background image

 

 

Model 30000-S DHPU Manual 

Rev. 0 

JRK 

17SEP12 

Page 9 

 

 

ID Tag 

Each unit has an identification tag installed on the skid.  Use the ID tag information (weight, 

model, serial number, etc.) for transportation documentation. 

Installation 

Once  the  power  unit  is  on  location,  then  the  installation  process  gets  the  unit  ready  for 
operation. 

Location of the Unit 

Remember the following points when positioning the power unit for installation. 

 

The physical space required for the unit is detailed in the general specifications page.  
Consideration  should  also  be  given  for  access  around  the  power  unit  for  startup 

procedures and maintenance activities.   

 

The power unit should be located on an area that is relatively flat.  Installing the unit 
on  an  incline  could  adversely  affect  the  fluid  levels  of  the  motor  oil  and  hydraulic 

fluid. 

 

Also, take into account the location of the power unit to keep it as close as possible to 

the  equipment  in  order  to  reduce  pressure  losses  in  the  line.   Pressure  losses  from 
long hose lengths can reduce the system performance and generate significant heat. 

 

Ensure the exhaust and intake air paths are unobstructed.  The engine exhaust should 
be  directed  towards  a  well  ventilated  area  and  pointed  away  from  any  operator 

positions. 

 

If  located  near  an  operator,  then  proper  safety  equipment  such  as  ear  protection 
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  explosion  proof 

system. 

 

The  unit  will  require  diesel  fuel,  engine  oil  and  hydraulic  fluid  to  be  added  or 
removed  during  operation  or  maintenance.    Take  precautions  when  adding  new 

fluids  to  avoid  spills  and  dispose  of  used  fluids  according  to  the  applicable  local 
environmental laws. 

Engine System Inspection 

Examine the following areas on the diesel engine after the unit is in its final position.  Do not 

inspect  the  engine  while  it  is  running.    Review  the  included  engine  manuals  for  detailed 

instruction.   

 

With the power unit on level terrain, check the motor oil level using the dipstick.  The 

level  should  be  between  the  minimum  and  maximum  marks.    Add  motor  oil  to  the 

inlet if the level is below the minimum mark.  Refer to the engine manual for the type 
of  motor  oil  required.    As  a  general  rule,  use  SAE  10W-30  motor  oil  for  average 

ambient operating temperatures below 45°F (7°C), SAE 15W-30 for 45° to 85°F (7° to 

30°C) operation and SAE 15W-40 for operation above 85°F (30°C).  If the oil level is 

above the maximum mark, then drain the motor oil level out of the outlet. 

 

It may be necessary to purge the fuel system from air that may have been introduced 

during transportation, during repair/maintenance work or if the system ran until the 
fuel tank was empty.  If air bubbles are in the fuel system, the power unit will have 

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...

Reviews: