................................................................................................334.7 Emergency Shutdown ...........................................................................................................39

4.7.1 Restart After an Emergency Situation ............................................................................40Section 5: Maintenance .................................................................................................415.1 Maintenance Schedules ........................................................................................................41

5.1.1 Daily Maintenance ..........................................................................................................415.1.2 100 Hour Maintenance ...................................................................................................425.1.3 500 Hour or Six Month Maintenance ..............................................................................425.1.4 1000 Hour or Annual Maintenance.................................................................................42

5.2 Maintenance Procedures.......................................................................................................42

USERS GUIDE TABLE OF CONTENTS

LEE SPECIALTIES, 2016 REV 0IV

Appendix A: Technical Information ...........................................................................A-1Consumable Parts .....................................................................................................................A-1Spare Parts ................................................................................................................................A-1Schematics and Technical Drawings.......................................................................................A-1Appendix B: OEM Reference Material........................................................................B-1

USERS GUIDE 20 GALLON VALVE CONTROL ACCUMULATOR

LEE SPECIALTIES, 2016 REV 01

Section 1: About This DocumentThis document contains the following information about the 20 Gallon Valve Control Accumulator with Auxiliary Nitrogen System and Remote Control Panel:

General safety information Set up, operation, and shut down procedures Maintenance schedules and procedures List of consumable parts and recommended spare parts Hydraulic schematic with parts information Electrical schematics Technical drawings with parts information Third-party reference information

USERS GUIDE ABOUT THIS DOCUMENT


1.1 Video Tutorial for the 3D ToolbarWatch this short video to learn how to use the toolbar associated with the interactive 3D model located in heading 3.1.1 Interactive 3D Model on page 6. Click on the LOADING image below to start the video. For best results, maximize the width of the PDF file you are viewing.



Section 2: SafetyAll personnel must be aware of the dangers related to the operation and maintenance of well site equipment, as well as to site-specific hazards. The following are critical to well site safety:

The wearing of personal protective equipment (PPE) Regular safety orientations Correct use and handling of lifting equipment

HydraulicsPressurized hydraulic systems store energy capable of exerting extreme force. Serious injuries or even death can occur as a result of improper use or mishandling of such equipment.To minimize the dangers of equipment operation and maintenance:

Perform all required pre-start checks and inspections Ensure that all lines and hoses are connected correctly to prevent any

unintended operation of the equipment Shut down the equipment and release pressure from the system before

performing any kind of maintenance or disconnecting any hydraulic lines Never use your hands to try and detect a pinhole leak. Always use a

piece of wood or cardboard, and wear safety glasses, a face shield, or both

ElectricalEnsure that equipment and tools are properly grounded prior to startup and operations. Never touch a tool and test equipment simultaneously. Stand on a dry wooden platform, a rubber mat, or a similar type of insulation when working on tools. Use grounding jumpers that are separate from the AC input lines.EnvironmentalSome of the fluids used in the operation and maintenance of the equipment can be harmful to the environment if not handled correctly. To minimize risk to the environment:

Dispose of waste fluids in accordance with local guidelines and regulations

Clean up spilled fluids in accordance with local guidelines and regulations

Report spills in accordance with applicable guidelines and regulations to the appropriate authorities

USERS GUIDE SAFETY


Notice SymbolsThe following safety notices have been added to this manual, however these notices do not replace proper training on equipment or well site safety procedures. Symbol Definition

DANGER! This symbol and paragraph indicate a risk of serious injury or death to personnel.

WARNING! This symbol and paragraph indicate a risk of severe damage to equipment.

CAUTION: This symbol and paragraph indicate a risk of moderate injury to personnel or damage to equipment.

NOTE: This paragraph indicates useful information that will allow the user to complete tasks quickly and efficiently.



Section 3: Description & Specifications

3.1 OverviewThe 20 Gallon Valve Control Accumulator provides a reliable source of hydraulic pressure to actuate hydraulically controlled valves. The 20 Gallon Valve Control Accumulator can operate three valves on up to two wells. A diesel engine powers the system hydraulic pump. The hydraulic pump charges two, 10 gallon accumulator bottles that connect in series for redundancy and to provide a sufficient volume for multiple valve actuations. A 3000 PSI nitrogen bottle provides an auxiliary source of pressure for valve actuation in the unlikely event that the main hydraulic system should fail.A 3 cylinder, 4 cycle diesel engine provides power for the hydraulic circuit. A 25cc variable displacement piston pump is driven by the diesel engine. It provides hydraulic flow for accumulator functions.Four hose reels contain the six hydraulic hoses. These are required to actuate up to two sets of three hydraulically controlled valves. Hand cranks allow you to quickly spool and un-spool the hydraulic hoses on and off of the hose reels. The control panel contains the controls and gauges required to safely operate your 20 Gallon Valve Control Accumulator. The ACCUMULATOR BOTTLES valve, located on the control panel, directs the accumulator system to build or relieve hydraulic pressure.A 60 US gallon hydraulic tank helps to ensure that a sufficient amount of hydraulic oil is available to actuate up to six hydraulically controlled valves. A vented, 22 US gallon fuel tanks supplies the diesel engine with fuel during operations.The Accumulators frame is constructed out of 2-1/2 x 2-1/2 in. reinforced steel tubulars to provide strength and durability. The control panel is manufactured out of polished Stainless Steel and is engraved with the functions of its controls and gauges. Forklift pockets and a four-point lift system allow for easy transportation and setup of the 20 Gallon Valve Control Accumulator.

USERS GUIDE DESCRIPTION & SPECIFICATIONS


3.1.1 Interactive 3D ModelClick on the image below to see an interactive model. You can use this model to assist you in ordering replacement parts. See heading 1.1 Video Tutorial for the 3D Toolbar on page 2 for more information on how to use the 3D Toolbar..



Figure 3-1: Skid Components Front View

1. Hood mounted work light2. Control panel3. Emergency shutdown control

4. Hydraulic tank - 60 US gal (227 L)5. Diesel tank - 22.5 US gal (85 L)



Figure 3-2: Skid Components Reel Side View

1. WELL #1 Master and RW Valve - 4 x125 ft of hydrau-lic hose (the first 25 ft. is fireguard)

2. WELL #2 Master and RW Valve - 4 x 125 ft of hydrau-lic hose (the first 25 ft. is fireguard)

3. WELL #1 LW Valve - 2 x 125 ft of hydraulic hose (the first 25 ft. is fireguard)

4. WELL #2 RW Valve - 2 x 125 ft of hydraulic hose (the first 25 ft. is fireguard)



Figure 3-3: Skid Components Rear View

1. Lift lugs for four-point lift system2. Work lights3. 10 US gal accumulator bottles (x2)

4. Backup nitrogen bottle5. Engine radiator6. Forklift pockets

Figure 3-4: Engine View

1. 3-Cylinder, 21.9 HP (16.3 kW) @ 3600 RPM 2. 25cc pump for accumulator functions3. Battery



3.2 Control Panel HoodThe hood protects the control panel from adverse weather, damage during transport, and provides light for nighttime operations. Latches on both sides of the hood secure it in the closed position during transport and storage. Weatherstripping along all four sides helps keep the panel dry. A work light, that runs off the 12V battery, mounts to the underside of the hood. To help ensure operator safety, a locking gas shock holds the cover open when the unit is in use.

