Manual - EH Wachs
Contents
1. 32 Part No H10 030 Wachs Subsea LLC Chapter 4 Maintenance Hydraulic System Figure 4 6 Remove the screw on the baffle cover and remove the baffle cover to access and check the oil strainer e Change the hydraulic oil periodically especially if the oil looks dirty or discolored or has a burnt odor It is recommended to clean the system by flushing and filter ing using an external slave pump Figure 4 7 Drain the hydraulic oil by removing the drain plug and then opening the drain valve When re filling the reservoir use filtered oil Fill the reservoir with enough fluid so that you can see it in the En NOTE Make sure the reservoir and circuit are clean and free of dirt debris before refilling the reservoir with hydraulic oil Wachs Subsea LLC Part No H10 030 33 S4HP Hydraulic Power Unit User s Manual ENGINE MAINTENANCE AND SERVICE Check the engine oil and engine coolant levels every time you use the HPU The Kubota manufacturer s manual is provided with the HPU Refer to it for the periodic maintenance schedule and for performing service and repair on the diesel engine The following table summarizes the service intervals prescribed in the Kubota manual refer to the manual for detailed instructions Adjusting the Pressure Relief Valve q Connect a pressure gauge and flow meter to the cutter circuit at the bulkhead panel looping the pressure back to tank 2 Make sure2. Wachs Subsea LLC 11050 West Little York Bldg N Houston Tx 77041 1713 983 0784 www wachssubsea com 84HP Hydraulic Power Unit Wachs Subsea LLC Part No H10 030 000 H10 030 001 Electric Start November 2011 Revision History June 2013 Copyright 2011 Wachs Subsea LLC All rights reserved This manual may not be reproduced in whole or in part without the written consent of Wachs Subsea LLC 84HP Hydraulic Power Unit User s Manual Part No H10 030 Wachs Subsea LLC Table of Contents Table of Contents Chapter 1 84HP Hydraulic Power Unit 0 0 ccc cece cece eee eee 1 Purposeof This Mahal v ires scere ah En I ee NER 1 How to Use The 233 NU KUNA RAE ARS IET MS 1 symbols and AVarnings a Slee er Pane So Saad Dad as 2 Manual Updates and Revision Tracking o Loue er ee Ga he 3 Equipment Description 4 od esa einlesen kun ea el 3 System Specifications esda se ee ars Ap Pp oed eee ES mete Peewee 3 System Comporents s on wha date ue ate eier 4 Hydraulic Fluid Overview rate PR ote baa CER Eq dash RR PEE 6 SPECIHCAUONS n u en a DIC DE IQ MI 7 Chapter 2 Safety 2 es u rs russ 9 Operator Sa lety 2 ecu voee ana Paw M UNIS Pu MUS eus Tat uade es 9 Safety Symbols reenit view avon re ME ROE across Danse du quia Soc me eas 10 Protective Equipment Requirements a2 dew ER en 11 Safety PIOQOdUtes s eed d Bia ead Ce DRAG Een ER sa in Ode N
3. s For optimum operation the starter requires a clean air source with 200 cfm flow at 90 psi 5 663 l min at 6 2 bar Do not exceed 120 psi 8 3 bar Make sure the engine coolant is filled to the correct level in the overflow bottle Figure 3 6 The engine coolant overflow bottle should be filled within the range shown 7 Make sure the fuel shut off valve below the fuel tank is open 8 Make sure the air supply for the starter is turned off at the air source Skip steps 9 amp 10 for electric start motor 9 Connect the air supply line to the connector on the back of the unit Inlet is 3 4 14 taper pipe thread per ANSI B1 20 1 Insert the locking key to secure the connection and whip check required 18 Part No H10 030 Wachs Subsea LLC Chapter 3 Operating Instructions Start Up and Operation STARTER VALVE STARTER CONNECTOR Figure 3 7 Attach the air supply line to the starter connector on the back of the HPU Insert the locking pin and whip check if required to secure the connec tion START UP AND OPERATION 1 Make sure the throttle the engine shut off and the emergency shut off on the control panel are pushed in En NOTE Ed Do not let the fuel tank run dry Shut off the HPU and refill the tank if the fuel level gets low Push the throttle all the way in to the idle position hold the center button in while moving the throttle Push the engine shut off all th
4. 11 Chapter 3 Operating Instructions ek ERE OR EE a EREEEREF ES 15 setting Up the Power Unit icf aves re ERR Roe ue a AC ea d h 15 Start Up and Operation u pee coeds phate ua pa b ees 19 Engine Starting Tips hee es es quM Eee Sut uS du M Rer ra 21 Operating Checks ka EE qe eines dete tu qo do 22 Electric Starter Set up and Operation nt a TE S HERES 26 Chapter 4 Maintenance ICE en IAEA RE a a 29 Disabling the Starter Tor Services so Se bee ae Bun ee 29 Hydraulic Systema Ew eg RETI do AO A eS 31 Engine Maintenance and Service a ade a Re a a a u d 34 Adjusting Pressure Relief Valve codex Seti ee el 34 s SI eds edt hA LE aur du a a d e s AR 37 Ar EHCESC ovx em cae a tut pre utto dtt bete 37 Spark Arresto T Lacus Bert pesi sf bias gan eltta ede p ebd 39 TUE Starter Systemen eh 39 Starter Motor Oiler os une 40 Checking tor LEAKS eis od es qi ocu PERI WS Tuae Nadel elu m 41 Tro blesh otllg 2a sone Pa areas 41 Engines ea RA ne Be ee ee 41 Hydraulic System u en a ee een 43 Wachs Subsea LLC Part No H11 024 i 84HP Hydraulic Power Unit User s Manual Chapter 5 Parts List and Ordering Information 47 Otderms Infotiiatlotio 2s es A d demos oc Hed EQ e e oe o 47 Ordering Replacement Parts A a lan e Malin tee a ics liat M merae 47 Repair Informations C so vete v rp epu eeu ES er dS DER QE dq 47 Go
