Tandem Pump Offshore Hydraulic Power Unit User`s Manual
Contents
1. 7 If you need to stop the HPU immediately pull the emergency stop handle on the control panel j 3 del 1 n E i Figure 3 32 Pull the emergency off handle if you need to shut down the engine immediately Q When you have completed the operation move the flow control levers back to the minimum flow setting Figure 3 33 Set the flow control levers back to the minimum flow setting before shutting down the HPU O Turn 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 E H Wachs Part No 14 MAN 12 Rev 2 0709 EI IMPORTANT Do not use the emergency stop for a normal engine shutdown Repeated use of the emergency stop could damage the engine 35 Tandem Pump Offshore Hydraulic Power Unit User s Manual Gm 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 36 Figure 3 34 Push the throttle button and push in the throttle to return the engine to idle 10 To turn off the engine pull out the STOP handle Figure 3 35 Pull the stop handle out to shut off the engine Part No 14 MAN 12 Rev 2 0709 E H Wachs Chapter 4 Maintenance Chapter 4 Maintenance In This Chapter DISABLING THE STARTER FOR DISABLING THE STARTER FOR SERVICE2. E H Wachs 600 Knightsbridge Parkway Lincolnshire IL 60069 www ehwachs com Tandem Pump Offshore Hydraulic Power Unit User s Manual E H Wachs Part No 14 MAN 12 Rev 2 0709 July 2009 Revision History Original October 2008 Hev 1 November 2008 Copyright 2009 E H Wachs All rights reserved This manual may not be reproduced in whole or in part without the written consent of E H Wachs Tandem Pump Offshore Hydraulic Power Unit User s Manual Part No 14 MAN 12 Rev 2 0709 E H Wachs Table of Contents Table of Contents Chapter 1 About the Tandem Pump Power Unit 1 Purpose of This Manual ze uw 22 2 22 211 ee EE I Howto Use HEM ee ee dent ek l Symbols dE derr e EE Eb wate Ann 2 Manual Updates and Revision Tracking 3 Equipment DescriDHOll dd nr A EE ES 3 SYSIEM SPE NCA OS u u so uu arp eed m e RC E o dE Dd doe p o bd HE FE Dd E 3 System EI LEE 4 Fre NNN 7 DDECIHCOLIOgS o d RR duo EE NED NE EE NE EE a eie boton bod 8 Chapter SID NN 11 OPS l ly es AT Wi re PE 11 Daleby 5 VInDOISQ s ute oasis lao is a le 12 Protective Equipment Requirements 13 Safety PrOCCdUICS EE A A qe xn oe i de dr ee lu dos 13 Saey Labe EEE oe debe uid bd PT dup n ee hes deus d doped debe dpud Pod Satin dos 15 Chapter 3 Operating Instructions 17 Setting UP the Power Ulla ao oa
3. of the tank is open handle is in line with the pipe A Connect the hydraulic hoses to the equipment accord ing to the illustration in Figure 3 4 and description in Table 1 18 Part No 14 MAN 12 Rev 2 0709 E H Wachs Chapter 3 Operating Instructions Setting Up the Power Unit Ret rn tank ports P y E e E P aM p i H r LE P d Figure 3 4 Connect hydraulic hoses as required to the Circuit 2 connectors left and Circuit 1 connec tors right The top connectors are for pressure hoses and the bottom connectors are for return hoses Table 1 Hydraulic hose configurations P pe m eronowing Make the following hsse connections circuit s Circuit 1 up to 8 gpm One hose pair to Circuit 1 connectors Circuit 2 up to 16 gpm One hose pair to Circuit 2 connectors Circuits 1 and 2 independently 8 gpm and 16 gpm Circuits 1 and 2 mE combined 24 gpm One hose pair to Circuit 2 connectors 5 Fill the fuel tank with enough diesel fuel for the Gm NOTE One hose pair to Circuit 1 connectors and one hose pair to Circuit 2 connectors planned operation The burn rate for the engine 1s about 2 75 gallons 10 4 liters of fuel per hour of The fuel tank does not have a operation gauge To check fuel level remove the cap and look into the tank The fuel tank holds 16 gallons 61 liters E H Wachs Part No 14 MAN 12 Rev 2 0709 19 Tandem Pump Offshor
4. s 0 80 1 000 v1 NdH 10YSJHO dung Wapue JO 1O31NOO 3HL V XIONIAAV ZV L OL6L Lal vd ai 6C INIWAINOI ONIOIA33S NAHM S3310320 ld LNOOVL ANY 10003201 Q33 0038 1 UE 9L o zere 1 AT om 6 Ka mm mmm mmm NdT 06 Wd9 rZ h LINDHID INd1 09 Wd9 91 T LINDYID bz _ iz NIT 0 Wd e LE E LINDYID 6z GAV ONVIS VHSO 33S NOILYWJOJNI SYOW O3 ooo omo Z Z Tee ND 20900 e ATMWBSV3SOH yey E1080 OF AMWiISSV3SOH evt 090 67 IVNBIOJNI SON 803 AMWISSV3SOH ceyeL080 87 1v MOTIOJ OL 38NS G A WISSV3SOM 1 I r o9_ EN 0 A WISSV3SOM Z w 080 97 M WISSVaSOH 1 J rginm S gt AM MWISSV3SOH 1 gring vt AlWESSv3SOH 1 Scr 080 AMWBSv3sOH II v re E n ANWBSSV3SOH 1 Re eLOBO IZ M WISSVaSOH Z 18784080 OG ov 0 A WASSV3aSOH l oerezoso 61 o ANWSSV3SOH l ging t e A18W3SSY ISOH Ht 91 20 80 E A18W3SSY ISOH 0 80 91 Ge AMWBSv3SOH U ire080 st A WIASSWaSOH 1 004080 PL Fs AG L NONO A19W3SSY IOYINOD MOI 9 2080 TEL me a 3 Z NOXO AIGWASSV TOAINOD MO I 19 2080 l A18W3SSY 3NION3 oL 60 090 LL s BONDI ES NO NIdS 31114 780 2080 T Ova I 180 7080 116 97 A18W3SSV XIL NYNLIY L 08082080 6 AT8W3SSY 831000 IT ER 3313W MOT WdO OL 1 L 840 2080 Z ded0000 30nvO Z A
5. 044 e or RE ERR paper pb ed ame ba da a aaa 17 Start Up AOPEN EE dnx Ra rem ausu u S anys doa 23 Epone starine Lips 222 4 vene a a NUS uta n teo A e Sees 25 Op eratine Checks ere ehr ea Er Eege 26 TwoesCircuit Mode Operation bad di di 26 Combined Circuit Mode Operapon es 32 Chapter 4 Viale mane iris rin 37 Disabling the Slarter Jor SET VICO Jaer as en 37 ek e EE 39 E T u rr ARE 43 Engine Maintenance and Service 43 AS SEES SEES pm eon ECL TEE 45 Wu 45 Spark UNTICSIOT sue cm ch a Re A EAS EE AA a 47 Va SIALIEE CM RENE RE a EE e 47 NO O nn usaq N e escolar O 48 CHECKING TOP Led costas ea vatis bh wbte E dava Abb uta s datos aad dt ween oe 49 is EE 49 EFN TEST 49 KOG TEGN JESPER SKEE EEE EE EEE 22 E H Wachs Part No 14 MAN 12 Rev 2 0709 i Tandem Pump Offshore Hydraulic Power Unit User s Manual Chapter 5 Parts List and Ordering Information 55 Ordering Il ormatl oh zer i Soci ped OP ee REI CU d pone db Dd dd dub eda 55 Ordenmne Replacement Patfs ai exa oe EE UE awama a EE 29 Fo TN SE 55 Warranty torna rs ceed Skane a ren DR adas be 56 Return Goods Address su dressere ee D eS 56 Drawings and EE 56 11 Part No 14 MAN 12 Rev 2 0709 E H Wachs Chapter 1 About the Tandem Pump Power Unit Chapter 1 About the Tandem Pump Power Unit In This Chapter PURPOSE OF THIS MANUAL PURPOSE OF THIS MANUAL How TO USE THE MANUAL This manual ex
6. CSt Always consult your hydraulic tool manufacturer for hydraulic fluid guidelines Table 1 Viscosity Data Minimum Optimum Maximum Viscosity Range Continuous Operating Viscosity at Requiring lt 50 Viscosity Viscosity Range Pressure Outlet Pressure 470 5000 8 Part No 14 MAN 12 Rev 2 0709 E H Wachs Chapter 1 About the Tandem Pump Power Unit Hydraulic Fluid Overview Table 2 Hydraulic Fluid Specifications Flash Point ASTM D 92 340 F 171 C min Emulsion Test ASTM D 1401 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 Citgo AW anti wear 32 e Shell Tellus T 32 e Shell Tellus S 46 e Chevron AW 32 E H Wachs Part No 14 MAN 12 Rev 2 0709 9 Tandem Pump Offshore Hydraulic Power Unit User s Manual 10 Part No 14 MAN 12 Rev 2 0709 E H Wachs Chapter 2 Safety The E H Wachs Company 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
7. OT WldNS EX4ldNg L uionddd I 09 2080 6 06 dW OZ X dI OZ taLdvav 1 60662080 8 IHOIWUIS dd OZ X OW vz Wildvav T v0Et O80 L 6 06 dW 02 X W OZ VILdVAV 1 60662080 9 IHOVMIS IYON 8 W8 valdvav Zoe 2080 S 06 8UOVIN bZ X fn OZ HAYA I 00 2080 yaLvalan asvowan a vas n T 80 2080 AIA IN3SS V VALT NYNLSY 1 080t 080 z Uu1002WoLvIavd EG 6 0 10 80 ER A qwassy 19114 UINISY 080 20 80 CL 000 t L NdH 340YSHO dung wapuep v T 31W9S AVAHLMIOS OndadldLdN 8 T c TOBZI06 v 19NSV9 uaria 1 9 38 vn OS I TZZ L080 PAI INAH T ce8e0 080 z LAN Y T T ASSV QV3H Ed SZ TI 180 20 80 T NOILdIYIS3G un Y39WNN LuVd Wall K quuassy exe1u IV S0p EZ0 80 CL 000 t L NdH 10YSHO dung wapuep AIGWASSV 3IBV2 1OHLNOO T OET 20 80 dli v12 35 OH SS 00 CANN Bit HE 8ZT 20 80 dal ld LCL L0 80 ETT url ALd33 VS 9CL EZL0 80 Yall Hv 3NION3 vZT EL0 80 II nel X JENS ERE NEN Hg E x IS OH VIGEN Z T Z E3E EA T JJOLnHS DIVLNIHIY I 090 EL0 80 T NOMdR2SId MD Y39WNN Leva Wall K quiessy UOIPDNS 60t 20 80 CL 000 tL NdH alOUSUO dund uepue NOLLINS OL dWNd YY39 REESEN OH T 07rEL080 8 MIONGAM dd 8 dN ZE Valdvav I SZEEL080 Ir LAN ZE LAN ZE LAN ZE LUNSSIHA MOT T vzEELOS0 9 L N ZE L N ZE Wald VV T EZE
8. gets thinner lower viscosity and as it cools it gets thicker higher viscosity Your Wachs hydraulic power unit has an optimal viscosity range which 1s 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 hydraulic oil 1s extremely important for the life expectancy of the hydraulic components Wachs rec ommends 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
9. 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 Ball valve on off Starter connector Figure 3 10 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 The ball valve on off handle should be closed as shown The handle may go to either the left or right depending on valve configuration Part No 14 MAN 12 Rev 2 0709 E H Wachs Chapter 5 Operating Instructions Start Up and Operation 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 Gm NOTE as shown in Figure 3 11 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 the way in EMERGENCY Push the emergency shut off all the way in Figure 3 11 Start the engine with the controls set as shown 2 Set both flow control levers to the minimum flow set ting Figure 3 12 Set the flow control levers at their mini mum flow positions as shown E H Wachs Part No 14 MAN 12 Rev 2 0709 23 Tandem Pump Offshore Hydraulic Power Unit User s Manual En NOTE lt
10. seconds to shut the engine off If you need to shut the engine off immedi ately in an emergency pull y the emergency off handle saa i I Lal i K s OG Figure 3 25 Pull the stop handle out to shut off the engine E H Wachs Part No 14 MAN 12 Rev 2 0709 3 Tandem Pump Offshore Hydraulic Power Unit User s Manual 6 CAUTION Make sure the throttle is set at idle and both flow control levers are set at the minimum flow setting before changing the flow mode 22 Combined Circuit Mode Operation This section describes how to operate the HPU with one combined 24 gpm 90 l min circuit 1 Attach the hydraulic hoses to the combined circuit connectors as illustrated in Figure 3 26 j i i gt Combin d circuit pressure Combined EN Circuit return w af iu t Figure 3 26 For operating in combined circuit mode connect hydraulic hoses to the combined circuit as shown 2 Set the flow mode lever down to use one combined circuit at 24 gpm 90 l min maximum Figure 3 27 Set the flow mode lever down to operate a single combined circuit Part No 14 MAN 12 Rev 2 0709 E H Wachs Chapter 5 Operating Instructions Start Up and Operation Hold in the throttle button while pulling the throttle until the engine is running at maximum Gm NOTE Typically you can run the engine at maximum throttle throttle pulled out to physical stop Figure 3 28 Hol
11. 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 e ALWAYS READ PLACARDS AND LABELS Make sure all placards labels and stickers are clearly legible and in good condition You can purchase replacement labels from E H Wachs Company e KEEP CLEAR OF MOVING PARTS Keep hands arms and fingers clear of all rotating or moving parts E H Wachs Part No 14 MAN 12 Rev 2 0709 Chapter 2 Safety In This Chapter OPERATOR SAFETY SAFETY LABELS Look for this sym N bol throughout the manual It indicates a personal injury hazard 11 Tandem Pump Offshore Hydraulic Power Unit User s Manual 12 Always turn machine off before doing any adjustments Or service e 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 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 1s displayed with any safety alert that indicates a personal injury hazard N WARNING
12. 8 1 AIR SIARTPUSH VALVE 4 08 073 070 1 GAUGE PRESSURE S 08 073 071 1 GAUGE TEMP 6 08 073 077 2 0 3000 PSI PRESSURE GAUGE 7 08 073 100 1 CONTROL LABEL 8 08 073 101 1 OPERATING INSTRUC TIO NS 9 08 073 103 1 DIREC TION LABEL 1 10 08 073 104 1 HYD 1 LABEL 11 08 073 105 1 HYD 2 LABEL 12 08 073 106 1 DIREC TION LABEL 1 2 13 08 073 109 1 DIREC TION LABEL 1 14 08 073 131 1 CONTROL CABLE FUEL SHUT OFF 15 08 073 152 2 HO SE 1 4 HIGH TEMP 16 08 073 153 2 HOSE FITTING 1 8 NPTx 1 4 HO SE 17 08 073 165 4 LATCH 18 08 073 166 4 PALSTIC RETAINER 19 08 073 170 1 COVER PLATE 20 08 073 171 1 BACK COVER BRACKET 21 08 073 188 1 ADAPTER 1 8 F NPTx 4JIC 90 ELBOW 22 08 073 337 2 ADAPTER 4J IC 4 NPTF 23 08 073 350 1 FLOW METER ASSEMBLY CIRC UIT 2 24 08 073 351 1 FLOW CONTROL ASSEMBLY CIRC UIT 2 25 08 073 352 1 FLOW METER ASSEMBLY CIRC UIT 1 26 08 073 353 1 FLOW CONTROL ASSEMBLY CIRC UIT 1 27 08 073 354 1 3 WAY VALVE ASSEMBLY 28 08 073 421 2 HO SE ASSEMBLY PRESSURE GAUGE 29 08 073 423 1 HOSE ASSEMBLY CIRC UIT 1 PRESSURE 30 08 073 424 1 HO SE ASSEMBLY CIRCUIT 2 PRESSURE 31 08 073 425 1 HOSE ASSEMBLY CIRCUIT2 TANK 32 08 073 426 1 HOSE ASSEMBLY CIRC UIT 1 TANK 33 08 073 427 1 HOSE ASSEMBLY 3 WAY INLET 34 08 073 429 2 HOSE ASSEMBLY PUMP OUTLET 35 08 073 431 1 HOSE ASSEMBLY CIRC UIT 1 2 36 08 073 432 1 HOSE ASSEMBLY CIRC UIT 2 37 08 073 433 1 HOSE ASSEMBLY CIRCUIT 1 FLO WMETER 38 08 073 435 1 HO SE ASSEMBLY ENGINE O
13. 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 MN 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 1s 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 1s 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 Part No 14 MAN 12 Rev 2 0709 E H Wachs Chapter 1 About the Tandem Pump Power Unit Manual Updates and Revision Tracking NOTE This symbol indicates a user note Notes Gm 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 custo
14. ELO8B0 S dW ZE dW ZE Yad VV Tt ZE O080 Ip 06 fIN8 X diN Z T Wald VV I gteezogo NOILdIYIS3G un d3J8WfN LAVA Will ITEM PART NUMBER DESCRIPTION T n S 13 soo 6 mcswezxe 14 9005502 6 nmam Tandem Pump Offshore HPU 14 000 12 08 073 407 Hydraulic Reservoir Assembly ITEM PART NUMBER DESCRIPTION 4 08030 i ADAPER20M x0MPS LOW PRESSURE T 20 20 20 eo n 05053 p 0507346 is 0505418 19 EX EN HO SE ASSEMBLY TANK TO FILTER o 21 080345 08072426 1 HOSEASSEMALY CRCUITI TANK 23 140060 2a 1400702 A 26 902355 27 emm 28 06073130 29 050733 30 SS EXC ES EE EN Ce 13 EA E EN EN ER EN E ES ES EN ES EN Tandem Pump Offshore HPU 14 000 12 08 073 413 Hydraulic Reservoir and Fittings quuassy soH uonons OLH EZO 80 CL 000 tL NdH 9410usjjo duung urepue 3SOH Z X1dN uz DNI 3SOH T 97 080 v 3SOH uz X DI Z DNILLH3SOH T 9ST EL0 80 lt NOlLdld5S3G ub Y39WNN LdVd Wall dar il TaN ANIONA OL K quuessy que an SLpy 0 80 3NIVA NIVuO CL 000 t L NdH 940usjjO duung wapuey SNOI SE SNOILIINN O 9 QIQAVIAHL TIV DNITVIS d Od INVIV3S SNNVYCAH 695 ALILD O71 ASN ONOI SC NOUT Tana IN Otd 8 855 3201 Z T YIHSVM v gesetoe 8 8ISS LVH Z T u3HSV
15. ESIGN BINDER CONTAINS SPEC SHEET EXHAUST FLANG E INC LUDES 4 BOLTS KUBO TA P N 01123 50825 I A MANUS am VOR NA AF m m mm Ti Yen TH IER mil AI fom Wm i 1 E mmh m u m m mmu L M af mild nn a DE D Dien LE ET IP EES LI P A vi SA ima mm EES pa eg OTIO LIPO F el ig gt be 2 mm AVA TA IG Tea Ge PE CH JE KT om N d O cf Y SI I 7 Kegel OIL FILTER WAC HS P N 08 073 XXX KUBO TA P N XXXX BELT WACHS P N 08 073 125 2 BOLTSAE A AUX PTO MOUNT KUBOTA P N 1G 354 97010 b 3 25 PILOT INTERNAL SAE SPLINE DATA FUEL FILTER 9 TOO IH WACHS P N 16 32 DIAMETRAL PITCH KUBOTA P N 16631 43560 30 PRESSURE ANGLE RPM 1 172x ENGINE RPM ROTATION AS SHOWN Tandem Pump Offshore HPU 14 000 12 Kubota Diesel Engine Figure 3 1 LS 8 SERIES STARTER EXPLODED PARTS VIEW Universal Drive Housing Parts Table 3 1 LS 8 SERIES STARTER PARTS LIST 17 121 Nut 46 iud Adaptor Shim MUST PROVIDE MODEL NUMBER OF STARTER 4 x x QUANTITY INDEXNO PARTNO DESCRIPTION PERUNT LL 18106 JRotrHosing 1 14 2 18 04R _ RotorCasing Right Hand 1714 j 181040 Rotor Casing Left Han 1 o 3 18 503R _ iniet End Plate Right Hand 1 1 185030 inlet End Plate Left Hand o o 4 18 502R EndPlae Righ Hand f 18502 End
16. IL PRESSURE 39 17 065 00 1 VERNIER C ONTROL 30 SERIES 40 90 401 03 1 LABEL EAR AND EYE PROTECTION CIRCUIT 1 PRESSURE RELIEF ENGINE OIL PRESSURE CIRCUIT 1 PRESSURE CIRCUIT2 CUTOUTER CABLE SLEEVE TO 40 1 CUTOUTER CABLE SLEEVE TO 44 1 CIRCUIT 2 142 PRESSURE LOCAJE MAL SKRT MM FLAT WEUL VEAILATED AREA BEFORE STARTING B CHECK THE HYDRAULIC RESERVOIR OR LEVEL H ATTACH AIR LINE TO STARTER CONNECTION una CONTROL A IN Au THE WAT 2 SET BOTA ROW CONTROL VALVES FO MINDAUM FLOW PONDONS amp rO DANT PUSH AND HOLD THE START BUNN UNTIL BAGAJE STARTS A FULL TIROL CONTROL OUT ALL THE WAY TO OPERATIA SPEED NOTE CHECK OG HLR GAUGE POR COMPACT OP BRATING PRESSURE GFO HUT OFF PULL AND HOU THE ENGINE SIC e CONTROL UNTA ENGINE SOPS OMERGENGY SHUI OWN ONLY o PULL THE EMERGENCY OFF B HANDLE DO NOT USE THES HANDLE POR ROUTINE SHUTDOWN REFER TO USER S MANUAL FOR MORE DETAILED OPERATING SAFETY AND MAINTENANCE INSTRUCTIONS ER MADE o HEMKE PARC gt UPCOLHERIP R GB US IA EE REL o DAOC PRESSURE RELIEF 24 GALLON MINUTE 90 LITER MINUTE Tandem Pump Offshore HPU 14 000 12 08 073 400 Front Panel EY MAIN HYD PUMP 1 GEAR PUMP 08 073 023 08 073 024 08 073 041 ITEM PART NUMBER lary DESCRIPTION a EN 3 CODE 61 FLANGE ADPATER 1 1 3 EH ER 6 EA EM EXHAUST MUFFLER 08 073 050 08 073 065 08 073 072 4 MOTOR M
17. M eent LVOOVULIN 8 AUD Z T T X ET Z T SOHH ST T6T 06 35 OH 9T S X LdN 8 BNLLLIH ISOH LvUELOS0 L 35 OH v T X Str IVS S ONILLIH 35 OH 9bT EL0 80 LAN Z T AYAH X3H DMA SvLE OS0 S Sp IVS 02 Z T X LdN 8 T daldvav VVLl 0 80 LAN 18 E X Z T ONIHSNE WH3ld VQ V evT L0 80 AN vL ru L 9 T EL0 80 c JATVA 440 1 HS Dr 3NIW VIN c 060 0 80 L NOILdIuUDSIA E Y39WNN LdVd WALI ITEM PART NUMBER an DESCRIPTION 08 073 069 AIR RELAY VALVE 08 073 115 LUBRICATOR 08 073 151 HOSE 3 4 HIGH TEMP 08 073 152 HOSE 1 4 HIGH TEMP 08 073 158 HOSE FITTING 1 4 NPTx 1 4 HOSE 08 073 159 ELBOW 12 MJ x 16 MP 90 08 073 160 HOSE FITTING 12 JIC x 3 4 HOSE DEEST HOSEFITING 12 JIC x 374 HOSE 08 073 162 STREET TEE 12 MP x 12 FP x 12 FP 0 08 073 307 ELBOW 12 MJ x 12 MP 90 11 08 073 309 BUSHING 12 MP x 04 FP 2 08 073 330 ADAPTER 12 FJ S 12 MP 13 08 073 331 REDUC ER BUSHING 16 MPT 1 FPT 14 08 073 332 12 BULKHEAD NUT 15 08 073 347 ADAPTER 12 MP x 12 MJ RA IG HT BULKHEAD EN 5 6 EX 8 ER EN 2 B EG Ei CUTLENG TH 32 FROM AIR STARTVALVE ON CONTROL PANEL se gt A CUT LENG TH 36 TO AIR STARTER 2 CUTLENG TH 10 TO AIR STARTVALVE ONCONIROLPANEL uet N N Tandem Pump Offshore HPU 14 000 12 08 073 418 Air Relay Assembly NO TES 1 MANUFACTURER KUBOTA 2 MANUFACTURER P N 1JJ 465 2100 3 D
18. OUNT Ea ES SAE B PUMP SPACER M UFFLER SPARK ARRESTOR 08 073 089 08 073 099 ES ENGINE ASSEMBLY HUB ES 08 073 118 ES E ER EEN EES EA as e EC En 19 ES ER 1 EXHAUSTFLANGE BRACKETASSY Eu 08 073 121 OVERFLOW BOTTLE ASSEMBLY 08 073 122 2 SAEMANGERT 1 33082 Li ae 1 ADAPTER 08 073 123 08 073 135 08 073 155 12 MJ x 12 MP STRAIGHT 08 073 311 32 MJ 32 MAORB 90 1 ADAPTER BH 08 073 344 1 DAN CAP EXTENSION 2 5 EN 08 073 319 ADAPTER 8 MJ 8 MAORB 08 073 343 HHCS 5 8 11 X 3 1 2 08 073 349 08 073 405 08 073 410 AIR INTAKE ASSEM BLY SUC TION HO SE ASSEM BLY Ea 1 08 073 420 EN 3 RZ ea dic 22 ES d Y CA ANS uro p d em dr m OMY a Kies ds um av mm ka HOSE ASSEM BLY PUMP OUTLET 2 08 073 434 ES 08 073 429 24 ES ER ES ES 4 WASHER 5 8 FLAT EN HHCS M12 x 40 MM 4 6 08 073 168 1 90 205 59 08 073 142 WASHER 1 2 LOCK SS18 8 90 195 58 90 195 52 WASHER 1 2 FLAT SS18 8 RAIN CAP 2 5 HHC S 3 8 16 X 3 4 SS18 8 29 30 31 90 171 07 90 175 51 WASHER 3 8 FLAT SS18 8 3 8 SPLITRING SS18 8 32 9017552 8 WASHER 33 ES 35 HHCS 1 2 13 X 1 3 4 ADAPTER 8 MJ X 6 MORB 90 Eg 08 073 186 1 90 091 18 MUFFLER CLAMP 2 5 OD 304 SS Ea 08 073 181 Tandem Pump Offshore HPU 14 000 12 lt
