SECTION IV
OPERATION INSTRUCTIONS
4. THEORY OF OPERATION.
4.1 GENERAL. The HPS system supplies fluid under fixed pressure and volume. A diesel engine provides power for the hydraulic system. The electrical system supplies power for engine starting and operation of the electrical components.
4.2 HYDRAULIC SYSTEM.
4.2.1 HYDRAULIC LOGIC. (Refer to figure 6-1).
± 10 has a red rod that will pop up to warn of a clogged filter.a. The high pressure pump delivers fluid through main supply filter (13) and then to the fixed displacement motor/pump (2) in the submersible pump assembly. The submersible pump sucks in the fuel in the underground tank and send it to the outlet where it is funneled to a fuel truck or whatever. The system has an emergency operation mode in that another external source of hydraulic pressure can be hooked to the HPU hydraulic system at (17) for supply pressure and (22) for return to the external source and still utilize the HPS hose reel. (See paragraph 4.5.7).
b. The main pump is an axial-piston type. Main pump output is managed by the volume compensator control. The pressure compensator has an adjustable range and will maintain a set pressure. A check valve is installed at the pump output to prevent back flow through the main pump. The volume and pressure compensators are set at the factory for fixed operation.
c. The supply & return ports of the submersible pump are fitted with quick-disconnects for rapid hook-up to the hoses.
d. Supply filter (14) is a high pressure unit incorporating a 10-micron disposable element. A mechanical differential pressure switch (14) set at 35 PSI
e. Relief valve (12) protects the system against surges & overpressurization.
f. Return filter (26) is a low pressure unit with a replaceable 10-micron filter elements. A normally open differential switch (27) activates a warning light on the instrument panel with a differential pressure of 35 PSI across the element.
g. A hydraulic oil temperature probe (6) is installed in the reservoir. The probe is connected to a gauge on the instrument panel and is a dial indicating thermometer with a bulb and capillary tube, & ranges from –20oF to + 180oF.
h. Pressure gauge (15) indicates hydraulic supply pressure. An instrument shutoff valve (16) with test port (28) permits calibration of the gauge.
4.3 DIESEL ENGINE.
4.3.1 GENERAL. The diesel engine is three cylinder, four cycle, fuel injected, air cooled engine. The firing order is 1-3-2. The number one cylinder is at the belt end of the engine. The serial number is found above the engine starter. Rotation of engine is counterclockwise as viewed from flywheel.
4.3.2 FUEL SYSTEM. The fuel system consists of an external fuel tank, transfer pump, fuel filter, fuel injection pump, fuel injectors, and piping. Fuel from an external source is supplied to the fuel injection pump. The injection pump provides a pressurized metered quantity of clean atomized fuel through the injector nozzles into the cylinder at a precise time near the end of the compression stroke of each piston. The fuel that is not used by the injectors is returned to the fuel tank via an excess fuel return.
4.3.3 ELECTRICAL SYSTEM. The electrical system is 12 VDC operation and consists of an alternator, starter, externally mounted battery, and other items as required. The alternator is mounted on front of engine and is belt driven. When the engine is operating, the alternator supplies 12 volts to recharge the battery and maintain it at a full state of charge. The starter is mounted on the flywheel housing and when energized engages the ring gear of the flywheel to rotate the engine.
4.4 ELECTRICAL SYSTEM ACTIVATION. When the engine start switch on the engine control panel is set to run, the electrical system is activated. The following events occur (see Figure 4-1).
a. Alternator indicator (3) illuminates, indicating the electrical system is energized and confirms the alternator has not come on line yet.
b. Panel light for low oil pressure (4) light will come on until the engine is started and oil pressure rises above 10 PSI.
c. Electrical system becomes operational.
d. Turning the key to START will initiate the diesel engine start sequence.
