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Model 30000-S DHPU Manual 

Rev. 0 

JRK 

17SEP12 

Page 16 

 

 

Safety Features 

The power unit is equipped with several safety features, which are explored in more detail in 

the following sections. 

Engine Silencer 

The  exhaust  from  the  engine  is  routed  through  a  silencer  (muffler)  to  reduce  the  engine 
noise.  See the location of the silencer in the picture below.  

Engine Spark Arrestor 

After  the  silencer,  the  exhaust  is  routed  through  a  spark  arrestor.    The  spark  arrestor,  as 

seen  below,  uses  centrifugal  force  to  separate  solids  from  exhaust  gas.    The  manufacturer 

recommends inspecting and cleaning out the spark arrestor every 1000 operating hours or 
three times per season, whichever time period is less.  The inspection should include a visual 

check  for  holes,  cracks  or  metal  corrosion.    If  any  of  the  above  conditions  are  found,  then 

replace the spark arrestor.  Also, ensure the mounting clamp is securely tightened.   

 
The  spark  arrestor  and  exhaust  are  wrapped  with  a  thermal  blanket  to  help  prevent  the 

operator  from  accidentally  touching  the  unit  during  operation.    This  area  should  not  be 

touched even though it contains this safety precaution.   

 

 

 

DO  NOT  SET  TOUCH  THE  EXHAUST  SYSTEM  COMPONENTS  DURING  OPERATION  OF 

THE  POWER  UNIT  AS  IT  HEATS  UP  TO  DAMAGING  TEMPERATURES.    THIS  HEAT  IS 
RETAINED EVEN AFTER THE POWER UNIT IS TURNED OFF.  VERIFY THE UNIT IS COOL 

BEFORE WORKING AROUND THE EXHAUST SYSTEM. 

 

 

Figure 9: Engine Exhaust Components and Over Speed Shutdown 

Over Speed Shutdown 

If the unit over speeds during a runaway condition such as the intake of gas, then the unit 

will automatically shut down when the speed exceeds the factory setting of 2400 RPM.  The 

engine  should  not  be  restarted  again  until  the  area  is  declared  safe  for  operation.    The 

location of the over speed shutdown is shown in the previous photo.  For maintenance and 
setting instructions, review the over speed shutdown manual. 

Summary of Contents for WELLKIN 30000-S HDPU

Page 1: ...Tubing Tong Diesel Hydraulic Power Unit Installation Operation Service and Parts Book Manual WPI WELLKIN Inc 8401 Industrial Dr Pearland TX 77584 PH 281 992 2064 FX 281 992 2076 E mail sales wpiwellk...

Page 2: ...tative or employee to witness and accept the material is the expense of the Buyer All costs associated with preparation crating insurance and ocean freight of the goods to the final destination to be...

Page 3: ...ereunder require in connection with the installation thereof the services of a contractor engaged by WPI WELLKIN or a supervisor engineer or other employee connected with or employed by WPI WELLKIN an...

Page 4: ...ion 11 Figure 5 Quick Disconnects and Ball Valves Location 12 Figure 6 Control Panel 13 Figure 7 Hydro Throttle 14 Figure 8 Spring Starter 15 Figure 9 Engine Exhaust Components and Over Speed Shutdown...

Page 5: ...er unit above the rated design pressure or engine speed Always check the pressure setting of the power unit before operating to prevent equipment damage Never add remove or convert equipment on the po...

Page 6: ...tion o Safety boots with steel toe o Safety gloves o Ear protection o Coverall Never use excessive force when coupling the wing style quick disconnects to the system Never disconnect any hose on the p...

Page 7: ...r Shutdowns for low oil pressure high oil temperature and fan belt break 30 gallon diesel reservoir with level gauge drain port and filler breather Hydraulic throttle System relief valve set at 3000 P...

Page 8: ...ifted a sling with four legs is required and the sling must at a minimum be rated for the gross weight of the power unit The lifting equipment should also be inspected to ensure it is in adequate cond...

Page 9: ...ection should be worn by all personnel near the unit The diesel power unit incorporates several safety devices However this combustion engine driven power unit is neither designed nor certified as an...

Page 10: ...should be used Refer to the engine manual for details on summer or winter grades of diesel fuel When filling the tank do not spill any fuel and avoid letting contaminants enter the tank The following...

Page 11: ...through the filler breather until the level reaches the top of the level gauge When the filler breather cap is removed take care to avoid the passage of contaminants into the hydraulic reservoir A pr...

Page 12: ...nt must be met before the integral check valve in the connector is forced to open The following photo shows the location of the pressure and return quick disconnects Figure 5 Quick Disconnects and Bal...

Page 13: ...so be placed in standby mode when long breaks are expected in operation Oil still flows through the heat exchanger but the unit will generate less heat because flow is at zero pressure instead of the...

Page 14: ...he internal piston will extend thereby increasing the motor speed The cylinder is pushed back by the spring when the pressure drops back down below the set point putting the engine into an idle mode t...

Page 15: ...ndby work ball valve to the work position Figure 8 Spring Starter Observe the engine speed oil temperature and oil pressure gauges The engine speed will be approximately 1400 RPM when the unit is in i...

Page 16: ...arrestor Also ensure the mounting clamp is securely tightened The spark arrestor and exhaust are wrapped with a thermal blanket to help prevent the operator from accidentally touching the unit during...

Page 17: ...the manual System Relief Valve The system hydraulic pressure relief valve RV 1 on the hydraulic schematic is shown in the following photo This valve limits the maximum pressure from the power unit hyd...

Page 18: ...dge stem To adjust the valve setting loosen the jam nut on the cartridge valve stem Turn the screw clockwise to increase the pressure setting and counter clockwise to reduce the setting Lock the jam n...

Page 19: ...oned in the system s safety feature section Heat Exchanger and Heat Exchanger Hydraulic Pump The unit incorporates an air over oil heat exchanger HX 1 driven by a hydraulic motor The heat exchanger al...

Page 20: ...Return Filter Before fluid reenters the reservoir it passes through the return filter FL 1 Figure 13 Suction Strainer and Return Filter Shutdown The proper way to stop the engine is to rotate the shut...

Page 21: ...into the storage basket on the lift frame Move the power unit to its storage location Clean and remove all debris from the power unit Afterwards inspect the unit for any damage Address all problems id...

Page 22: ...f it is defective 11 Verify the engine inlet outlet valve clearance is per the engine manual s recommendation Adjust if required 12 Verify the correct motor oil is being used especially in low tempera...

Page 23: ...n if too high 2 Inspect the engine air filter for debris Clean or replace if clogged 3 Ensure the engine fan blade is turning Inspect the tension in and condition of the fan belt Replace if the belt i...

Page 24: ...ects are completely tightened and engaged b Inspect the return filter pressure gauge Replace the filter elements if required c Ensure the hoses are adequate for the power unit flow 1 for pressure 1 1...

Page 25: ...d by any of the following a Verify the quick disconnects are completely tightened and engaged b Inspect the return filter pressure gauge Replace the filter elements if required c Ensure the hoses are...

Page 26: ...nctions properly 10 Drain water accumulation from the bottom of the reservoir after settled Each 500 Hour Interval 1 Inspect the fan belt for damage Replace if worn 2 Replace the hydraulic return filt...

Page 27: ...LG 1 Level gauge for hydraulic tank 30131 FB 1 Filler breather cap for hydraulic tank 80012 FF 2 Engine fuel filter 80012 OF 2 Engine oil filter 80012 FB 1 Engine fan belt 80002 1 Engine to pump shaf...

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