DANGER! Temperatures below -30C (-22F) may result in failure of the gas shock causing the hood to fall which could result in injury. Use the gas shock lock shown in Figure 3-6 on page 11 to prevent injury.

WARNING! Disengage the gas shock lock prior to closing the hood. Failure to do so could compromise shock integrity.

Figure 3-5: Weatherstripping and Hood Latch

1. Weatherstripping2. Hood Latch



Figure 3-6: Locking Gas Shock and Release

1. Locking mechanism for gas shock2. Gas shock

Figure 3-7: Hood Light and Light Switch

1. Hood work light2. Light switch



3.3 Control PanelFigure 3-8: Operators Control Panel

Table 3-1: Control and Gauge Descriptions for the Operators Control PanelItem Control/Gauge Label Description

WELL#1 VALVE CONTROLS1. MASTER VALVE OPEN gauge Displays hydraulic pressure used to open the WELL#1 Master Valve2. MASTER VALVE The control handle used to direct pressurized hydraulic oil to open or close

the WELL#1 Master Valve3. MASTER VALVE CLOSE gauge Displays hydraulic pressure used to close the WELL#1 Master Valve4. RIGHT WING VALVE OPEN gauge Displays hydraulic pressure used to open the WELL#1 Right Wing Valve5. RIGHT WING VALVE The control handle used to direct pressurized hydraulic oil to open or close

the WELL#1 Right Wing Valve6. RIGHT WING VALVE CLOSE gauge Displays hydraulic pressure used to close the WELL#1 Right Wing Valve7. LEFT WING VALVE OPEN gauge Displays hydraulic pressure used to open the WELL#1 Left Wing Valve8. LEFT WING VALVE The control handle used to direct pressurized hydraulic oil to open or close

the WELL#1 Left Wing Valve9. LEFT WING VALVE CLOSE gauge Displays hydraulic pressure used to close the WELL#1 Left Wing Valve



10. ACCUMULATOR PRESSURE gauge

Displays the accumulator system hydraulic pressure in psi and kPa.

11. ACCUMULATOR PRESSURE REGULATOR

Adjusts the accumulator hydraulic pressure.

12. ACCUMULATOR BOTTLES valve CHARGE - directs hydraulic oil to accumulator bottles. DUMP - to relieve hydraulic pressure from bottles.

13. ACCUMULATOR PUMP - OFF/ON switch

Controls the accumulator system charge pump. Engage after the ACCUMULATOR BOTTLES valve is set to the CHARGE position.

14. 40 Amp Breaker Protects engine functions from electrical overloads - push to reset 15. 5 Amp Breaker Protects work lights from electrical overloads - push to reset16. WORK LIGHTS Toggle Switch Controls the work lights turning them on/off

NOTE: You must have the toggle switch in the on position in order to turn the dash-mounted light on/off

17. ENGINE SPEED gauge Displays the engine speed in rpm18. VOLTAGE meter Displays the 12 volt battery voltage19. ENGINE TEMPERATURE Displays the engine temperature20. OIL PRESSURE gauge Displays the engine oil pressure21. ENGINE START -

PRE-HEAT/START switchPRE-HEAT warms the glow plugs. START starts the engine.Pre-heat the plugs for at least 5 seconds prior to starting.

22. ENGINE STOP switch Turn to OFF to shut engine off Turn to ON to enable the engine start function

23. THROTTLE rotary/pull control Controls the speed of the engine:= increase; = decreaseWELL#2 VALVE CONTROLS

24. WELL#2 - RIGHT WING VALVE OPEN gauge

Displays hydraulic pressure used to open the WELL#2 Right Wing Valve

25. WELL#2 - RIGHT WING VALVE The control handle used to direct pressurized hydraulic oil to open or close the WELL#2 Right Wing Valve

26. WELL#2 - RIGHT WING VALVE CLOSE gauge

Displays hydraulic pressure used to close the WELL#2 Right Wing Valve











Table 3-1: Control and Gauge Descriptions for the Operators Control PanelItem Control/Gauge Label Description



3.4 EMERGENCY SHUTDOWN ControlThe EMGERGENCY SHUTDOWN control is located below the dash. Only use this control to stop the engine in emergency situations. Pull the EMERGENCY SHUT-DOWN control out to activate the engine air shutdown valve. The air shutdown valve is positioned between the engine air intake manifold and the engine. Activating this system prevents air from entering the engine so, if H2S gas or another hydrocarbons enters the engine, the engine cannot continue to run. Push the EMERGENCY SHUT-DOWN control back in to reset the shutdown valve for normal operations. Figure 3-9: EMERGENCY SHUT-DOWN Control



3.5 Hydraulic TankThe 60 US gal (227 L) hydraulic tank is located on the reel side of the 20 Gallon Valve Control Accumulator. The hydraulic tank supplies hydraulic pumps that are used for the following functions:

Operate the reels containing the accumulator lines Functioning the valves connected to the reel lines to the open or closed positions

Figure 3-10: Hydraulic Tank

1. Clean out cover2. Main hydraulic pressure control

CAUTION: Pressure is preset and should only be adjusted by Lee Specialties technicians.

3. Hydraulic filter4. Supply valve

5. Filler cap6. Sight glass7. Drain plug



3.6 Diesel Fuel TankThe tank holds 22 US gal (85 L) of diesel fuel. Figure 3-11: Diesel Fuel Tank Elements

1. Clean out cover2. Fill cap3. Sight glass4. Supply valve5. Water bleed-off port



3.7 SpecificationsTable 3-2: 20 Gallon Valve Control Accumulator SpecificationsSpecification Group Specification Details

General Skid InformationMain Assembly Lee Assembly Number AM804UU0164Operating Parameters Maximum operating pressure 3,000 PSI (20.7 MPa)

Temperature Range -40F to +104F (-40C to +40C)Skid Information Length 99 in. (251.5 cm)

Width 56.25 in. (142.8 cm)Height 72.5 in. (184.1 cm)Weight MGW: 5300 lbs (2404 kg)

TARE: 1420 lbs (644 kg)WLL: 3880 lbs (1760 kg)

Construction Mild steelTransportation Four-Point lift system, and forklift

pocketsControls Stainless steel engraved operator panelContainment Spill containment floor pans with drain

plugs

Accumulator System InformationAccumulator Bottles Manufacturer Parker/Greer

Type Pneumatic bladder accumulator10 US gallon per bottle (37.8 L)

Quantity 2Lee Part No. PM810UU0002Pressure 1500 PSI, pre-charged with nitrogen

NOTE: The pressure rating of each accumulator bottle is 3000 PSI.

Nitrogen Bottle Quantity 1Lee Part No. PM810UU0519



EngineEngineRefer to the diesel engine manual for more information.

