Texas International Oilfield Tools, Ltd.
Table of Contents Specifications…………………………………………………4 Safety Issues…………………………………………………..7 Component Locations………………………………………..9 Hydraulic Circuit Diagram…………………………………11 Hydraulic System Functioning……………………………..12 Hydraulic Connections……………………………………...13 Installation…………………………………………………...14 Operation…………………………………………………….15 Adjustment…………………………………………………...16 Service………………………………………………………...18 Hydraulic System Troubleshooting…………………………19 Electrical System Troubleshooting………………………….
Metaris Gear Pump Code Book Extract…………Appendix D Parker Filter Data…………………………………Appendix E ISO Fluid Cleanliness Levels……………………...
Texas International Oilfield Tools, Ltd.
Hydraulic tank capacity Diesel tank capacity Performance 135 gallons maximum 118 gallons working Sight and temperature gages Filtered breather Top access hatch Fully welded steel construction 35 gallons maximum 33 gallons working Top access filler Fully welded steel construction 47 gpm @ 1800 rpm 66 gpm @ 2500 rpm 6 gallons per hour fuel consumption at maximum output (approximately) Maximum operating pressure 2500 psi (higher available) Pump Single stage, heavy duty gear type pump 6.
Standard gages cont'd Tank level Filtration status Optional gages Voltmeter Engine Temperature Engine Oil Pressure Engine hour meter Tachometer Battery (Electric start only) Group type 8D, heavy duty 12 volt commercial battery 1300 cold cranking amps at 0 F., 1560 cold cranking amps at 32 F.
Safety Issues 1. Location – always insure the unit is properly located away from hazardous vapor sources, in a solid, level location. 2. Electrical wiring –Insure that connections are properly made, that there are no breaks in the insulation, and that cables are running where they won’t be cut, nicked or squeezed during operation. 3. Cooling – always operate the unit with cooling fan properly adjusted.
High temperatures decrease the useful life of the hydraulic oil, the hoses and the seals in the equipment being powered. Very high temperatures can cause burns, as shown on the previous page. 5. Mechanical parts – don’t allow items like clothing or tools close to the accessory drive. Don't let items intrude into the fan at the front of the engine. The engine develops nearly 300 foot pounds of torque while running, and foreign objects can be drawn in with great power at rapid speed.
1 2 3 4 5 6 7 8 9 10 11 Component Locations 1. Breather cap and fill neck 2. Full flow return filter 3. Level gage and fluid thermometer 4. Return disconnect 5. Pressure disconnect 6. Bypass control 7. 0 – 3000 psi pressure gage 8. Relief valve (back side of block) 9. Cooling fan needle control valve 10. Gage panel / starting key 11.
11 12 13 14 15 16 17 18 Component locations 11. Skid eyes (4) 12. Air cleaner 13. Battery box (electric start only) 14. Diesel tank filler neck 15. Forklift tube 16. Air / oil cooler 17. Tank outlet to pump inlet shutoff valve 18.
Hydraulic Circuit Diagram Red lines are pressure lines, aqua (blue) lines are return lines, green lines are suction lines.
Hydraulic System Functioning The diesel engine drives the single stage pump at a setting of 1800 rpm. The pump draws hydraulic fluid from the tank and delivers hydraulic fluid up to 2500 psi on the pressure line, adjustable at the relief valve. The pump delivers 47 gpm at 1800 rpm, and 66 gpm at the engine's maximum speed of 2500 rpm. The engine is controlled by the hydro-throttle, which opens the throttle as the load increases.
Hydraulic Connections The power unit is equipped with Snaptite 78 series quick disconnect couplings (or equivalent), 1 inch for the supply line and 1-1/4 inch for the return line. These couplings contain check valves to prevent the loss of hydraulic oil during connection and disconnection. Proper connection is required to fully open the check valve. Connect the hoses as follows: 1. Wipe the connections clean as required to remove dirt and dust. 2.
Installation The diesel hydraulic power unit requires a location where adequate air flow and exhaust removal are available. It’s important to consider hydraulic line losses from size, length and head in choosing where to put the unit. The sizes of the hydraulic lines should be large enough to limit friction losses to 300 psi or less. This may mean using hoses larger than the connections on the unit. There should be at least three feet between the oil cooler and any wall or obstruction.
Operation The unit comes preset from the factory with the relief valve set at 2500 psi. See the “Adjustment” section on page 16 of this manual for how to change this setting. 1. Review the Deutz engine manual, Appendix A, for detailed instructions on start up, shut down and operation of the engine. 2. Check the condition of all hoses. Look for worn or scraped areas, bubbles, wrinkles or any other indication that the hose may need replacement. 3.
Adjustment Adjustments should be made with the oil at normal operating temperature of 80 to 130 degrees F. Relief valve adjustment screw (back side of this block) The adjustment for the relief valve is located as shown above. Turning the adjustment screw clockwise (in) raises the relief pressure: turning it counterclockwise lowers the relief pressure. The screw takes a 5/32" Allen wrench: the locknut for the screw a 9/16" wrench.
Adjustment (continued) Fan speed needle valve adjustment Rotating the needle clockwise (viewed from the top) slows down the fan. Rotating it counter-clockwise speeds the fan up. Muncie Hydro-Throttle See Appendix C for adjustment procedure.
Service Servicing of the power unit consists of periodic inspection, lubrication and if necessary, adjustment. Repairs are covered under the Hydraulic System Troubleshooting section beginning on page 19 or the Engine System Troubleshooting section beginning on page 21. The unit should be fully inspected at the start of every job.
Hydraulic System Troubleshooting Additional troubleshooting info is available in the appendices covering individual components. Problem Pump excessively noisy. Suction side plumbing is restricted or blocked. Viscosity of oil is too high. Air in suction side. Loose or worn out parts. Corrective action Insure that no foreign matter is blocking the tank outlet by removing the access hatch and looking inside. Verify suction shutoff valve is wide open. Change the oil to a lower ISO VG grade.
Problem Flow rate (tool speed) is low. Pump inlet flow is restricted. Damaged or worn pump parts. Oil is bypassing through relief or unloader valves. Disconnect fittings not tightened. Oil viscosity low or high. Plumbing is too restrictive. Engine speed is low. Corrective action Insure that no foreign matter is blocking the tank outlet by removing the access hatch and looking inside. Verify suction shutoff valve is wide open. Inspect the parts and replace as necessary.
Engine System Troubleshooting Additional troubleshooting info is available in the appendices covering individual components. Problem Engine will not start. No electrical power. Battery dead. Control circuit wiring incorrect or disconnected. Air in fuel system. Corrective action Verify and repair power connections. Recharge battery then find source of drain. Verify wiring is correct. Tighten connections. Bleed fuel system (See Appendix A section 3.1.4. Engine stalls.
Hot or noisy operation. Fan rubbing or hitting. Misalignment. Insufficient oil. Deterioration of lubricant. Excess oil. Engine loose. Remove interference with fan cover, etc. Tighten hold down bolts. See “engine vibrates” above. Lubricate engine per instructions in the engine manual. Remove old oil and lubricate engine per instructions in the engine manual. Drain excess oil. Verify oil level. Verify engine mounting bolts are tight.
NOTICE This portion of the manual was removed for web publication as the file size was too large, and the graphics not reduceable. Contact TIOT for complete and detailed information.
LOFA EP250 Operation and Troubleshooting Introduction This document provides general information on LOFA Industries EP250 control systems operation and troubleshooting. EP250 control systems are a very flexible platform for diesel engine control, monitoring, and protection, featuring LOFA’s powerful First Fault Diagnostics (FFD). After pinpointing the initial failure, FFD stores it in memory and alerts the end user via a single bright LED.
LOFA EP250 Operation and Troubleshooting Warning When replacement parts are required, LOFA Industries recommends using replacement parts supplied by LOFA or parts with equivalent specifications. Failure to heed this warning can lead to premature failure, product damage, personal injury or death. Important Safety Information The warnings in this publication are not all inclusive. LOFA Industries cannot anticipate every potential hazard.
LOFA EP250 Operation and Troubleshooting Operation Turning the control system key to the run position starts a self-test which causes all LEDs to illuminate once, activates the alarm output for one second and enables the fuel run/stop solenoid output. After self-test, the LEDs indicate the state of the inputs they monitor. The normal indications are battery charge and oil pressure on most applications. If these LEDs are not illuminated at this time it may indicate the inputs are not properly connected.
LOFA EP250 Operation and Troubleshooting To prevent unintentional engine shutdowns caused by intermittent conditions (i.e., pressure spikes, coolant movement) the control system requires a constant 1 second fault input to cause engine shutdown. Warning When used in combination with mechanical float type switches engine vibrations may prevent constant contact closure. The control system can be configured to shutdown with no delay. See the EP250 Configuration Guide for detailed preheat control instructions.
LOFA EP250 Operation and Troubleshooting Oil Pressure LED (Red) A solidly illuminated Oil Pressure LED indicates low oil pressure failure. The control system typically senses low oil pressure from a ground contact switch on the engine. When a sender/switch combination is used on the engine, the marking WK generally indicates the switch terminal. This input typically expects a normally closed switch (ground contact when oil pressure is low).