19. Plate Left Hand j 5 18101 7 Rotor Assembly 1 6 17115 ThrustBeaing 12 e ee GEM NM IE 1 MEN 8 I 17124 RetainingRing 14 e 9 134746 Ra 2 10 5403 Muffer Optional I At 47402 Bearing A 12 12 105 Rotor Vane NEM 5 13 17316 WoodruffKey Z 14 25127 Jm GE aa DJ 19414 oe 19 17209 jORing 00 0 1 20 18 508 Saw 6 23 82500 ju 4 j 24 47401 j Beaig 1 ota 427 26 21120 Gear 1 20Ratio CCOO gt A 21175 Gear 1 75 Ratio Standard 27 17206 O Ring 28 18111 Drive Pin 29 18 103 ArborShaft 471dia Pinio 1 x 18 105 Arbor Shaft 625 dia Pinion 9 3 17200 lom 7 32 17207 jORng 4 33 Drive Pinion See Table 2 1 O lO 1 34 jDriveHousing See Table21 h Z 1 36 I 17117 Srew 6 38 Universal Mounting Flange See Table 2 1 1 39 533161 JjO Ring 2 dO 54105 Gasket 1 Long Roll Pin 17 105 Short Roll Pin 1 43 1 Cap Screw 6 44 17 112 Lockwasher 6
20. SERVICE HYDRAULIC SYSTEM 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 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 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 shiown in closed position E H Wachs Part No 14 MAN 12 Rev 2 0709 37 Tandem Pump Offshore Hydraulic Power Unit User s Manual 38 3 Remove the air supply line from the starter connector and insert the locking pin in the connector V H e d Me Figure 4 2 Remove the air 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 EU s P OG a Figure 4 3 Remove the plug in the air relay to disable the air starter Part No 14 MAN 12 Rev 2 0709 E H Wachs HYDRAULIC SYSTEM When servicing components of the hydraulic system such as replacing a pump you can close the hydraulic suction line fr
21. This safety alert indicates a potentially hazardous situation that if not avoided could result in death or serious injury 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 if not avoided will result in damage to the equipment Part No 14 MAN 12 Rev 2 0709 E H Wachs 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 informatio
22. aged components and air leaks Replace any worn or damaged compo nents Loose connections check all threaded connections for tightness e Hose wear check for kinked crushed damaged or worn hoses Damaged hoses can restrict or reduce air flow and lead to unpredictable system behavior 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 have been completed Starter Motor Oiler Each time you use the HPU check the oil level 1n the air starter oiler Add oil through the port in the top of the oiler shown in Figure 4 17 Adjust the drip rate knob on top of the oiler to the maximum by turning it all the way counter clockwise Adjust the drip e knob to the maximum turn counter clockwise Remove screw cap to add oil Check oil level in sight glass m si Figure 4 17 Check the oil level in the oiler and fill as necessary Part No 14 MAN 12 Rev 2 0709 E H Wachs 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 There is an access panel on the front of the HPU Remove the panel to access the front part of the unit for cleanout or checking for l
23. anual e 50 gallon 189 liter hydraulic tank Inline flow meters one each circuit 30 gpm 114 I m and 10 gpm 38 l m e 0 3000 psi 207 bar pressure gauges one each circuit e Steel tubular frame with drip pan e Lifting eyes at 4 corners e Approximate dimensions height 60 25 153 cm length 72 183 cm width 40 102 cm e Approximate weight 1920 lbs 864 kg empty 2400 lbs 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 4 Part No 14 MAN 12 Rev 2 0709 E H Wachs Chapter 1 About the Tandem Pump Power Unit Equipment Description Lift eyes Hydraulic oil Exhaust Lift cooler Fuel cap pipe eyes A AT Hydraulic oil reservoir Hydraulic oil temperature Drain Control Diesel and level gauge plug panel engine Figure 1 1 The photo shows the front view of the HPU with major components illustrated E H Wachs Part No 14 MAN 12 Rev 2 0709 5 Tandem Pump Offshore Hydraulic Power Unit User s Manual Hydraulic Hydraulic oil Engine Engine air Diesel fuel reservoir temperature Hydraulic oil radiator filter tank fill cap and level gauge cooler Diesel Hydraulic Hydraulic Air starter Hydraulic oil engine suction line connectors connection drain valve Figure 1 2 The photo shows the components visible from the rear sid
24. cooler e Once a year disconnect piping to the cooler and circu late a degreasing agent through the unit and the rest of the hydraulic system Service the tank strainer and replace the hydraulic filter after performing this service ENGINE MAINTENANCE AND SERVICE Check the engine oil and engine coolant levels every time you use the HPU The Kubota manufacturer s manual 1s 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 E H Wachs Part No 14 MAN 12 Rev 2 0709 43 Tandem Pump Offshore Hydraulic Power Unit User s Manual SERVICE INTERVALS Observe the follewing for service and maintenance The lubricating oil change intervals listed in the table below are kr Class CF panties od of API Cacao wilh a low ege in use B GE CH bricati ed will Every 100 hours Replacement of oil filter cartridge depending on the oil pan Check of intake air line Every 200 hours Repleeomem of fuel filter cartridge Every 400 hours se em sen E Every 500 hours Every 1500 hours 1500 hours Check of turbo charger ate Every 3000 hours aos U s gt ple Every two years iator I Jam Replacement of fuel pipes and clamp bands 14 3 8 Replacement of intake air line je Not
25. d in the button and pull the throttle out all the way or to the desired engine operating speed Release the button and turn the throttle locking ring clockwise to lock the throttle PS E H Wachs Part No 14 MAN 12 Rev 2 0709 33 Tandem Pump Offshore Hydraulic Power Unit User s Manual Gm NOTE When you are operating in combined flow mode the flow gauge for Circuit 41 does not register flow 34 Circuit 1 contributes Circuit 2 contributes up to 8 gpm up to 16 gpm Move the flow control levers to adjust the flow as required for the tool s you are operating Use the gauge on Circuit 2 to monitor the flow Use Circuit Z2 flow and pressure gauges for combined flow up to 24 gpm Figure 3 30 Set the flow control levers to the desired flows The flow from both circuits is added together and the Circuit 42 flow gauge registers the total 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 31 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 Part No 14 MAN 12 Rev 2 0709 E H Wachs Chapter 5 Operating Instructions Start Up and Operation
26. dS4d ub d39MWNN LdVd WAL K quiessy 04 U0D M0 J Z HND LSE EZO 80 CL 000 p L NdH 310ysyo dung uj pue 334 M3ATYATOUNOOMOH I z8T EL0 80 T NOlLdIaDSsIA un d38WAN LdVd WALI A quiassy 1919 MOI UNI ZS EZ0 80 CL 000 p L NdH 910YSHO dung Wapue NVNN38 06dWYo X WtO Moa II x NVNNHS dd v0 X din ZT DNIHSNA EU NVNNS8 O6dWzLtX WNZL MOSH II NYNNIYE d3ZT X dWZT x WZT MILdVAVL T VASWNMO 1iOVugdOQL z 790 2080 ES EN was als ECTE slo L Sd OLINOIN DVI INdO OT T YAW MOH L 6S0 Z0 80 L dJdNIIVIANVIA NOlLdIaDSsIA ALO 439WNN LUVd Wall quuassy o43u0 MO AND EGE 20 80 CL 000 VL NdH 940usjjO dung wapuep 1HOMIS SHOW OT X W ZT MLdvav T 9TE L0 80 06 8YOVIN OT W9T I STE 20 80 06 8YOVIN OT X W ZT Mora I vIE O80 Z 33038 MANTVATOHLNOD MOH T SZO L0 80 T NOILdIYIS3A un d38WAN LdVd WALI K quiessy 9A eA PM 3YL vSE EZ0 80 CL 000 t L NdH 940usjyo dund uj pue LHOIVUIS dW ZT X N ZT HALA WOW T TTE 2080 06 dW ZT X W ZT MOST LOE ELO 80 AYM ut INIVA T 90 080 I NOlLdIaDSIA ub Y39WNN LYVd WAL ITEM PART NUMBER QTY DESCRIPTION 1 08 073 020 1 CONTROL PANEL 2 08 073 064 1 AIR SHUTOFF T HANDLE 3 08 073 06
27. draulic fluid under the skin can 9 Avoid locating equipment in any environment for cause serious injury and which it was not designed and which may create a even result in death If an dangerous operating condition such as an explosive injection injury occurs seek atmosphere e g gas dust high heat e g molten medical treatment immedi metal furnace chemicals extreme moisture etc ately 10 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 11 Use only E H Wachs parts and materials when servic ing the equipment Substitute parts or materials could produce a hazardous operating condition 12 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 SAFETY LABELS The following two safety labels are on the HPU If a safety label is damaged or missing call E H Wachs Company to order a replacement See Chapter 5 for ordering informa tion and use the part numbers listed below with the labels CAUTION Do NOT exceed 120 PSI 8 3 bar Figure 2 1 Pressure limit caution label part no 08 073 220 E H Wachs Part No 14 MAN 12 Rev 2 0709 15 Tandem Pump Offshore Hydraulic Power Unit User
28. e Hydraulic Power Unit User s Manual Gm 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 20 Figure 3 6 Check the engine oil level using the dip stick on the front side of the engine behind the control panel 7 Makesure the engine coolant 1s filled to the correct level in the overflow bottle Part No 14 MAN 12 Rev 2 0709 E H Wachs Chapter 3 Operating Instructions Setting Up the Power Unit Figure 3 7 The engine coolant overflow bottle should be filled within the range shown 9 Make sure the fuel shut off valve below the fuel tank is open Xm Le Figure 3 8 Make sure the fuel shut off valve is open the handle is in line with the fuel line Q Make sure there is oil in the starter motor oiler See Chapter 4 for instructions on adding starter motor oil E H Wachs Part No 14 MAN 12 Rev 2 0709 21 Tandem Pump Offshore Hydraulic Power Unit User s Manual EE CAUTION 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 22 Figure 3 9 Check the oil level in the starter motor oiler using the sight glass on the side of it Viewed from front of power unit 10 Make sure the air supply for the starter is turned off at the air source 11 Connect the air supply
29. e of the HPU 6 Part No 14 MAN 12 Rev 2 0709 E H Wachs Chapter 1 About the Tandem Pump Power Unit Hydraulic Fluid Overview Instruction label Circuit 41 hydraulic pressure Circuit 41 hydraulic flow Circuit 1 flow control Engine oil pressure Engine temperature Throttle Engine shut off Engine starter Emergency shut off Circuit 22 hydraulic pressure Circuit 42 hydraulic flow NOTE In combined circuit mode the Circuit Z2 gauges register the com bined circuit pres sure and flow Circuit 42 flow control Front service panel turn and Flow mode lever release pins to remove the panel Down z combined circuit mode Right z two circuit mode Figure 1 3 HPU control panel When the flow mode lever is in the two circuit position both hydraulic cir cuits are operating When the lever is in combined cir cuit position only Circuit 2 is operating 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 E H Wachs Part No 14 MAN 12 Rev 2 0709 Tandem Pump Offshore Hydraulic Power Unit User s Manual Fluid temperature greatly affects its viscosity As the fluid warms it
30. eaks Turn the 4 locking pins counter clock wise to release them and remove the panel The pins are captivated to prevent them from falling out of the panel Remove d Re tighten k nn DA 1 MAJO J f D Figure 4 18 Turn the 4 locking pins counter clock wise to remove the front access panel TROUBLESHOOTING Engine The table below lists common troubleshooting issues See the Kubota engine manual for more detailed procedures E H Wachs Part No 14 MAN 12 Rev 2 0709 Chapter 4 Maintenance Checking for Leaks 49 Tandem Pump Offshore Hydraulic Power Unit User s Manual Symptom Potential Cause Solution 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 Engine won t turn over 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 Fuel tank is empty Fill fuel tank Fuel line valve is closed Open fuel line valve below fuel tank Air in the fuel line Bleed air from the fuel system Engine turns over but won t start 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 50 Part No 14 MAN 12 Rev 2 0709 E H Wachs Chapter 4 Main
31. ed or has a burnt odor It is recommended to clean the system by flushing and filter ing using an external slave pump E H Wachs Part No 14 MAN 12 Rev 2 0709 Chapter 4 Maintenance Hydraulic System Gm NOTE Make sure the reservoir and circuit are clean and free of dirt debris before refilling the reservoir with hydraulic oil 4 Tandem Pump Offshore Hydraulic Power Unit User s Manual Figure 4 9 Drain the hydraulic oil by removing the drain plug and then opening the drain valve e When re filling the reservoir use filtered oil Fill the reservoir with enough fluid so that you can see it in the temperature level gauges on the front and back of the reservoir e When intially starting the HPU after changing the oil remove all trapped air from the system All inlet connec tions must be tight to prevent air leaks Figure 4 10 Bleed air at the flow control valves one shown 42 Part No 14 MAN 12 Rev 2 0709 E H Wachs Chapter 4 Maintenance Engine Maintenance and Service T Figure 4 11 Bleed air from above the flow meters one shown Cooler e Inspect the cooler regularly for corrosion and for dirty or clogged heat transfer service Remove any dirt and dust by washing brushing or blowing with compressed air To remove grease or oil use a non flammable degreasing solution one that is safe on copper steel and aluminum and then a hot rinse You can also steam clean the
32. er and blow it out or replace it if necessary Part No 14 MAN 12 Rev 2 0709 E H Wachs Figure 4 16 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 e 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 e Three Monthly Remove the spark arrestor and tap it with a soft mallet to loosen any internal deposits Shake it to remove loosened deposits and to check for loose baffles e 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 Peform the following air system checks on a regular basis E H Wachs Part No 14 MAN 12 Rev 2 0709 Chapter 4 Maintenance Air Starter System 47 Tandem Pump Offshore Hydraulic Power Unit User s Manual Gm NOTE Use Wachs air motor oil part no 02 407 00 one pint or a good quality SAE 10 weight oil 48 Oiler operation every time you use the HPU check the oil level in the oiler and verify that it is working Air leakage look and listen for dam