Manufacturer YanmarType Liquid-Cooled, 4-cycle, 3 cylinder (2

valves per cylinder) Model 3TNV88-BDSALee Part No. AM810UU0984Power 36 HP (36.9 kW) @ 3000 RPM

PumpAccumulator Hydraulic Pump

Lee Part No.: PM735UU3787Type: 25cc, thru drive piston pumpModel LRR025CRP2020NNN3C2RGA6NAAA

NNNNNNManufacturer: Sauer Danfoss

TanksHydraulic Tank Lee Part No.: AM816UU0084

Volume: 60 US gal (227 L)Diesel Tank Lee Part No.: AM817UU0026

Volume: 22.5 US gal (85 L)

Table 3-2: 20 Gallon Valve Control Accumulator SpecificationsSpecification Group Specification Details



Reels and HosesReels Lee Part No.: AM808UU0162

Type: 28 in. x 17 in. (Four port 3/8 in. fittings)Quantity: 2

Reels Lee Part No.: AM808UU0163Type: 20 in. x 19 in. (Two port 3/8 in. fittings)Quantity: 2

Valve Actuator Hoses Lee Part No.: AM506-AF06-P06-P08-1200/300-2SLength: 125 ft. (38.1 m) - 100 ft. of hydraulic

hose and 25 ft. of fireguard hoseDiameter: 3/8 in. (~9.5 mm)Quantity: 6

MiscellaneousFluids* Refer to the diesel engine manual for more information.

Hydraulic fluid ATF Dexron IIIEngine fuel* Diesel fuel oil No. 2-DEngine oil* MIL-L-2104C or be above CD grade

(API classification)Engine coolant* 1:1 (50%) solution of purified/distilled

water and (50%) anti-freeze or pre-mixed 50/50 anti-freeze.

Table 3-2: 20 Gallon Valve Control Accumulator SpecificationsSpecification Group Specification Details



Section 4: OperationsThis section contains information on operating procedures for the 20 Gallon Valve Control Accumulator.NOTE: Refer to the diesel engine manual for more information about the operation of the engine.

4.1 Pre-Operation Checklist1. When the accumulator skid arrives on site, check to ensure that all required components required to operate the skid are present.2. The placement of the equipment at site is determined by the site manager in accordance to local safety requirements, job requirements, and operating conditions.3. Perform the following inspections before you operate the equipment:

WARNING! Failure to perform the following checks could result in equipment shut down.

a. Look and feel for broken or loose equipment. Replace components and correct problems before you operate the equipment.b. Look and feel for loose nuts and bolts, tighten as necessary.c. Inspect all hose connections to ensure they are correctly and securely fastened.d. Inspect all safety guards and shields. Replace as necessary.e. Inspect the water separation wells beneath the hydraulic fluid and fuel tanks (if applicable) and drain them if necessary.f. Verify all fluid levels and fill if required:

Hydraulic fluid CAUTION: Both of the accumulator bottles hold 10 US

gallons of hydraulic fluid; ensure these are unloaded back to the hydraulic tank before adding more hydraulic fluid to the tank.

Engine oil* Engine coolant* Engine fuel*

*Refer to the diesel engine manual in Appendix B: OEM Reference Information for more information.

USERS GUIDE OPERATIONS


4.2 Maintenance During OperationPerform the following inspections and tasks during the operation of the 20 Gallon Valve Control Accumulator.

WARNING! Failure to perform these inspections could result in equipment shut down or malfunction.

Maintenance Point TaskHydraulic fluid tank Monitor levels. Fill when necessary. The sight glass is

located on the side of the tank.NOTE: Each of the two accumulator bottles hold 10 US gallons (37.8 L) of hydraulic fluid when fully charged, so the hydraulic fluid tank might appear to be only half full during operation. Do not overfill the hydraulic fluid tank.

Hydraulic system pressure

From the control panel, monitor the ACCUMULATOR PRESSURE gauge.

Engine temperaturea

a. Please see the engine owners manual for more information.

Monitor the ENGINE TEMPERATURE gauge at the control panel.

Engine oil pressure* Monitor the OIL PRESSURE gauge at the control panel.Engine speed* Monitor the ENGINE SPEED gauge at the control panel.Engine fuel* Use the site glass on the side of the fuel tank to monitor fuel

levels.



4.3 Set Up ProceduresThese procedures assist you in correctly setting up the 20 Gallon Valve Control Accumulator skid.

4.3.1 Engine Start Up1. Open the hydraulic tank supply valve.

2. Open the fuel supply valve.



3. Ensure the EMERGENCY SHUT-DOWN switch is in the disengaged position by pushing it all the way in.

4. Place the ENGINE STOP OFF/ON in the ON position.



5. Preheat and start the engine:a. Turn the ENGINE START switch to PREHEAT and hold it in position for approximately 5 seconds.

NOTE: PREHEAT engages the glow plugs for the engine. In cold temperatures, hold the switch for a longer period of time. Refer to the diesel engine manual for details.

b. Turn the ENGINE START switch to the START position to start the engine.CAUTION: Do not engage the ENGINE START switch

for more than 10 seconds at a time. If the engine does not start, preheat the engine and try again. Allow the starter to cool off for 40 seconds after each attempt.



6. Once the engine has started, allow it to idle at low speed.7. Check all engine-related gauges to ensure the engine is working normally.

NOTE: Refer to the engine owners manual for details on operating parameters.8. While the engine is idling, inspect the entire system for leaks.

DANGER! NEVER use your hands or any other body part to test for leaks. Use a piece of wood or cardboard. Fluids under high pressure can cause serious injuries. If you find any leaks, shut down the system and correct the leaks before you continue operations. See heading 2. Use the VALVE controls in the control panel as required to actuate the required hydraulically controlled valves. on page 32.

9. Once you are ready for operations, turn the THROTTLE control counter-clockwise to Increase engine speed to around 1400 RPM.NOTE: The THROTTLE knob is equipped with a full speed bypass that is engaged by pressing the orange button and pulling up on the control.



4.3.2 Un-Spool and Connect the Hydraulic HosesThis procedure assumes that the diesel engine and hydraulic pump are operating.

1. Unpin and remove the crank handle from its stow point.

2. Insert the handle into the reel collar and secure the handle using the locking pin.



3. Disconnect the reel hydraulic lines from the dock points.

4. Unlock the reel by pulling the plunger lock up and turning it 90.

5. Spool the line off of the reel and connect it to the required hydraulically actuated valves.NOTE: Metal rings are installed on the ends of the hydraulic lines to you help with connections.

CAUTION: Incorrectly connecting the hydraulic lines to the valves will have unintended results.

6. At the control panel, ensure all the VALVE controls are set to the center (disengaged) position.



4.4 Charge the Accumulator SystemThis procedure assumes that the diesel engine is running.

1. Rotate the ACCUMULATOR PRESSURE REGULATOR in a counter-clockwise motion until you can feel no tension on the control.

2. At the control panel, turn the ACCUMULATOR BOTTLES valve to the CHARGE position.



3. Turn the ACCUMULATOR PUMP valve to the ON position.

4. Monitor the ACCUMULATOR PRESSURE REGULATOR gauge to ensure the accumulator bottles are charged to approximately 3000 PSI.NOTE: The accumulators pump has a relief valve set to maintain a constant pressure rating of 3000 PSI.