LOFA EP250 Operation and Troubleshooting the shutdown input to ground can cause fault indications. The system can be configured for auxilary 1 failure to indicate only. A blinking AUX 1 LED indicates SW input failure. The control system typically senses failure using a ground contact switch. The SW input is equipment specific and determined by the equipment manufacturer. A defective switch or shorting the shutdown input to ground can cause fault indications.
LOFA EP250 Operation and Troubleshooting Warning Low oil pressure is an indication of engine wear, not an accurate indication of low oil level. Note Senders and gauges must be matched to indicate correctly. Most senders are grounded through the sender body. Do not use insulating sealant (i.e. Teflon tape) when installing senders. Temperature Gauge The gauge measures engine temperature with a resistance sender on the engine referenced to ground.
LOFA EP250 Operation and Troubleshooting Harness Sealed Connectors The provided sealed weather proof plug includes a grey locking device which must be released to separate the connectors. Press the tab on the connector housing to release the connectors. Warning LOFA does not recommend using dielectric grease or sealant with sealed connectors. These chemicals may cause seal damage and allow water entry. Use LOFA provided cavity plugs to seal the connector if wires are removed.
LOFA EP250 Operation and Troubleshooting Battery Circuit Requirements Battery Positive Connection The electronic control system operates on either a 12 VDC or 24 VDC electrical systems. The unswitched battery positive connection to the control system is made at the weather proof connector. The control system provides switched positive battery protected by a 15 Amp fuse (12 V or 24 V system). Protection for the unswitched battery positive circuit is dependent on specific equipment configuration.
LOFA EP250 Operation and Troubleshooting system is equivalent to quickly turning the key switch to off and back to run without starting the engine. Since the control system did not sense a start signal, the fuel run/stop solenoid deactivates after 10 seconds. Voltage drops can be caused by transients from external equipment, improper wire sizes, faulty wiring or nearby lightning strikes. In the absence of a LOFA Power Box, relays may be needed for long wire runs.
LOFA EP250 Operation and Troubleshooting Welding on Equipment with Electronic Controls Proper welding procedures are required to avoid damage to electronic controls, sensors, and associated components. The component should be removed for welding if possible. The following procedure must be followed if the component must be welded while installed on equipment with electronic controls. This procedure will minimize the risk of component damage.
LOFA EP250 Operation and Troubleshooting General Troubleshooting For additional information, refer to engine manufacturer troubleshooting guide.
LOFA EP250 Operation and Troubleshooting Fuel Run/Stop Solenoid Troubleshooting Engine does not stop immediately Possible Cause Back feed from motor (i.e.
LOFA EP250 Operation and Troubleshooting Control System Troubleshooting Control system does not perform self test Possible Cause Tripped overcurrent protection Faulty connection to battery Possible Remedy Correct fault, replace or reset overcurrent protection Correct battery connections (see Battery Circuit Requirements above) Control system performs normal self test, engine cranks, runs and shuts down Possible Cause Only Battery LED illuminated Only Oil Pressure LED Illuminated Only Temperature LED Illu
LOFA EP250 Operation and Troubleshooting Typical Schematics The following pages show typical schematics. Details vary from installation to installation. See the specific schematics for installation for details. 463-3000-01 Rev C.
LOFA EP250 Operation and Troubleshooting THE INFORMATION CONTAINED IN THIS DRAWING IS CONFIDENTIAL AND THE SOLE PROPERTY OF LOFA INDUSTRIES INC. Reproduction or dissemination in whole or in part in any form or medium without express priorwritten permission of LOFA INDUSTRIES INC is prohibited. X11 58 X6 K4-87 X7 Sol+ X8 MSS200 INTERFACE X1 31 1 30 2 30 3 31 4 Sol2 X10 K4-87a 16 AWG Black G1 Customer Supplied - 6 Pos.
LOFA EP250 Operation and Troubleshooting THE INFORMATION CONTAINED IN THIS DRAWING IS CONFIDENTIAL AND THE SOLE PROPERTY OF LOFA INDUSTRIES INC. Reproduction or dissemination in whole or in part in any form or medium without express prior written permission of LOFA INDUSTRIES INC is prohibited.
LOFA EP250 Operation and Troubleshooting THE INFORMATION CONTAINED IN THIS DRAWING IS CONFIDENTIAL AND THE SOLE PROPERTY OF LOFA INDUSTRIES INC. Reproduction or dissemination in whole or in part in any form or medium without express priorwritten permission of LOFA INDUSTRIES INC is prohibited.
LOFA EP250 Operation and Troubleshooting THE INFORMATION CONTAINED IN THIS DRAWING IS CONFIDENTIAL AND THE SOLE PROPERTY OF LOFA INDUSTRIES INC. Reproduction or dissemination in whole or in part in any form or medium without express priorwritten permission of LOFA INDUSTRIES INC is prohibited. Gt 14 Pos.
MODEL MH25/50/51 Performance data shown are the average results based on series of tests of production units and not necessarily representative of any one unit. Tests were run with oil viscosity 150 SUS at 100°F MH25/50/51 PUMP PERFORMANCE DATA Speed RPM 900 GPM LPM 1" G.W. 8.5 32 1 1/4" G.W. 10.5 39.5 1 1/2" G.W. 13 49 1 3/4" G.W. 15 57 2" G.W. 17.5 66 2 1/4" G.W. 20 75.5 2 1/2" G.W. 22 83.5 1200 GPM LPM 12 46.5 15 57 18 68 21 79.
DIMENSIONAL DATA MH50 SERIES SINGLE UNIT Shaft Dimension will change with the type of shaft used 5.44 50/51 6.94 3.38 Width will change with size of gear housing .75 1.75 plus gear width 50/51 6.00 MH50 SERIES MULTIPLE UNIT 3.755 plus 50% of gear width plus total gear width 9.510 50/51 5.44 add total gear width 3.38 .750 2.88 .750 1.75 50/51 6.00 All dimensions in inches.
DRIVE SHAFT DIMENSIONS Shaft extension may change according to models SAE A ANSI 16-4 1.38 Mtg face .94 spline .94 DIA 9 TOOTH SPLINE 16/32 DIAMETRAL PITCH MAJOR DIA. .603 .609 MINOR DIA. .4835 MAX. SAE B ANSI 22-4 1.625 Mtg. face 1.25 spline .99 DIA 13 TOOTH SPLINE 16/32 DIAMETRAL PITCH MAJOR DIA. .853-.858 MINOR DIA. .7335 MAX. SAE C ANSI 32-4 2.190 1.38 spline SPLINE MH25 = 1.50 MH50 = 1.38 MH75 = 1.75 MH37 = 1.62 1.25 DIA 14 TOOTH SPLINE 12/24 DIAMETRAL PITCH MAJOR DIA. 1.223-1.
BEARING SERIES PRESSURE AND DISPLACEMENT MH20 .05 .07 1. 1.25 1.50 1.75 2. MH30/31 .05 .07 1. 1.25 1.50 1.75 2. MH50/51 .05 .07 1. 1.25 1.50 1.75 2. 2.25 2.5 MH75/76 .07 1. 1.25 1.50 1.75 2. 2.25 2.5 2.75 3 Gear size 1/2" 3/4" 1" 1 1/4" 1 1/2" 1 3/4" 2" In. 3 /rev .99 1.48 1.97 2.46 2.96 3.45 3.94 cm. 3 /rev 16.1 24.2 32.3 40.4 48.4 56.5 64.
MH50/51 SERIES GEAR HOUSING PORTS NOTE * N.P.T. PORTING IS NOT RECOMMENDED FOR PRESSURES ABOVE 1500 P.S.I. * Ports marked with a “X” are recommended porting, for all other porting please consult the factory * SHADED CELLS ARE GOOD FOR MOTOR UNITS * ORIENTATION IS VIEWED FROM THE SHAFT END NPT.
MH50/51 SERIES GEAR HOUSING PORTS O.D TUBE.
MH50/51 SERIES GEAR HOUSING PORTS SPLIT FLANGE PORT LEFT PORT RIGHT 05 07 10 12 15 17 20 22 25 AB NONE NONE X X X X X X X X X UC 3/4" NONE X X X X UD NONE 3/4" X X X X UF 3/4" 3/4" X X X X X X X UG 3/4" 1" X X X UH 3/4" 1 1/4" X X X UJ 1" 3/4" X X X UK 1 1/4" 3/4" X X X OC 1" NONE X X X X X X X OD NONE 1" X X X X X X X OF 1" 1" X X X X X X OG 1" 1 1/4" * X X X X OH 1" 1 1/2" * X X X X X OJ 1
MH50/51 SERIES GEAR HOUSING PORTS METRIC S. F.