5. User s Manual 2 Make sure the hydraulic tank oil level is visible in the sight gauge Figure 3 2 Make sure the hydraulic oil level is visible in the sight gauge on the front of the reservoir Connect the hydraulic hoses to the equipment accord ing to the illustration in Figure 3 3 and description in Table 1 Pressure ports Figure 3 3 Connexct hydraulic hoses as required to the Feed Connectors orange Cutter Connectors green and Clamp Connectors yellow The top con nectors are for pressure and the bottom connectors are for return hoses Fill the fuel tank with enough diesel fuel for the planned operation The burn rate for the engine is about 3 21 gallons 12 15 liters of fuel per hour of operation Shown in Figure 3 4 16 Part No H10 030 Wachs Subsea LLC Chapter 3 Operating Instructions Setting Up the Power Unit Mur 7 r y HN i s T t as v t t n Lad a 5 Figure 3 4 Remove the fuel cap to fill the diesel tank 5 Make sure the engine oil is filled to the correct level i y NOTE Engine Oil Specification Diesel engine oil CE grade or better 10W 30 can be used but is not recommended if routine engine maintenance is not peformed Figure 3 5 Check the engine oil level using the dip stick on the front side of the engine behind the control panel Wachs Subsea LLC Part No H10 030 17 S4HP Hydraulic Power Unit User s Manual CAUTION
6. line valve is closed Open fuel line valve below fuel tank Air in the fuel line Bleed air from the fuel system Air filter is clogged Blow out or replace filter ele ments Fuel filter is clogged Replace fuel filter Air intake shut off valve malfunc tioning Service air intake shut off valve Engine starts but will not stay running Air filter is clogged Blow out or replace filter ele ments Fuel filter is clogged Replace fuel filter Air vent cock on the engine is open Close the air vent cock See Kubota manual for instructions Emergency shut off is pulled out partially or completely Push in emergency shut off Overspeed function in air intake shut off out of adjustment or mal functioning Service air intake shut off valve Engine overloaded Set flow control valves to mini mum flow settings increase engine RPM to maximum before increasing flow output Engine overloaded hydraulic malfunction Service hydraulic system Engine malfunction Service engine 42 Part No H10 030 Wachs Subsea LLC Chapter 4 Maintenance Troubleshooting Hydraulic System Symptom Potential Cause Solution No flow and no pressure on either hydraulic circuit The valve on the suction line coming out of the hydraulic res ervoir is closed Open the suction line valve The hydraulic reservoir oil level is too low Fill t
7. photo shows the front view of the HPU with major components illustrated Wachs Subsea LLC Part No H10 030 5 S4HP Hydraulic Power Unit User s Manual Clamp Pressure Cutter Drive gauge pressure gauge System Pressure Feed Pressure Clamp gauge Gauge Feed Controls Control Engine temperature Engine Shut Off Bypass Valve Feed hydraulic Emergency Shut Cutter Drive Con Cutter Drive Flow off trol Hydraulic Flow Figure 1 2 HPU control panel HYDRAULIC FLUID OVERVIEW The performance and life expectancy of your Wachs hydraulic power unit largely depends on the hydraulic fluid used One of the most important fluid characteristics is vis cosity the thickness of the fluid Viscosity choice is a compromise the fluid must be thin enough to flow easily but thick enough to seal and lubricate mating surfaces Fluid temperature greatly affects its viscosity As the fluid warms it gets thinner lower viscosity and as it cools it gets 6 Part No H10 030 Wachs Subsea LLC Chapter 1 About the 84HP Hydraulic Power Unit Hydraulic Fluid Overview thicker higher viscosity Your Wachs hydraulic power unit has an optimal viscosity range which is listed in the follow ing Specifications section Ambient temperatures operat ing loads and many other contributors affect the fluid s viscosity A hydraulic fluid for use in 0 F 18 C may not work adequately in 100 F 38 C Cleanliness of the
8. supply hose from the starter connector If applicable lock out tag out the connector while servicing the HPU 4 Asaredundant safety measure you can remove the plug in the air relay Air will bypass the relay and the starter will not engage 30 Part No H10 030 Wachs Subsea LLC Chapter 4 Maintenance Hydraulic System HYDRAULIC SYSTEM When servicing components of the hydraulic system such as replacing a pump you can close the hydraulic suction line from the reservoir to keep the reservoir from draining Figure 4 3 Push the valve handle back perpendicu lar to pipe to close the hydraulic suction line coming out of the hydraulic reservoir e Replace the hydraulic oil filter periodically Frequency of replacement depends the operating load and how clean the hydraulic oil is kept Monitor the pressure indicator gauge on the front of the HPU whenever it is running and change the filter when the gauge reads in the red zone above 25 psi 1 7 bar Wachs Subsea LLC Part No H10 030 31 64HP Hydraulic Power Unit User s Manual VDRAULIC OILONLY _ Figure 4 4 Replace the hydraulic oil filter when the filter pressure gauge reads above 25 psi 1 7 bar Figure 4 5 Unscrew the hydraulic oil filter to replace it Each time you drain the hydraulic reservoir check the strainer in the bottom of the reservoir and clean it if nec essary You can see the strainer with the reservoir cover removed