5. Use the ACCUMULATOR PRESSURE REGULATOR to adjust accumulator pressure.



4.5 Actuate the Hydraulic ValvesThis procedure explains how to actuate hydraulic valves once they are connected to the 20 Gallon Valve Control Accumulator.

4.5.1 From the Operators Control Panel1. From the control panel, view the at the ACCUMULATOR PRESSURE gauge to ensure the accumulator system is charged to 3,000 PSI.

NOTE: You must charge the accumulator system prior to operations if the pressure is less than 2,500 PSI (see heading 4.4 Charge the Accumulator System on page 28.)



2. Hold down the spring-loaded locking mechanism.

3. Use your desired VALVE OPEN/CLOSE controls to actuate the valves open or closed as required.



4.5.2 Actuate Valves Using the Nitrogen Back-UpIn the unlikely event that the primary accumulator system fails, you can use the auxiliary nitrogen system to actuate the valves open or closed. The auxiliary nitrogen system forces nitrogen gas into the hydraulic lines at a high enough pressure to allow actuation of the valves.NOTE: Since the auxiliary nitrogen system uses compressed gas to supply the pressure required for valve actuation, all hydraulic lines must be purged of gas before you can again use the primary accumulator.

1. From the back of the skid, there is a valve fitted to the line coming off the top of the nitrogen tank. Turn this valve 90 counter-clockwise to engage nitrogen.

2. Use the VALVE controls in the control panel as required to actuate the required hydraulically controlled valves.



4.6 Shut Down ProceduresUse the following procedure to shut down the 20 Gallon Valve Control Accumulator. This procedure assumes that the engine is still running.

1. From the control panel, set the ACCUMULATOR BOTTLES valve to the DUMP position to relieve hydraulic pressure from the accumulator system.

2. Set the ACCUMULATOR PUMP valve to the OFF position.



3. Ensure all VALVE controls are set to the center (neutral) position.

4. Ensure the ACCUMULATOR PRESSURE gauge reads 0 PSI.

5. Disconnect the hydraulic lines from the valves.DANGER! Disconnect the hoses ONLY when pressure

no longer exists within the hydraulic lines. Check the ACCUMULATOR PRESSURE gauge reads 0 PSI first.



6. From the reel control panel, use the VALVE levers to spool the accumulator lines onto the reels by placing the levers in the IN position. NOTE: Use the flow control valve below the operators control panel to control the speed of the reels.NOTE: Reeling the accumulator lines onto the reels is easiest when you use a second person to spool the line.

7. Unpin and remove the crank handle from its stow point.



8. Insert the handle into the reel collar and secure the handle using the locking pin and spool the hydraulic hose on to the reel.

9. Lock the reel by pulling the plunger lock up, turning it 90 so it can slide, and adjusting the reel until the spring loaded pin catches.



10. Reconnect the reel hydraulic lines to the dock points.

11.Turn the THROTTLE control in a clockwise motion to slowly reduce the engine speed.NOTE: Allow the engine to idle unloaded for five minutes before you shut it off.



12.Turn the ENGINE STOP switch to the OFF position.

13. Close the valves on the hydraulic and fuel tanks.



4.7 Emergency ShutdownIf an emergency situation occurs, follow your organizations emergency shutdown procedure.To shut down the 20 Gallon Valve Control Accumulator, simply pull out the EMERGENCY SHUT-DOWN control that is located below the control panel. Pulling this control will engage the engines air shut down valve causing the engine to stop.



4.7.1 Restart After an Emergency Situation1. At the Control Panel, set the controls in their start up positions (see heading 4.3 Set Up Procedures on page 22).2. Reset the engines air shut down valve by pushing the EMERGENCY SHUTDOWN control all the way in.

3. Restart the engine when conditions are safe to do so and then continue with operations.



Section 5: MaintenanceThis section contains maintenance schedules and procedures for the 20 Gallon Valve Control Accumulator. See heading 4.2 Maintenance During Operation on page 21.

WARNING! Failure to perform required equipment maintenance could result in equipment shut down or malfunction.

5.1 Maintenance SchedulesFollow the maintenance procedures outlined in this section to keep your equipment running at optimal performance.

5.1.1 Daily MaintenancePerform the following inspections and tasks at the beginning of every operating day and before you start the engine.

Maintenance Point TaskEngine oil level* Inspect for correct level. Fill if necessary.

See the Specifications table, cell Fluids on page 19.Engine fuel level* Inspect for correct level. Fill if necessary.

See the Specifications table, cell Fluids on page 19.Engine coolant level*

Inspect for correct level. Fill if necessary.See the Specifications table, cell Fluids on page 19.

Engine belts* Inspect for correct fit. Tighten if necessary.* Refer to the diesel engine manual for more information.Hydraulic fluid level Inspect for correct level. Fill if necessary.

See Fluids.Inspect for water contamination, dirt, foreign particles.NOTE: The accumulator bottles each hold 5 US gallons (19 L) of hydraulic fluid when fully charged, so the hydraulic fluid tank might appear to be only half full during operation. Do not overfill the hydraulic fluid tank.

Hoses Inspect for kinks, leaks, pinholes, or other defects.Inspect hose ends - remove and replace if any problems are found.

DANGER! Do not use hands or any other body part to test for leaks! Use a piece of wood or cardboard.

Pillow block bearings on reels

Inspect for adequate lubrication. Lubricate if necessary with EP2 grease.

Auxiliary nitrogen system

Check the gauge on the nitrogen bottle to ensure that the bottle is fully charged. A full charge is 3000 PSI.

USERS GUIDE MAINTENANCE


5.1.2 100 Hour MaintenancePerform the following inspections and tasks every 100 operating hours.

5.1.3 500 Hour or Six Month MaintenanceMaintenance Point Task

5.1.4 1000 Hour or Annual MaintenanceMaintenance Point Task

5.2 Maintenance ProceduresFor maintenance procedures for the diesel engine, refer to engine users guide. A copy of the engine users guide is located in Appendix B of the electronic version of this manual.

Maintenance Point TaskMounting bolts Inspect for wear and tightness. Tighten if necessary.Pillow block bearings on hose reels

Lubricate with EP2 grease.

Engine oil* Replace; see Fluids.Engine oil filter* Replace.Engine air cleaner* Clean or replace.Engine fuel filter* Clean or replace.*Refer to the diesel engine manual for more information.

Hydraulic system fluid filter

Replace (10 micron filter is recommended).

Hydraulic system fluid Replace. See Fluids.Engine air filter* Replace.Engine fuel filter* Replace.* Refer to the diesel engine manual for more information.

USERS GUIDE TECHNICAL INFORMATION

LEE SPECIALTIES, 2016 REV 0A-1

Appendix A: Technical InformationThis section contains the following information:

Spare parts Hydraulic schematic with parts information Electrical schematics Technical drawings with parts information

Consumable Parts Item Description Lee Part/Reference No.

Spare Parts Item Description Lee Part/Reference No.

Schematics and Technical DrawingsSchematics and technical drawings begin on the following page.

Hydraulic fluid filter PM810UU0050Engine oil filter PM810UU1051Engine air filter PM810UU1050Engine fuel filter PM810UU1052

Hydraulic filter housing PM810UU0049Fan belt PM810UU1053Alternator PM810UU1027Water pump PM810UU1188Water pump gasket PM810UU1031

7739 Edgar Industrial WayRed Deer, AlbertaCanada T4P 3R2

Ph # (403) 346-4487

Unless Otherwise Indicated: All Dimensions in Inches. 125 rms Finish Min.

Weight:

ofDrawing:

Checked By:

Exclusive Property Of Lee Specialties Considered Confidential And May Not Be Copied Or Reproduced Without Written Consent Of Lee Specialties Limited

Check Date:Drawn By:

Designer: Date:

Sheet:

REVISION HISTORYREV. DESCRIPTION DATE APPROVED

Revision:

3 AM804UU0164

Valve Control Accumulator 20 Gal w/N2 Backup

1

N/A

GF 11/12/2015

1

RC 11/4/2015

3221 lbmass

1 ECN 15-129: as built changes 12/16/2015 RC/GF

Status: Released

AM804UU0164

Appr'd By: GF Approved Date: 11/12/2015

RC

REV 1

MaterialSpec:

ProcessSpec:

x.xx `0.01 Fractional Tolerances: `1/16Decimal Tolerances: x.xxx `0.005 Concentricity: 0.005 TIR

Lee Rev 9 Ledger

Lee Specialties

DESCRIPTIONPART NUMBERQTYITEM

Accumulator Valve Skid WeldmentPM804UU056811

Accumulator Manifold Block Assembly, 40 Gal. Acc.AM804UU013612

Dash Panel AssemblyAM804UU016313

Hand Crank AssemblyAM808UU013914

Hose Reel Assembly Manual 4 Port 3/8" AM808UU016225

Hose Reel Assembly Manual 2 port 3/8" AM808UU016326

Yanmar 3 Cylinder Engine 3TNV88BDSAAM810UU098417

Dash Hood AssemblyAM813UU009618

Piston Pump AssemblyAM804UU016619

60 Gallon Hydraulic Tank AssemblyAM816UU0084110

22.5 Gallon Fuel Tank Complete AssemblyAM817UU0026111

Hydraulic Coupler, Steel, 1/2" Plug x 1/2" FNPT, Quick Connect PM512UU0022612

Hydraulic Coupler, Steel, 1/2" Socket x 1/2" FNPT, Quick Connect PM512UU0023613

1/4" 2 Way Ball Valve Swagelok SS43F4PM515UU0016114

Plug, #24 ORBPM553UU0091215

6ORBX6JICX6JIC Branch TeePM556UU0004116

Serial Number PlatePM809UU0031117

3000 psi 10 gallon Accumulator BottlePM810UU0002218

Accumulator Bottle Rubber BushingPM810UU0006219

Stop CablePM810UU0025120

12 Volt BatteryPM810UU0087121

All Weather Battery BoxPM810UU0114122

Emergency Shut Down PlatePM813UU0202123

Fitting, 2", Polyethylene Drum PlugPM810UU0224424

Accumulator Bottle BracketPM810UU0293325

60lb Gas Shock 17.13 Ext Length 6.3 StrokePM810UU0388126

60lb Gas Shock with lock 17.13 Ext Length 6.3 StrokePM810UU0389127

Nitrogen Bottle Type TPM810UU0519128

Work LightPM810UU0565229

*PART REMOVED* 30

Cable, Battery, Black, 4Gauge, 56"LongPM810UU0852131

Cable, Battery, Red, 4Gauge, 56"LongPM810UU0853132

Cable Clamp Throttle CablePM810UU1178133

Nitrogen Bottle CapPM810UU1220134

Nitrogen Bottle NutPM810UU1221135

Nitrogen Bottle Valve StemPM810UU1222136

Decal, WELL #1 Master and RW Valve, 1/2"PM735UU3838B137

Decal, WELL #2 Master and RW Valve, 1/2"PM735UU3839B138

Decal, WELL #1 LW Valve, 1/2"PM735UU3840B139

Decal, WELL #2 LW Valve, 1/2"PM735UU3841B140

Throttle Cable BracketPM813UU0277141

Hyd/FG Hose 3/8" 100Hyd 25FG 6MNPTX8MNPT SleevedAM506AF06P06P081200/3002S642

Sling 1/2" x 80"L 2 Leg Assembly w/ 3/4" ShacklesPM810UU0904280243

HOSE ID TAG 2.5"X1.5" SSPM810UU13201244

CABLE TIE 0.37"X8" SSPM810UU13212445

Fitting Hyd Coupler 1/2" Male BOP x FNPTPM512UU0024646

Fitting Hyd Coupler 1/2" Female BOP x FNPTPM512UU0025647

Dash Work LightPM810UU0070148

MGW: 5300 LB / 2404 KG

TARE: 1420 LB / 644 KG

WLL: 3880 LB / 1760 KG

(72

1/2

)

(56 1/4)

(99)

1

1

1

1

1

1

1


Ph # (403) 346-4487


Weight:

ofDrawing:

Checked By:



Designer: Date:

Sheet:


Revision:

3 AM804UU0164


2

N/A

GF 11/12/2015

1

RC 11/4/2015

3221 lbmass


Status: Released

AM804UU0164


RC

REV 1

MaterialSpec:

ProcessSpec:


Lee Rev 9 Ledger

Lee Specialties

46

1347

12

1

73341

9

22 21 32 31

24

8 26 27

5

6

11

10

1819251516

282534353614

17

29

4

3

NOTE: ITEMS 42-45 NOT SHOWN

11

1


Ph # (403) 346-4487


Weight:

ofDrawing:

Checked By:



Designer: Date:

Sheet:


Revision:

3 AM804UU0164


3

N/A

GF 11/12/2015

1

RC 11/4/2015

3221 lbmass


Status: Released

AM804UU0164


RC

REV 1

MaterialSpec:

ProcessSpec:


Lee Rev 9 Ledger

Lee Specialties

2

20 23

37 38

39 40


48

1


Ph # (403) 346-4487


Weight:

ofDrawing:

Checked By:



Designer: Date:

Sheet:


Revision:

Accumulator Valve Skid with N2 Backup

2 AM804UU0163

Dash Panel Assembly

1

N/A

RC 11/9/2015

1

CAJ 11/2/2015

36 lbmass

1 ECN 15-129: removed PM810UU1123 12/16/2015 RC/GF

Status: Released

AM804UU0163

Appr'd By: RC Approved Date: 11/9/2015

CJ

REV 1

MaterialSpec:

ProcessSpec:


Lee Rev 9 Ledger

Lee Specialties


Control Panel PM804UU057111

Gauge Tachometer 4" 4000 Rpm Alt Pickup

Chrome Bez

PM810UU106512

Gauge Oil Pressure 080 Psi Chrome BezelPM810UU106313

Engine Start SwitchPM810UU003614

Yuken Relief Valve (Small)PM810UU007615

Throttle CablePM810UU002616

Gauge, 5000psi, 2.5", Panel Mount, LB,

1/4"MNPT, LF

PM509UU0060137

Gauge BracketPM509UU0061138

1/4" NPT Angle Pattern Ball ValvePM810UU058329

Lever Switch (OnOff)PM810UU1034110

Boot, Switch Cover ( Large)PM810UU0038111

Gauge Voltmeter 818 VDC Chrome BezelPM810UU1064112

Gauge Water Temp 240 F Chrome BezelPM810UU1062113

Directional Control Valve, 3/8" PortingPM810UU1261614

6ORBX6JICX6JIC Branch TeePM556UU00041015

Adapter Steel, 4MJIC X 4FNPTPM525UU00221316

ELB STL 6MORB X 6MJICPM553UU07021417

Parker TripleLok NPTM Elbow, 44 CTXSPM525UU0021318

ADAPTER 6K 4MNPT X 4MJIC STEELPM525UU0020319

6MJICX6MJICX6FJIC SWIVELPM525UU00141320

Fitting, 4MJICx4MJICx4FJIC, SWL Nut Run

Tee

PM553UU0683121

REDUCER 4MJICX6FJICPM553UU04431322

Pigtail Light for All Datcon GaugesPM810UU1067323

5/16" X 18 UNC X 1/2" Stainless Hex BoltPM951SD031180502424

BREAKER PUSH/PULL 5AMP

W32X1A1G5

PE735UU2086125

BREAKER PUSH/PULL 40AMP

W23X1A1G40

PE735UU2093126

BREAKER TOGGLE 5AMP W31X2M1G5PE735UU2088127

Plunger with LockPM810UU03641228

*PART REMOVED* 29

CONNECTOR DEUTSCH 12 SOCKETPE168UU00090048130

Wedge, 12 Position Locking DeviceW12P131

CONNECTOR DC HIGH CURRENTPM735UU2056232

Cable, Battery, Red, 4Gauge, 56"LongPM810UU0853133

(22

)

(32) (9 3/16)4 10 6

157 7 7

14 24

14

14

26 25

11 27

9

9 7

7

7

7

24

24

24

24

2414

14

14

7

7

7

7

7

7

2

12

13

3

21


2828

2828

2828 28 28

2828

2828

1

1


Ph # (403) 346-4487


Weight:

ofDrawing:

Checked By:



Designer: Date:

Sheet:


Revision:

Accumulator Valve Skid with N2 Backup

2 AM804UU0163

Dash Panel Assembly

2

RC 11/9/2015

1

CAJ 11/2/2015

36 lbmass

1 ECN 15-129: removed PM810UU1123 12/16/2015 RC/GF

Status: Released

AM804UU0163


CJ

REV 1

MaterialSpec:

ProcessSpec:


Lee Rev 9 Ledger

Lee Specialties

8 18

16

22

22

1718

18

21

15

8

22

27 25 26

8

8

7

8

7

787 7 8 7 8 8 7

2220

17

22

20

17

7

8

7

8

7

8

7

8

17

16

22

22

17

16

20

17

22 20

19

19

15

15 15

1515

17

1515

17

20

22

15

17

2022

16

17

17

20

22 22

17

20

1720


Ph # (403) 346-4487


Weight:

ofDrawing:

Checked By:



Designer: Date:

Sheet:


Revision:

1 AM808UU0162

Hose Reel Assembly Manual 4 Port 3/8"

1

N/A

RC 11/10/2015

0

CJ 10/31/2015

87 lbmass

Status: Released

AM808UU0162


CJ

REV 0

MaterialSpec:

ProcessSpec:


Lee Rev 9

Lee Specialties


17" Reel Core BarPM808UU028261

Outer Thrust WasherPM808UU005112

28" Reel Flange - 2.25" Shaft Mount PM808UU028423

Hose Reel Support FlangeAM807UU004914

3/8 -16 X 1 UNC GR 8 HEX HEAD CAPSCREWPM952MS038-16-100185

Flat Washer 1.125, GR8, NormalPM953UU0016186

3/8" GR8 LockwasherPM954MS038187

O-Ring Viton 75 2-226PM933RB222658

4 Port, 17" Spacing, Manual Shaft WeldmentPM808UU033719

2MNPT Hollow Hex PlugPM553UU0519410

Shoulder Bolt, 3/8" x 1.5"LPM810UU0798211

SetScrew 3/8-16 UNCx0.5PM950MS037-16-050212

1/4" MNPT X 3/8" FNPT 90 Swivel ElbowPM553UU0607413

2" Pillow Block BearingPM810UU0029214

4 Port Swivel HousingPM808UU0049115

2" Inner Thrust WasherPM808UU0050116

2" External Snap RingPM810UU0696117

Elbow 45deg 6K #4MNPT X #6MJIC SteelPM553UU0777418

(29 11/16) (n28)

(17)

9

14

3

5

7

6

4

1 13

14

17

16 18

5

6

7

2

11

8

3

10

12


Ph # (403) 346-4487


Weight:

ofDrawing:

Checked By:



Designer: Date:

Sheet:


Revision:

1 AM808UU0163

Hose Reel Assembly Manual 2 port 3/8"

1

N/A

RC 11/10/2015

1

CJ 10/31/2015

61 lbmass

1 ECN 15-129: Item 1 was PM808UU0040 12/16/2015 RC/GF

Status: Released

AM808UU0163


CJ

REV 1

MaterialSpec:

ProcessSpec:


Lee Rev 9

Lee Specialties


20" Reel Flange - 2.0" Shaft MountPM808UU001421

19" Reel Core BarPM808UU028662

2 Port Swivel HousingPM808UU005613

Outer Thrust WasherPM808UU005114

2" Inner Thrust WasherPM808UU005015

2" Pillow Block BearingPM810UU002926

Hose Reel Support FlangeAM807UU004917

3/8 -16 X 1 UNC GR 8 HEX HEAD CAPSCREWPM952MS038-16-100188


O-Ring Viton 75 2-226PM933RB2226310

Flat Washer 3/8", GR8, NormalPM953UU00121811

2" External Snap RingPM810UU0696112

2 Port, 19" Spacing, Manual Shaft WeldmentPM808UU0338113

1/4" MNPT X 3/8" FNPT 90 Swivel ElbowPM553UU0607214

2MNPT Hollow Hex PlugPM553UU0519215

Shoulder Bolt, 3/8" x 1.5"LPM810UU0798216

Adapter 6K #4MNPT X #6MJIC SteelPM553UU0776217

30 3/16

n20

19

6

13

7

1

2 14

1

8

9

11

12 5

17

6

16

3

4

10

15

8

9

11

1

1


Ph # (403) 346-4487


Weight:

ofDrawing:

Checked By:



Designer: Date:

Sheet:


Revision:

1 AM816UU0084

60 Gallon Hydraulic Tank Assembly

1

N/A

GF 12/22/2015

0

RC 12/16/2015

276 lbmass

Status: Released

AM816UU0084


RC

REV 0

MaterialSpec:

ProcessSpec:


Lee Rev 9

Lee Specialties


60 Gallon Tank - WeldmentPM816UU020811

Tank Cleanout CoverPM813UU002112

Hydraulic Filler Cap AssemblyPM810UU001513

FILTER BASEPM810UU004914

Filter- Hydraulic- Donaldson - P165659PM810UU005015

1 1/4" NPT CLOSE NIPPLEPM556SA125N26

1/4-20 X .75 UNC GR 8 HEX HEAD CAPSCREWPM952MS025-20-07567

1/4" GR8 FlatwasherPM953MS02568


10" Sight GlassPM810UU0016110

1-1/4" Brass Gate ValvePM810UU0341111

Decal - "HYDRAULIC"PM816UU0115112

Cleanout Cover Gasket - RubberPM813UU0135113

1/4" MNPT x 1/4" MNPT 90deg ElbowPM556CB025EL114

1/4" FNPT-Ball ValvePM810UU0728115

2" Suction ScreenPM810UU0192116

1 1/4" SS Street ElbowPM556SA125SL117

Plug, 1" MNPTPM553UU0664118

20MNPTx12FNPT, BushingPM556UU0036119

Adapter, 20MNPT X 20MJIC STRPM553UU0681120

Plug Hex Head Steel Male NPT 1/4"PM553UU0675121

TEE 8MJICx8MNPTx8MJIC Branch TeePM553UU0230122

Fitting, 8FJICx4MJIC, Reducer PM553UU0679223

Fitting, 4MJICx4MJICx4FJIC, SWL Nut Run TeePM553UU0683124

1/2"NPT PLUGPM553UU0044125

ELBOW, 20MJICx20FJIC Swivel, 90 Deg.PM553UU0187126

TEE 3K 12MJICX12MJICX12MNPT STEELPM553UU0109127

2

131

3

105

46

151421

17616

7

9

8

12

24 1/4 34 5/16

35 1

/4

18262011

22

23

24

232719

25

DETAIL A

Parts List


3/8 MNPT x 3/8 MNPT 90deg Elbow SteelPM553UU068811

Hose, 5/16" Clear Urathane x 25"Hose5/162.12

ELB, STL, 1/4" MNPT, 90PM502UU000413

3/8"NPT Brass - 5/16"Hose Barb 90deg ElbowPM556CB038-031BEL44

3/8" FNPT Ball Valve, StainlessPM556SA375BV15

Fuel Filler Cap AssemblyPM810UU001116

1/4" FNPT-Ball ValvePM810UU072817

Tank Cleanout CoverPM813UU002118

Cleanout Cover Gasket - RubberPM813UU013519

22.5 Gallon Tank - WeldmentPM817UU0055110

1/4-20 X 1.0" UNC SS HEX HEAD CAPSCREWPM927UU0088611

1/4" SS FlatwasherPM927UU0091612

1/4" SS LockwasherPM927UU0092613

1/4 Hex Plug, 4MNPTPM553UU0675114

Hose Clamp, Size 002 (6/12 mm) TRIDONPM810UU0048415

Cap Screw 10-32 UNF x 0.75" STAINLESSPM951SB010-32-075616

A


Ph # (403) 346-4487


Weight:

ofDrawing:

Checked By:



Designer: Date:

Sheet:


Revision:

Fuel Tanks

1 AM817UU0026

22.5 Gallon Fuel Tank Complete Assembly

1

N/A

CJ 7/17/2013

4

GDS 11/23/2012

N/A

1 General Update 5/17/2010 CAJ

2 CR 10870 11/23/2012 GCP

3 ECN 13-376 7/15/2013 BM

4 ECN 13-740 UPDATED HARDWARE TO SS 11/27/2013 BMStatus: Released

AM817UU0026

Appr'd By: CJ Approved Date: 7/17/2013

BM

REV 4

MaterialSpec:

ProcessSpec:

N/A


Lee Rev 9

Lee Specialties

11

13

12

8

9

616

10

3 7

1

5

4

4

4

4

14

2

15

3

3

3

4

4

4

4

USERS GUIDE OEM REFERENCE MATERIAL

LEE SPECIALTIES, 2016 REV 0B-1

Appendix B: OEM Reference MaterialThis appendix contains the following reference information:

Accumulator hydraulic pump Diesel engine manual

MAKING MODERN LIVING POSSIBLE

Technical Information

Series 45 Pumps

powersolutions.danfoss.com

Revision history Table of revisions

Date Changed Rev

March 2015 Add E Frame ETL control and Angle Sensor HC

October 2014 Add ETL control and Angle Sensor HB

July 2014 Danfoss layout HA

Technical Information Series 45 Pumps

2 520L0519 Rev HC March 2015

General informationOverview..............................................................................................................................................................................................7Design...................................................................................................................................................................................................7

High Performance.......................................................................................................................................................................7Latest Technology.......................................................................................................................................................................7Reliability........................................................................................................................................................................................7

Benefits.................................................................................................................................................................................................7Reduced Installation Costs...................................................................................................................................................... 7Reduce Operating Costs........................................................................................................................................................... 8Increased Customer Satisfaction........................................................................................................................................... 8Reduced Heat Load on Cooling System............................................................................................................................. 8

Typical applications......................................................................................................................................................................... 8The Series 45 product family........................................................................................................................................................8

Basic units...................................................................................................................................................................................... 8Load sensing open circuit system.............................................................................................................................................. 9Servo Control Orifice.....................................................................................................................................................................10

Servo Control Orifice Principle.............................................................................................................................................10Servo Control Orifice Performance.................................................................................................................................... 11Pacing Factor..............................................................................................................................................................................12

Hydraulic Controls......................................................................................................................................................................... 13Pressure compensated controls..........................................................................................................................................13Remote pressure compensated controls.........................................................................................................................14Load sensing controls............................................................................................................................................................. 15

Electric Controls..............................................................................................................................................................................16Electric Proportional Controls (EPC)...................................................................................................................................16Electric On-Off Controls..........................................................................................................................................................20Electric dump valve PC/LS controls....................................................................................................................................24Electronic Torque Limiting Controls (ETL)....................................................................................................................... 25

Angle Sensor....................................................................................................................................................................................28PLUS+1 Compliance................................................................................................................................................................ 28Angle Sensor Principle............................................................................................................................................................28Angle Sensor Characteristics................................................................................................................................................ 29

J & F-Frame (45-90cc) Angle Sensor Identification Convention:........................................................................29E-Frame (100-147cc) Angle Sensor Identification Convention:..........................................................................30

Angle sensor electrical specifications............................................................................................................................... 33Angle Sensor Calibration....................................................................................................................................................... 33Angle Sensor Functionality................................................................................................................................................... 33

Charge Pump Circuits...................................................................................................................................................................33Example Circuit #1....................................................................................................................................................................33Example Circuit #2....................................................................................................................................................................34

Operating parameters..................................................................................................................................................................35Fluids............................................................................................................................................................................................. 35Viscosity........................................................................................................................................................................................35Temperature...............................................................................................................................................................................35Inlet pressure..............................................................................................................................................................................36Case pressure............................................................................................................................................................................. 36Pressure ratings.........................................................................................................................................................................36Speed ratings............................................................................................................................................................................. 36Duty cycle and pump life.......................................................................................................................................................37Speed, flow, and inlet pressure............................................................................................................................................37