Figure 4-1. Instrument Control Panel
Table 4-1. Instrument Control Panel
Figure/ |
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| 4-1 | INSTRUMENT CONTROL PANEL | |
1 |
ENGINE SWITCH | Used to start the engine, pre-heat the glow plugs or turn on electrical power to panel. |
2 |
GLOW PLUG (PRE-HEAT) | Shows when plugs are ready for start. |
3 |
INDICATOR LIGHT, ALTERNATOR | Indicates that alternator is not putting out a sufficient voltage charge. |
4 |
INDICATOR LIGHT, ENGINE OIL PRESSURE | Indicates engine low-oil pressure. |
5 |
INDICATOR LIGHT, AIR FILTER | Indicates clogged air filter. |
6 |
INDICATOR LIGHT, ENGINE TEMPERATURE | Indicates engine temperature exceeds 212 ± 36oF. |
7 |
THROTTLE CONTROL | Adjust throttle speed. Pull to increase, push to decrease, and turn knob to fine tube RPM. |
8 |
TACHOURMETER | Indicates speed of engine and operation time (0-4000 RPM) and (.01 to 9999 hours). |
9 |
FUEL LEVEL GAGE | Indicates fuel level in fuel tank. |
10 |
HIGH PRESSURE GAGE | Indicates main hydraulic pressure (0 to 6000 PSI). |
11 |
HYD. OIL TEMP. GAGE | Indicates temperature of hydraulic fluid entering main pump (Range –20 to 180oF). |
12 |
BYPASS VALVE | When open directs supply fluid back to the reservoir and when closed allows pressure to the submersible pump. |
13 |
HYD. OIL LEVEL GAGE | Displays how much fluid is contained in the hydraulic reservoir. |
14 |
ENGINE SHUTDOWN OVERRIDE SWT. | Pushing the switch disables the automatic engine shutdown system. This switch would be used in an emergency situation where the engine may have to be sacrificed in order to continue to withdraw critical fuel supplies from an underground tank. |
15 |
INDICATOR LIGHT, D P L.P. FILTER | Red light indicates low pressure filter needs servicing. |
16 |
GAGE SHUTOFF VALVE | Isolates pressure gage for external test. |
17 |
TEST PORT | Allows for external calibration of the pressure gage. |
18 |
PANEL LIGHT | Used to illuminate the instrument panel. |
19 |
LIGHT SWITCH | Used to turn on the panel light. |
20 |
CIRCUIT BREAKER (40 AMP) | Protects control panel from electrical surges/shorts. |
21 |
FLUORESCENT LIGHT | Above instrument panel. |
4.4.1 DIESEL ENGINE START SEQUENCE. (Figure 6-3). When the engine starter switch is set to START the following occurs:
a. Battery current will actuate fuel solenoid valve (9), allowing fuel to diesel engine.
b. Start solenoid (3) will energize. Its contacts will close, switching battery current to starter motor (2).
c. Starter motor will crank the diesel engine.
4.5 OPERATING INSTRUCTIONS.
a. Operating personnel must learn the functions of all controls & indicators prior to operating the HPS.
b. Check fuel, hydraulic fluid, engine oil levels.
c. Position HPS in proper location, set handbrake & close all access panels.
4.5.1 PRE-START PROCEDURES.
a. Connect bonding cable (Figure 1-1) to PFTU.
b. Remove submersible pump from hose reel compartment.
c. Crank (2, Figure 4-4) located on inside of hose reel compartment is normally used to crank in the hoses.
d. Turn knob (1) counterclockwise to unlock hose reel.
e. The two hose reels are interconnected and both hoses are to be manually pulled out simultaneously.
f. Make submersible pump hose connections (see Figure 4-2). The hose to pump quick-disconnects (male to female) for the supply side are reversed for the return side of the pump (female to male). Theoretically it is impossible to make a wrong hose connection to the pump since two male QD’s cannot be joined. See Paragraph 4.5.7 and Figure 4.5 for emergency external connections.
Figure 4-2. Submersible Pump
(Shown without strainer)
NOTE
The high and low pressure hoses each have metal tags at each end for identification.
g. Extend remote engine shutdown reel (Figure 1-1, 75 ft max) to a position where it is readily accessible.
h. Insert submersible pump into disabled tank in accordance with H-14 T.O. when available.