9. 0 Wachs Subsea LLC Chapter 3 Operating Instructions Start Up and Operation 5 When you have completed the operation move the flow control levers back to the minimum flow setting Figure 3 18 Set the flow control levers back to the minimum flow setting before shutting down the HPU 6 Turm the throttle locking ring counter clockwise to unlock it Hold in the throttle button and push the throttle in all the way so that the engine idles Figure 3 19 Push the throttle button and push in the throttle to return the engine to idle Wachs Subsea LLC Part No H10 030 25 S4HP Hydraulic Power Unit User s Manual amp NOTE The STOP handle shuts off fuel to the engine and may take several seconds to shut the engine off If you need to shut the engine off immedi ately in an emergency pull the emergency off handle 7 To turn off the engine pull out the STOP handle Figure 3 20 Pull the stop handle out to shut off the engine Electric Starter Set up and Operation Engine Pressure Gauge Temperature Gauge HPM Gauge Glow Plug Indi cator Light Battery Indicator Light Glow Plug Pre heat Button Engine Start Switch Figure 3 21 The Electric Starter Control Box is shown 1 Tum the start switch clockwise to the first click when the battery indicator light is on 26 Part No H10 030 Wachs Subsea LLC Chapter 3 Operating Instructions Start Up and Op
10. D PARTS LISTS Wachs Subsea LLC Part No H10 030 47 64HP Hydraulic Power Unit User s Manual Before we perform any repair we will estimate the work and inform you of the cost and the time required to com plete it Return Goods Address Return equipment for repair to the following address Wachs Subsea LLC 11050 West Little York Building N Houston Tx 77049 USA DRAWINGS AND PARTS LisTS The following bill of materials and drawings will help you identify parts for service and ordering The drawings at the end of the chapter illustrate the electrical and hydraulic schematics 48 Part No H10 030 Wachs Subsea LLC
11. Unit User s Manual WARNING gt A WARNING alert with the safety alert symbol indicates a potentially hazardous situa tion that could result in seri ous injury or death CAUTION gt A CAUTION alert with the safety alert symbol indicates a potentially hazardous situa tion that could result in minor or moderate injury CAUTION A CAUTION alert with the damage alert symbol indi cates a situation that will result in damage to the equipment IMPORTANT An IMPORTANT alert with the damage alert symbol indi cates a situation that may result in damage to the equipment SYMBOLS AND WARNINGS The following symbols are used throughout this manual to indicate special notes and warnings They appear in the out side column of the page next to the section they refer to Make sure you understand what each symbol means and follow all instructions for cautions and warnings This is the safety alert symbol It is used to alert you to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death This is the equipment damage alert symbol It is used to alert you to poten tial equipment damage situations Obey all messages that follow this sym bol to avoid damaging the equipment or workpiece on which it is operating N Part No H10 030 Wachs Subsea LLC Chapter 1 About the S4HP Hydraulic Power Unit Manual Updates and Revision Tracki
12. We Every 100heurs Cheofbateysecrdyeie 2225 Check ottan bottone aff EH Draining water separator Check of radiator hoses and clamp bands Every 200 hours of oil filter cartridge depending on the Check of intake air line Replacement of fuel filter cartridge Every 400 h Cleaning of water separator Removal of sediment in fuel tank very 500 hours Cleaning of water jacket radiator interior 18 to 20 Replacement of fan belt E Everyyear Replacement of air cleaner element Every 800 hours Check of valve clearance Check of injection pump Change of radiator coolant L L C 18 to 20 Replacement of battery E ours ne or two ar Every 1500 hours Check of fuel injection nozzle injection pressure Check of turbo ch years very o ths Every ye very 3 very two Replacement of radiator hoses and clamp bands Replacement of fuel pipes and clamp bands Replacement of intake air line ee Notes The jobs indicated by must be done after the first 50 hours of operation Air cleaner should be cleaned more often in dusty condi tions than in normal conditions 2 After 6 times of cleaning 3 Consult your local Kubota dealer for this service 4 Replace only if necessary When the battery is used for less than 100 hours in a year check its electrolyte yearly refillable batteries only 36 Part No H10 030 Wachs Subsea LLC Chapter 4 Mai
13. e way i Push the emergency shut off all the way in Figure 3 8 Start the engine with the controls set as shown 2 Set both flow control levers to the minimum flow set ting Wachs Subsea LLC Part No H10 030 19 64HP Hydraulic Power Unit User s Manual Figure 3 9 Set the flow control levers at their mini mum flow positions and valves to there neutral posi tion as shown 3 Make sure that the bypass valve is in the on position Figure 3 10 Turn the handle to open the bypass valve 4 Turn on the air supply at the air source see page 29 for electric start motor 5 Kick start the spring loaded air starter valve and hold it until the engine starts Release the valve 20 Part No H10 030 Wachs Subsea LLC Chapter 3 Operating Instructions Start Up and Operation Figure 3 11 Operate the spring loaded air starter and hold it until the engine starts 6 Pull the throttle control out about halfway to warm the engine up at medium speed Figure 3 12 Pull the throttle out about halfway to warm up the engine before applying load to the HPU Engine Starting Tips e If the fuel tank runs dry or if you drain the fuel system you will need to prime the engine before starting it Wachs Subsea LLC Part No H10 030 21 S4HP Hydraulic Power Unit User s Manual A NOTE Monitor all system gauges continuously while operating the power unit Figu
14. engine 84 5 HP 2600 rpm Air start 3 4 14 taper pipe thread per ANSI B1 20 1 Dry air cleaner By NOTE A NOTE provides supple mentary information or oper ating tips Wachs Subsea LLC Part No H10 030 64HP Hydraulic Power Unit User s Manual e 80 gallon 305 liter diesel fuel tank e ATEX rated spark arrestor muffler e Safety air shut off overspeed valve 114 gallon 436 liter hydraulic tank e Inline flow meters one each circuit 30 gpm 114 l m and 10 gpm 38 e 0 3000 psi 207 bar pressure gauges one each circuit e Steel tubular frame with drip pan Lifting eyes at 4 corners e Approximate dimensions height 60 25 153 cm length 89 226 cm width 45 114 cm e Approximate weight 1920 lbs 864 kg empty 2400 Ibs 1082 kg with fuel and hydraulic oil tanks full For detailed information on the diesel engine see the Kubota engine manual System Components The following figures illustrate the components of the power unit Part No H10 030 Wachs Subsea LLC Chapter 1 About the 84HP Hydraulic Power Unit Equipment Description Lift Eyes Hydraulic oil temp Hydraulic oil Control Panel Exhaust pipe Lift Eyes and level gauge cooler SRS e 1 gt a 3 4 L fa HT 9 LI E hum Hydraulic Oil Res L vel Fuel Cap Diesel Drain Air St rter Diesel Engine Coolant ervoir Gauge Only Plug reservoir Figure 1 1 The
15. eration 2 Push and hold the glow plug preheat button in for as long as the glow indicator is on 10 to 15 seconds Figure 3 22 Glow plug preheat indicator light is shown in this picture 3 Tum the key switch clockwise to start the motor 4 the key switch counter clockwise to turn off the motor Wachs Subsea LLC Part No H10 030 27 64HP Hydraulic Power Unit User s Manual 28 Part No H10 030 Wachs Subsea LLC Chapter 4 Maintenance Chapter 4 Maintenance In This Chapter DISABLING THE STARTER FOR SERVICE DISABLING THE STARTER FOR SERVICE Before performing any service on the HPU disable the starter so that the engine cannot be started while you work on the unit Follow all required lockout and tagout proce dures when performing service HYDRAULIC SYSTEM ENGINE MAINTENANCE AND SERVICE AIR STARTER SYSTEM CHECKING FOR LEAKS Disengage the starter as described below 1 Make sure the air supply to the starter air line is off 9 Close the ball valve on the starter air connector The ball valve has relief to let the pressure off the air starter Figure 4 1 Close the ball valve on the starter air connector shown in closed position Wachs Subsea LLC Part No H10 030 29 S4HP Hydraulic Power Unit User s Manual 3 Remove the air supply line from the starter connector and insert the locking pin in the connector STARTER CONNECTOR Figure 4 2 Remove the air
16. he reservoir until oil is visible in the sight glass The suction strainer in the bot tom of the hydraulic reservoir is plugged and relief valve is stuck closed Clean suction strainer see main tenance section Sheared drive key or hub Service drive system Pump malfunction Service pump Pressure but no flow on either hydraulic circuit Flowmeter malfunction Refer to flowmeter troubleshoot ing section Hydraulic lines not properly con nected Check hyaraulic connections Obstruction in cooler assembly return filter or return lines Check return line for obstruction Obstruction in connected hydrau lic system Check connected hyaraulic sys tem Flow control valve set to mini mum flow Increase flow setting on flow con trol valves Wachs Subsea LLC Part No H10 030 43 64HP Hydraulic Power Unit User s Manual Symptom Potential Cause Solution Flow but no pressure on either hydraulic circuit Pressure gauge malfunction Replace pressure gauge Relief valves part of flow control valve set low Set relief valve to required pres sure Factory setting 2100 psi 145 bar Flow mode lever out of position Select appropriate flow mode Hydraulic leak Check for leaks Pump malfunction Service pump Flow control valve malfunction Replace flow control valve No flow on only one hydraulic cir cu
17. hydraulic oil is extremely important for the life expectancy of the hydraulic components Wachs rec ommendis the fluid used to be maintained at ISO Cleanliness Code 19 17 14 per SAE J1165 Establishing a fluid mainte nance schedule is the best way of meeting viscosity and fluid cleanliness requirements Premium grade petroleum based hydraulic fluids will pro vide the best performance for your Wachs hydraulic power unit These fluids typically contain anti wear additives rust inhibitors anti foaming agents and oxidation inhibitors Premium grade fluids carry an ISO VG rating Synthetic fluids fluids with viscosity index improvers ATF or multi viscosity oil and SAE grade oils maybe used but their use will require more frequent maintenance intervals and appli cation review in your system Specifications NOTE These specifications are guidelines for the hydraulic power unit only Your hydraulic tools may require more stringent requirements For example your tool may limit the operating viscosity range to 85 450 SSU 16 95 CSt Always consult your hydraulic tool manufacturer for hydraulic fluid guidelines Table 1 Viscosity Data Minimum Optimum Maximum Viscosity Range Units Continuous Operating Viscosity at Requiring lt 50 Viscosity Viscosity Range Pressure Outlet Pressure SSU 41 55 190 450 470 5000 CSt 9 16 40 95 100 1000 Wachs Subsea LLC Part No H10 030 7 64HP Hydraulic Power U
18. it Flow mode lever out of position Select appropriate flow mode Hydraulic leak Check for leaks Pump malfunction Service pump Flow control valve malfunction Replace flow control valve Not cooling adequately Heat load exceeds cooler heat rejection Remove or decrease heat load and allow cooler to lower temper ature Cooler fans not spin ning jammed fan blades With system off unjam fan Cooler fans not spin ning hydraulic leak Fix leak Cooler fans not spinning fan motor malfunction Service fan motor Both cooler fans not spin ning gear pump malfunction Service gear pump Heat exchanger is fouled Clean heat exchanger see maintenance section Part No H10 030 Wachs Subsea LLC Chapter 4 Maintenance Troubleshooting Symptom Potential Cause Solution Flow meter sticks and won t return to no flow position Foreign matter in the meter is holding the internal parts from returning Disassemble and inspect the meter for contamination install proper filtration to prevent prob lem from re occurring A surge in fluid flow separated the follower from the magnet inside the meter Disassemble the meter and reas semble separated parts Flow meter window tube is crack ing or crazing Lexan window tube was dam aged by incompatible cleaning solution Replace Lexan tube if necessary To prevent re occ
19. ized accumulators actuators and lines sonnel are clear AN before removing tearing down or performing mainte from the machin nance on any remotely located actuators hoses fil ery being operated before ters valves piping etc shutting down the HPU 7 personnel observing or working on or adjacent to hydraulically powered equipment must never place themselves in a location or position that could produce an injury in the event of e hydraulic line failure either with the unit running or shut down pump or motor failure e pin hole leaks in hoses or fittings movement of machine components during normal oper ation or resulting from a component malfunction or fail ure 12 Part No H10 030 Wachs Subsea LLC Chapter 2 Safety 10 11 12 Do not inspect hoses and fittings for leaks using your bare hands A pin hole leak can inject hydraulic fluid through the skin with the potential for serious injury Avoid locating equipment in any environment for which it was not designed and which may create a dangerous operating condition such as an explosive atmosphere e g gas dust high heat e g molten metal furnace chemicals extreme moisture etc Avoid bodily contact with hydraulic fluids Some hydraulic fluids may irritate or injure the eyes and skin Check with your fluid suppliers to obtain this information Use only Wachs parts and materials when servicing the equipment Subs
20. kwise to lock the throttle position 2 Move the flow control levers to adjust the flow as required for the tool s you are operating Use the gauge for each circuit to monitor the flow bypass valve must be in the off position Flow gauges Figure 3 15 Set the flow control levers to the desired flows By NOTE Typically you can run the engine at maximum throttle throttle pulled out to physical stop Wachs Subsea LLC Part No H10 030 23 S4HP Hydraulic Power Unit User s Manual 3 Monitor the hydraulic oil temperature gauge below the sight glasss on the front and back of the reservor If the temperature exceeds 180 F 82 C set the flow levers to the minimum setting and let the engine run at operating speed until the oil temperature has gone down Figure 3 16 Monitor the hydraulic oil temperature as you operate the HPU If the temperature goes over 180 F 82 C turn off the flow control levers and run the HPU until the oil cools 4 Ifyou need to stop the HPU immediately pull the IMPORTANT emergency stop handle on the control panel and turn the bypass valve lever in on position Do not use the emergency stop for a normal engine shutdown Repeated use of the emergency stop could damage the engine Figure 3 17 Pull the emergency off handle if you need to shut down the engine immediately Emergency stop handle must be reset to restart the engine 24 Part No H10 03
21. l placards labels and stickers are clearly legible and in good condition You can purchase replacement labels from Wachs Subsea LLC KEEP CLEAR OF MOVING PARTS Keep hands arms and fingers clear of all rotating or moving parts In This Chapter OPERATOR SAFETY Look for this sym AN bol throughout the manual It indicates a personal injury hazard Wachs Subsea LLC Part No H10 030 64HP Hydraulic Power Unit User s Manual Always turn machine off before doing any adjustments or service SECURE LOOSE CLOTHING AND JEWELRY Secure or remove loose fitting clothing and jewelry and securely bind long hair to prevent them from getting caught in moving parts of the machine e KEEP WORK AREA CLEAR Keep all clutter and nonessential materials out of the work area Only people directly involved with the work being performed should have access to the area Safety Symbols A This icon is displayed with any safety alert that indicates a personal injury hazard Z WARNING This safety alert indicates a potentially hazardous situation that if not avoided could result in death or serious injury A CAUTION This safety alert with the personal injury hazard symbol indicates a potentially hazardous situation that if not avoided could result in minor or moderate injury NOTICE This alert indicates a situation that 1f not avoided will result in damage to the equipment 10 Part No H10 030 Wachs S
22. ng NOTE This symbol indicates a user note Notes En provide additional information to supple ment the instructions or tips for easier operation MANUAL UPDATES AND REVISION TRACKING Occasionally we will update manuals with improved opera tion or maintenance procedures or with corrections if nec essary Revised manuals will be available for customers When a manual is revised we will update the revision his tory on the title page and at the bottom of the pages You may have factory service or upgrades performed on the equipment If this service changes any technical data or operation and maintenance procedures we will include a revised manual when we return the equipment to you EQUIPMENT DESCRIPTION The unit has two hydraulic pumps driven off the Kubota Diesel Engine Pump one is driven directly off of the main crankshaft is a piston pump capable of 30 GPM 3 000 PSI at 2 500 engine RPMs Pump two is driven off the Kubota Diesel Engine PTO Port and is capable of 12 5 GPM 3 000 PSI at 2 500 engine RPMs Pump one con nects to the HPU control panel which divides its flow in to three seperate circuits Pump Two directly drives the hydraulic systems hydraulically driven motor that powers the air to oil hydraulic cooler System Specifications e Piston pump providing 40 gpm 151 hydraulic cir cuits at 3000 psi 207 bar and gear pump providing 19 25 gpm 72 9 m at 3000 psi 207 bar e Kubota V3000t diesel
23. nit User s Manual Table 2 Hydraulic Fluid Specifications Specification Range Pour Point 10 F 23 C min Flash Point ASTM D 92 340 F 171 C min Emulsion Test ASTM D 1401 30 minutes min Oxidation Test ASTM D 943 1000 hours min Rust Inhibition Test ASTM D 665 A amp B Pass No Rust Wear Test ASTM D 2882 60 mg maximum The following are recommended hydraulic fluids for typical industrial environments e Citgo AW anti wear 32 e Shell Tellus T 32 Shell Tellus 5 46 Chevron AW 32 8 Part No H10 030 Wachs Subsea LLC Chapter 2 Safety Chapter 2 Safety The Wachs Subsea LLC takes great pride in designing and manufacturing safe high quality products We make user safety a top priority in the design of all our products Read this chapter carefully before operating the hydraulic power unit It contains important safety instructions and recommendations OPERATOR SAFETY Follow these guidelines for safe operation of the equip ment READ THE OPERATING MANUAL Make sure you understand all setup and operating instructions before you begin INSPECT MACHINE AND ACCESSORIES Before starting the machine look for loose bolts or nuts leaking lubricant rusted components and any other physical conditions that may affect operation Properly maintaining the machine can greatly decrease the chances for injury ALWAYS READ PLACARDS AND LABELS Make sure al
24. ntenance The items listed with are registered as emission related critical parts by Kubota in the U S EPA nonroad emission regulation Fluid Levels Check the engine oil using the dipstick on the front side of the engine behind the control panel Figure 4 11 Check the engine oil level using the dip stick on the front side of the engine Check the level of the engine coolant in the overflow tank Figure 4 12 The engine coolant overflow tank should be filled within the range shown Air Filters Check the air filter and blow it out or replace it as neces sary There are two filter elements one inside the other Wachs Subsea LLC Part No H10 030 37 S4HP Hydraulic Power Unit User s Manual Figure 4 13 Release the three spring clips on the fil ter cover to remove the cover gt gt ee WWE Figure 4 14 Check the outer filter and blow it out or replace it if necessary Wachs Subsea LLC 38 Part No H10 030 Chapter 4 Maintenance Air Starter System Figure 4 15 Remove the outer filter to check the inner filter Blow it out or replace it as necessary Spark Arrestor Perform the following checks of the engine exhaust spark arrestor at the specified intervals Daily Examine the spark arrestor for any sign of gas leakage cracks or significant areas of damage such as dents more than a few millimeters in depth Three Monthly Remove the spark a
25. ods Address oss oe vus tota eas d p bd aU Vd Riot mna 48 Drawings and Parts Lists ican sott eio p EO Ua en erneut 48 ii Part No H1 1 024 Wachs Subsea LLC Chapter 1 About the S4HP Hydraulic Power Unit Chapter 1 About the 84HP Hydraulic Power Unit PURPOSE OF THIS MANUAL This manual explains how to operate and maintain the 84HP hydraulic power unit It includes instructions for set up operation and maintenance It also contains parts lists and diagrams to help you order replacement parts and per form user serviceable repairs How TO USE THE MANUAL This manual is organized to help you quickly find the infor mation you need Each chapter describes a specific topic on using or maintaining the equipment Each page is designed with two columns This large column on the inside of the page contains instructions and illustra tions Use these instructions to operate and maintain the equipment The narrower column on the outside contains additional information such as warnings special notes and defini tions Refer to it for safety notes and other information In This Chapter PURPOSE OF THIS MANUAL How TO USE THE MANUAL SYMBOLS AND WARNINGS MANUAL UPDATES AND REVISION TRACKING EQUIPMENT DESCRIPTION HYDRAULIC FLUID OVERVIEW Throughout this manual refer to this column for warnings cautions and notices with supplementary information Wachs Subsea LLC Part No H10 030 64HP Hydraulic Power
26. oiding risk of injury when followed by qualified experienced personnel These Wachs Subsea LLC Part No H10 030 64HP Hydraulic Power Unit User s Manual precautions should be included in the comprehensive safety program for the particular machinery equipment plant or process and overseen by personnel capable of analyzing any hazards associated with operating and maintaining the equipment WARNING 4 Return all movable parts of the machinery being oper Many types of AN ated to their normal startup condition if possible machinery have before starting unit parts that may start moving as soon as the 2 Be sure all personnel product etc are clear of hydraulic circuit is filled and machinery before starting hydraulic unit pressurized This could result in injury to personnel or dam 3 Check to make sure any hydraulic connections which age to machinery may have been removed replaced or disconnected during shut down have been reconnected securely before starting hydraulic unit 4 Before starting the unit perform all equipment checks described at the beginning of the operating instruc tions in Chapter 3 5 there are tools or machinery being operated by the HPU that may move when hydraulic flow or pressure are turned off or turned on block or lock these parts in position before shutting down the hydraulic unit WARNING 6 Shutdown the hydraulic unit and relieve pressure Make sure all per from all pressur
27. re 3 13 Engage the priming lever to prime the fuel pump after the tank or fuel system has been drained If the ambient temperature is below 50 F 10 C con sider pre warming the engine using a portable heater The engine will be easier to start if it is warm Cold temperatures affect the viscosity of the hydraulic oil making starts difficult and limiting system perfor mance After starting the power unit run the engine at idle until the hydraulic oil warms to 50 F 10 C Operating Checks While the power unit is running make sure it is operating within the ranges listed in Table 1 Table 1 Normal operation checks Operating Feature Operating Range Engine oil pressure high idle 40 60 psi 2 8 4 1 bar Engine operating temperature 175 185 F 79 85 C Hydraulic system pressure Less than 2100 psi 145 bar Hydraulic oil temperature 50 180 F 10 82 C Hydraulic oil filter pressure Less than 25 psi 1 7 bar Hydraulic cooler fans Continuously spinning 22 Part No H10 030 Wachs Subsea LLC Chapter 3 Operating Instructions Start Up and Operation Hold in the throttle button while pulling the throttle until the engine is running at maximum Release the button and turn the throttle locking ring clockwise to lock the throttle Daun Figure 3 14 Pull out the throttle to set the engine speed You can turn the locking ring cloc
28. rrestor and tap it with a soft mallet to loosen any internal deposits Shake it to remove loosened deposits and to check for loose baffles Six Monthly 1500 hours Examine the exhaust dis charge in darkness while repeatedly loading and acceler ating the engine If you see any sparks the spark arrestor must be replaced If any problems are identified during these checks do not use the engine until you have made the necessary repairs AiR STARTER SYSTEM Perform the following air system checks on a regular basis Wachs Subsea LLC Part No H10 030 39 64HP Hydraulic Power Unit User s Manual En NOTE Use Wachs air motor oil part no 02 407 00 one pint ora good quality SAE 10 weight oil e Olileroperation every time you use HPU check the oil level in the oiler and verify that it is working e Air leakage look and listen for damaged components and air leaks Replace any worn or damaged compo nents Loose connections check all threaded connections for tightness Hose wear check for kinked crushed damaged or worn hoses Damaged hoses can restrict or reduce air flow and lead to unpredictable system behavior e Dirt buildup clean any accumulated dirt and grime from air system components Dirt buildup may hide damage or potentially hazardous situations If you find any components requiring repair or replacement shut the system down immediately and do not use it until the repairs ha
29. the bypass valve is off 3 While the machine is running Turn the relief valve all the way out Figure 4 8 Shown in the picture The relief valve 4 the set screw on the pump pressure valve out until the pressure on the cutter circuit reads 500 PSI or lower 34 Part No H10 030 Wachs Subsea LLC Chapter 4 Maintenance Engine Maintenance and Service Figure 4 9 Shown in the picture The set crew for adjusting pressure on the Main Pump Slowly start backing in the set screw on the pump pressure valve until pressure reads about 2100 PSI Go back to the relief valve and slowly start backing it in until the pressure is at 2400 PSI at all times Be sure to compare the pressure and flow readings for drop offs between the control panel s gauges and the bulkhead panel gauge flow meter set up there shouldn t be a large drop off of pressure and flow between the two Figure 4 10 Shown in the picture The pressure gauge on the control panel Wachs Subsea LLC Part No H10 030 35 64HP Hydraulic Power Unit User s Manual SERVICE INTERVALS Observe the following for service and maintenance The lubricating oil change intervals listed in the table below are for Class CF lubricating of classification with a low rove Ever Sohous Check ottusi pipes ard damp bands 0 SeeNOTE Changesfengneoi dependngonteolpm TWIT leaning of air cieaner siemet a Cemmohe