Design parameters........................................................................................................................................................................ 37Installation...................................................................................................................................................................................37Filtration.......................................................................................................................................................................................38Reservoir...................................................................................................................................................................................... 38Fluid velocity.............................................................................................................................................................................. 38Shaft loads...................................................................................................................................................................................39Bearing life.................................................................................................................................................................................. 39Mounting flange loads............................................................................................................................................................39Estimating overhung load moments.................................................................................................................................39


Contents

520L0519 Rev HC March 2015 3

Auxiliary mounting pads........................................................................................................................................................40Input shaft torque ratings......................................................................................................................................................41Understanding and minimizing system noise............................................................................................................... 42Understanding and minimizing system instability...................................................................................................... 42

Sizing equations............................................................................................................................................................................. 43

Frames L and KDesign................................................................................................................................................................................................ 44Technical Specifications.............................................................................................................................................................. 45Order code........................................................................................................................................................................................45Performance L25C......................................................................................................................................................................... 50Performance L30D......................................................................................................................................................................... 51Performance K38C......................................................................................................................................................................... 52Performance K45D.........................................................................................................................................................................53Hydrauilic Controls........................................................................................................................................................................ 55

Pressure Compensated Controls.........................................................................................................................................55Remote Pressure Compensated Controls........................................................................................................................55Load Sensing/Pressure Compensated Controls............................................................................................................56Load Sensing Control with Bleed Orifice /Pressure Compensated........................................................................ 57

Electric Controls..............................................................................................................................................................................58Connectors..................................................................................................................................................................................58Continuous Duty Operating Range................................................................................................................................... 59Solenoid Data - Normally Closed........................................................................................................................................ 59Solenoid Data - Normally Open...........................................................................................................................................59Normally Closed Electric On/Off with Pressure Compensation Controls.............................................................59Normally Open Electric On/Off with Pressure Compensation Controls............................................................... 60Normally Closed Electric Proportional with Pressure Compensation Controls................................................. 61Normally Open Electric Proportional with Pressure Compensation Controls....................................................63

Input shafts.......................................................................................................................................................................................64Installation drawings.................................................................................................................................................................... 66

Axial Ported Endcap.................................................................................................................................................................66Axial Ported Endcap Installation Dimensions................................................................................................................ 66Radial Ported Endcap Split Flange Ports.......................................................................................................................... 67Radial Ported Endcap O-ring Boss Ports...........................................................................................................................67Radial Ported Endcap Rear View......................................................................................................................................... 68Radiall Ported Endcap Installation Dimensions.............................................................................................................69Front Mounting Flange - SAE-B two bolt......................................................................................................................... 69Auxiliary Mounting Pads........................................................................................................................................................70

SAE-A auxiliary mounting pad........................................................................................................................................70SAE-B auxiliary mounting pad........................................................................................................................................70Auxiliary Mounting Pad - Running Cover................................................................................................................... 71

Electric Solenoid, Left Side.................................................................................................................................................... 71Electric Solenoid, Right Side................................................................................................................................................. 71

Displacement limiter.....................................................................................................................................................................71

Frame JDesign................................................................................................................................................................................................ 73Technical Specifications.............................................................................................................................................................. 74Order code........................................................................................................................................................................................74Performance J45B.......................................................................................................................................................................... 83Performance J51B.......................................................................................................................................................................... 85Performance J60B.......................................................................................................................................................................... 87Performance J65C..........................................................................................................................................................................89Performance J75C..........................................................................................................................................................................91Hydrauilic Controls........................................................................................................................................................................ 92

Pressure Compensated Controls.........................................................................................................................................92Remote Pressure Compensated Controls........................................................................................................................93Load sensing/Pressure compensated Controls............................................................................................................. 94Load sensing Control with Bleed Orifice/ Pressure Compensated.........................................................................95

Electric Controls..............................................................................................................................................................................96


Contents

4 520L0519 Rev HC March 2015

Connectors..................................................................................................................................................................................96Continuous Duty Operating Range................................................................................................................................... 96Solenoid Data - Normally Closed........................................................................................................................................ 96Solenoid Data - Normally Open...........................................................................................................................................96Normally Closed Electric On/Off with Pressure Compensation Controls.............................................................97Normally Open Electric On/Off with Pressure Compensation Controls............................................................... 98Normally Closed Electric Proportional with Pressure Compensation Controls................................................. 99Normally Open Electric Proportional with Pressure Compensation Controls................................................. 100Normally Closed Electric Torque Limiting Control with Pressure Compensation Controls........................102

Input shafts.................................................................................................................................................................................... 103Installation drawings..................................................................................................................................................................106

Axial Ported Endcap.............................................................................................................................................................. 106Axial Ported Endcap Installation Dimensions..............................................................................................................107Radial Ported Endcap Split Flange Ports........................................................................................................................108Radial Ported Endcap Rear View.......................................................................................................................................109Radial Ported Endcap Installation Dimensions........................................................................................................... 110Right Angle Sensor Position Installation Dimensions...............................................................................................111Front Mounting Flange........................................................................................................................................................112Auxiliary mounting pads..................................................................................................................................................... 113

SAE-A auxiliary mounting pad (integrated)............................................................................................................ 113SAE-A auxiliary mounting pad (non-integral)........................................................................................................ 114SAE-B auxiliary mounting pad......................................................................................................................................115SAE-C auxiliary mounting pad..................................................................................................................................... 115Running cover....................................................................................................................................................................116

Radial Endcap Clockwise..................................................................................................................................................... 116Radial Endcap Counterclockwise..................................................................................................................................... 116Axial Endcap Clockwise........................................................................................................................................................117Axial Endcap Counterclockwise........................................................................................................................................117

Displacement limiter.................................................................................................................................................................. 117

Frame FDesign..............................................................................................................................................................................................119Technical Specifications............................................................................................................................................................120Order code..................................................................................................................................................................................... 120Performance F74B....................................................................................................................................................................... 126Performance F90C.......................................................................................................................................................................127Hydraulic Controls.......................................................................................................................................................................128

Pressure Compensated Controls...................................................................................................................................... 128Remote Pressure Compensated Controls..................................................................................................................... 128Load Sensing/Pressure Compensated Controls..........................................................................................................129Load Sensing Control with Bleed Orifice/Pressure Compensated.......................................................................130

Electric Controls........................................................................................................................................................................... 131Connectors............................................................................................................................................................................... 131Continuous Duty Operating Range................................................................................................................................. 132Solenoid Data - Normally Closed......................................................................................................................................132Solenoid Data - Normally Open........................................................................................................................................ 132Normally Closed Electric On/Off with Pressure Compensation Controls.......................................................... 132Normally Open Electric On/Off with Pressure Compensation Controls.............................................................133Normally Closed Electric Proportional with Pressure Compensation Controls...............................................134Normally Open Electric Proportional with Pressure Compensation Controls................................................. 135Normally Closed Electric Torque Limiting Control with Pressure Compensation Controls........................137

Input shafts.................................................................................................................................................................................... 138Installation drawings.................

Documents

Am804uu0164 dual20galaccum n2backup electronic version