4.5.2 ENGINE START (NORMAL).
a. For normal start (temperature above 20oF).
4.5.3 ENGINE START (PRE-HEATING).
a. If temperature below 20oF pre-heating is desired.
Do not use spray starting aids on this engine. (Manufacturer recommendation).
b. Turn the starter switch key clockwise to PRE-HEAT position in order to heat the glow plugs on the engine (see Figure 4-3).
c. Approximately 25 to 30 seconds are required until the control resistance coil turns red from heating.
d. Turn key to START position.
4.5.4 AFTER START PROCEDURES. (Figure 4-1).
a. Once the engine has started it should accelerate to 1800 RPM or adjusted to 1800 RPM if pre-heated.
b. If engine oil pressure light (4) does not go out within 10 seconds shut down engine and investigate malfunction. Check all engine red indicator lights are off.
c. Allow engine to warm-up (about 3 minutes) at 1800 RPM.
d. After engine warm-up is completed throttle up to normal operating speed of 2300 RPM. This RPM may be adjusted from 2000-2500 RPM depending on requirements.
e. Close bypass valve (12) when ready to start submersible pump operations.
4.5.5 SHUTDOWN PROCEDURES. To shutdown the HPS, proceed as follows (Figure 4-1).
a. Open the BYPASS valve (12).
b. Set throttle control for 1800 RPM. Allow engine to idle for about 3 minutes.
c. Turn engine switch (1) off.
d. The submersible pump may be left in the underground tank if required.
e. If submersible pump is to be removed from underground tank proceed as follows:
1. Lift pump from underground tank.
2. Disconnect all hoses.
3. Turn pump so that the fuel exit port is at the 6 O’clock position to drain.
4. Remove crank from inside reel compartment and insert as shown on Figure 4-4 crank in hoses.
5. Lock hose reel by turning knob (Figure 4-4, 1) clockwise.
6. Store pump in hose reel compartment.
7. Rewind bonding wire and remote engine shutdown switch.
4.5.6 AUTOMATIC ENGINE SHUTDOWN FEATURES.
a. There are 7 conditions that will cause automatic engine shutdown. However only 5 of these conditions can be over-ridden by the over-ride switch (14, Figure 4-1). As in all cases judgement and knowledge of the system must be used in evaluating the reason for shutdown. The following are the automatic shutdown conditions. There is a 3 second delay on items 1-6 before automatic shutdown begins. There is no override for items 2 & 7 once automatic shutdown begins.
1. Alternator not charging indicator (indicator 3, Figure 4-1).
2. Low engine pressure (indicator 4, Figure 4-1).
3. Air filter clogged (indicator 5, Figure 4-1).
4. Engine temperature (indicator 6, Figure 4-1).
5. Hydraulic fluid low level (no panel indicator).
6. Hydraulic fluid temperature (no indicator).
7. Cooling fan belt breaks (no panel indicator).
b. The first four can be easily determined because of panel lights that come on. If the engine shuts down and there are no panel lights then a process of elimination must be used. Check the hydraulic reservoir gage (13, Figure 4-1) to eliminate item (5). Check hydraulic oil temperature gage (11) to eliminate (6). Take a visual look to see if the cooling belt (10, Figure 5-8A) is still there to eliminate item 7. The over-ride switch allows the engine to keep running, or be re-started, and sacrificed if necessary.
Figure 4-3. Engine Start Switch
Figure 4-4. Hose Reel
Figure 4-5. Emergency External Connections
4.5.7 EMERGENCY EXTERNAL CONNECTIONS (Figure 4-5).
a. The return shutoff valve handle (1) is safety wired to the open position (vertical) which is the normal setting.
b. If the FSU has failed, for whatever reason, an external source of hydraulic pressure can be used to operate the submersible pump.
c. Remove dust caps from quick disconnects (2) and (3).
d. Connect the external source of supply pressure hose to quick disconnect #2.
e. Connect the external return line to quick disconnect #3.
f. Break the safety wire and move handle (1) to the closed position (horizontal). This will prevent the external fluid going to the FSU reservoir and creating an overflow condition.