30. titute parts or materials could pro duce a hazardous operating condition When piping your equipment use only materials of adequate size and strength to suit the flows and pres sures of the system Consider all safety factors when selecting the strength of materials to allow for shock and over pressure conditions which could occur WARNING The injection of hydraulic fluid under the skin can cause serious injury and even result in death If an injection injury occurs seek medical treatment immedi ately Wachs Subsea LLC Part No H10 030 64HP Hydraulic Power Unit User s Manual 14 Part No H10 030 Wachs Subsea LLC Chapter 3 Operating Instructions Chapter 3 Operating Instructions In This Chapter SETTING UP THE POWER UNIT 1 Position the HPU in a flat well ventilated location Use a forklift in the frame channels at the bottom or a crane attached to all 4 lifting eyes with a 4 point verti cal sling Attach a crane to the lift eyes at all 4 cornerz in 8 WARNING Use a 72 183 cm or longer sling to lift d power unit by the lift eyes The minimum angle of the sling straps should be at least 60 to pro vide a 4x safety factor Reducing the angle will lower the safety factor SETTING UP THE POWER UNIT START UP AND OPERATION Use a forklift in the frame channels Figure 3 1 Lift the HPU at the points shown Wachs Subsea LLC Part No H10 030 15 64HP Hydraulic Power Unit
31. ubsea LLC Chapter 2 Safety Operator Safety IMPORTANT This alert indicates a situation that if not avoided may result in damage to the equipment Protective Equipment Requirements WARNING Always wear impact resistant eye pro tection while operating or working near this equipment For additional information on eye and face protection refer to Federal OSHA regulations 29 Code of Federal Regula tions Section 1910 133 Eye and Face Protection and American National Standards Institute ANSI Z87 1 Occu pational and Educational Eye and Face Protection Z87 1 is available from the American National Standards Institute Inc 1430 Broadway New York NY 10018 CAUTION Personal hearing protection is recom mended when operating or working near this equipment Hearing protectors are required in high noise areas 85 dBA or greater The operation of other tools and equipment in the area reflective surfaces process noises and resonant struc tures can increase the noise level in the area For additional information on hearing protection refer to Federal OSHA regulations 29 Code of Federal Regulations Section 1910 95 Occupational Noise Exposure and ANSI 512 6 Hearing Protectors Safety Procedures All safety requirements listed below are those generally applicable to hydraulically powered machinery but are not intended to be an all inclusive list They are intended as guidelines only and will assist in av
32. urrence use soap and water Flow meter scale is fogging or coming loose Ambient or fluid temperature is too high See Hyaraulics section for possi ble solutions Scale was damaged by incom patible cleaning solution Replace scale if necessary To prevent re occurrence clean with soap and water Wachs Subsea LLC Part No H10 030 45 64HP Hydraulic Power Unit User s Manual 46 Part No H10 030 Wachs Subsea LLC Chapter 5 Parts List and Ordering Information Chapter 5 Parts List and Ordering Information ORDERING INFORMATION To place an order request service or get more detailed information on any Wachs Subsea LLC products call us at one of the following numbers U S and Canada 1 713 983 0784 Ordering Replacement Parts When ordering parts refer to the parts list in this chapter Please provide the part description and part number for all parts you are ordering Specify your machine model num ber and serial number when ordering Repair Information Please call us for an RMA Return Material Authorization number before returning any equipment for repair or fac tory service We will advise you of shipping and handling When you send the equipment please include the following information e Your name company name e Your address e Your phone number e A description of the problem or the work to be done In This Chapter ORDERING INFORMATION DRAWINGS AN
33. ve been completed Starter Motor Oiler Each time you use the HPU check the oil level in the air starter oiler Add oil through the port in the top of the oiler shown in Figure 4 16 Adjust the drip rate knob on top of the oiler to the maximum by turning it all the way counter clockwise Adjust the drip rate knob to the maximum Figure 4 16 Check the oil level in the oiler and fill as necessary 40 Part No H10 030 Wachs Subsea LLC Chapter 4 Maintenance Checking for Leaks CHECKING FOR LEAKS Each day before operation check all hydraulic and engine components for oil leaks Keeping the bottom of the frame pan clean will help you detect leaks TROUBLESHOOTING Engine The table below lists common troubleshooting issues See the Kubota engine manual for more detailed procedures Symptom Potential Cause Solution Engine won t turn over Inadequate air supply Recommended pressure and flow to air starter connection 90 psi 6 2 bar 200 SCFM 5663 l min Plug is removed from air relay Replace plug in air relay Air relay is malfunctioning Service air relay Air intake shut off valve malfunc tioning Service air intake shut off valve Wachs Subsea LLC Part No H10 030 41 64HP Hydraulic Power Unit User s Manual Symptom Potential Cause Solution Engine turns over but won t start Fuel tank is empty Fill fuel tank Fuel
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