MH50/51 SERIES CODING GEAR SIZE MH 50 / 51 50 MH 50/51 CU. IN. MAX. PSI 7 8 SHAFT TYPE CODE 07 S.A.E. "C" 14 TOOTH SPLINE 1.250" dia 11 S.A.E. "C" KEYED 1.25" dia 5/16" X 15/32" X1 1/2" KEY 25 S.A.E. "B" 13 TOOTH SPLINE .88" dia 43 S.A.E. B B KEYED 1" dia. 1/4" X 3/8" X 1 1/4" KEY 53 S.A.E. C 14 TOOTH SPLINE 1.25" dia. 65 S.A.E. "B" 13 TOOTH SPLINE .875" dia TYPE 2 67 S.A.E. B B KEYED 1" dia. 1/4" X 3/8" X 1 1/4" KEY TYPE 2 73 S.A.E. "C" KEYED 1.25" dia 5/16" X 15/32" X 2 1/4" KEY 98 S.A.E.
Moduflow™ Series ILP and RFP Low Pressure Filters 27
Low Pressure Filters Moduflow™ Series Applications for Moduflow Filters ■ Power Unit Fabrication ■ Off-line Filter Loops ■ Mobile Equipment The Moduflow filter is widely considered the most versatile filter available on the market. The unique diverter valve assembly, and inside to outside flow through the element, allows the Moduflow to be configured for in-line, in-tank or suction filtration. The flow diverter minimizes turbulence and pressure loss through the filter, improving system performance.
Low Pressure Filters Moduflow™ Series Features Flanges Cover SAE ¾” to 2” ■ Lightweight aluminum ■ Lightweight ■ NPT or ■ Slotted for quick release aluminum Bowl Indicators ■ Single or double ■ Visual or electrical ■ Mounted on either side ■ Standard “no element” length ■ Durable steel construction indication Bypass Element (not visible) ■ Available in cellulose, (not visible) ■ Integral 35 psi wire mesh or high performance Microglass III media ■ Single or double length bypass replac
Low Pressure Filters Moduflow™ Series RFP-1 & ILP-1 Element Performance Capacity Efficiency Beta Rating 10000 Efficiency % 2Q PSID 50 BAR 2Q 5Q 10Q 20Q 5Q 40 99.9 1000 3.0 2.5 10Q 200 99.5 100 99.0 30 20Q 2.0 1.5 20 20 95.0 1.0 10 2 0.5 50.0 0 4 8 12 16 0 20 0 20 Micron Size (c) 40 60 Capacity grams 80 0.0 100 Multipass tests run @ 40 gpm to 50 psid terminal - 5mg/L BUGL Flow vs. Pressure Loss LPM 0 20 50 100 150 200 250 300 350 1.
Low Pressure Filters Moduflow™ Series RFP-2 & ILP-2 Element Performance Capacity Efficiency Beta Rating 10000 Efficiency % 2Q BAR PSID 50 2Q 5Q 10Q 20Q 5Q 40 99.9 1000 3.0 2.5 10Q 200 30 99.5 100 2.0 99.0 20Q 1.5 20 20 95.0 1.0 10 2 0.5 50.0 0 4 8 12 16 0 20 0.0 0 20 40 60 Micron Size (c) 80 100 120 140 160 Capacity grams Multipass tests run @ 80 gpm to 50 psid terminal - 5mg/L BUGL Flow vs. Pressure Loss LPM 0 20 100 200 LPM 300 400 500 0 10 150SUS 1.
Low Pressure Filters Moduflow™ Series Specifications: RFP, ILP Dimensions: Pressure Ratings: Maximum Allowable Operating Pressure (MAOP): 200 psi (13.8 bar) Design Safety Factor: 2:1 Rated Fatigue Pressure: 150 psi (10.3 bar) Element Burst Rating: 70 psid (4.8 bar) Filter Materials: Head, Cover, Flanges: die cast aluminum Bowl: steel Operating Temperatures: Nitrile: -40°F to 225°F (-40°C to 107°C) Fluorocarbon: -15°F to 275°F (-26°C to 135°C) mm inch Model A B RFP-1 without optional 2” fitting 65.
ISO Cleanliness Levels ISO 4406 Code Cleanliness levels are defined by three numbers divided by slashes (/.) These numbers correspond to 4, 6, and 14 micron, in that order. Each number refers to an ISO Range Code, which is determined by the number of particles for that size (4,6, & 14µm) and larger present in 1 ml of fluid. Each range is double the range below. Refer to the chart below to see the actual ranges.
ISO Cleanliness Levels Finding the cleanliness level required by a system 1. Starting at the left hand column, select the most sensitive component used in the system. 2. Move to the right to the column that describes the system pressure and conditions. 3. Here you will find the recommended ISO class level, and recommended element micron rating.