33. es 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 The items listed with Q are registered as emission related critical parts by Kubota in the U S EPA nonroad emission regulation 4 2 Part No 14 MAN 12 Rev 2 0709 1 EH Wachs Chapter 4 Maintenance Engine Maintenance and Service Fluid Levels Check the engine oil using the dipstick on the front side of the engine behind the control panel Figure 4 12 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 13 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 E H Wachs Part No 14 MAN 12 Rev 2 0709 45 46 Tandem Pump Offshore Hydraulic Power Unit User s Manual PF T u Figure 4 14 Release the three spring clips on the fil ter cover to remove the cover CHE Te a ET e Figure 4 15 Check the outer filt
34. h system off unjam fan Cooler fans not spinning hydraulic leak Fix leak Cooler fans not spinning fan motor malfunction Service fan motor Both cooler fans not spinning gear pump malfunction Service gear pump Heat exchanger is fouled Clean heat exchanger see maintenance section Part No 14 MAN 12 Rev 2 0709 Chapter 4 Maintenance Troubleshooting 53 Tandem Pump Offshore Hydraulic Power Unit User s Manual Flow meter sticks and won t return to no flow position Flow meter window tube is crack ing or crazing Flow meter scale is fogging or coming loose Part No 14 MAN 12 Rev 2 0709 Potential Cause Solution 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 Lexan window tube was dam aged by incompatible cleaning solution Replace Lexan tube if necessary To prevent re occurrence use soap and water 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 E H Wachs Chapter 5 Parts List and Ordering Informa
35. ic connections which may have been removed replaced or disconnected during shut down have been reconnected securely before starting hydraulic unit A Before starting the unit perform all equipment checks described at the beginning of the operating instruc tions in Chapter 3 5 If 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 6 Shut down the hydraulic unit and relieve pressure from all pressurized accumulators actuators and lines before removing tearing down or performing mainte nance on any remotely located actuators hoses fil ters valves piping etc 7 Any 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 ahydraulic line failure either with the unit running or shut down e pump or motor failure or 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 Part No 14 MAN 12 Rev 2 0709 E H Wachs Chapter 2 Safety Safety Labels 9 Donotinspect hoses and fittings for leaks using your WARNING bare hands A pin hole leak can inject hydraulic fluid The injection of through the skin with the potential for serious injury AN hy
36. is recommended that you close the ball valve and turn off the air supply after starting the HPU 24 3 Open the ball valve on the air starter connector Pull the safety lock out tab up the handle to allow it to turn Figure 3 15 Pull the safety lock out tab back 1 and turn the handle to open the ball valve 2 4 Turn on the air supply at the air source 5 Push in the ENGINE START button and hold it until the engine starts Release the button Figure 3 14 Push the ENGINE START button and hold it until the engine starts 6 Pull the throttle control out about halfway to warm the engine up at medium speed Part No 14 MAN 12 Rev 2 0709 E H Wachs Chapter 5 Operating Instructions Start Up and Operation Figure 3 15 Pull the throttle out about halfway to warm up the engine before applying load to the HPU 7 When the engine has warmed up pull the throttle out to maximum RPM 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 log Figure 3 16 Engage the priming lever to prime the fuel pump after the tank or fuel system has been drained E H Wachs Part No 14 MAN 12 Rev 2 0709 25 Tandem Pump Offshore Hydraulic Power Unit User s Manual Gm NOTE Monitor all system gauges continuously while operating the power unit CAUTION A Before changing the flow mode make sure the throttle is
37. lt m O 08 073 404 Engine Main Assembly gt Q c a WY NEUEN OU MAS o 3 Q AE UN WY Ou 5 e c LL PAR c gt om VON goo o wr 0 M asch Jon NG WRK Moe END Ni CGA Sa S N y e ORI AND HOSE KIT 03M FLANGE PIO BELL HOUSING PUMP BULK HEAD FITIING SWIVEL ASSEM BLY DESCRIPTION MURPHY ADAPTER NUT FUEL FILTER ASSEMBLY COVER FUEL SOLENOID TENSION PULLEY SUPPORT REAR SUPPORTKIT ELBOW 1 8 M NPTX 4 J IC 90 ADAPTER 1 8 J PTM x 1 8 NPTF FY AIR STARTER EX 1 RADIATORKTOM 1 TENSION PULLEY ASSEMBLY a 1 V2203 ALTERNATOR GUARD EX E Q m D E o Z LL 00 Ke x E o Z 2 00 Ke N LO x e E EN 00 08 073 073 08 073 088 08 073 093 08 073 094 08 073 095 08 073 097 08 073 113 08 073 117 08 073 120 ES 08 073 179 EN 08 073 180 EJ 08 073 187 EN 08 073 345 NN oO o N m E 8 073 021 LO N EN 08 073 074 EN ES 08 073 098 CS FRONTSUPP ME E RUB BEE EA 10 a ri qI q ri IM lei Ajquassy 131 14 pue 19 00 0t 0 80 CL 000 t L ot NYNLIY ZLIN YIO ANY TLINDYID NdH 940usgyo duung uepue dWAd XQ V IN Odd IP q m INE GO UT e SS Ss SS 431009 OL did XNV AIAWASSVISOH T veveLo8o vt ANVL QLYTIOOD ATAWNASSV3SOH I 9rrezoso ZT MALT QLYNWLATAWSSSW3SOH T vtbEL080 IT UJI002 OLXNVLATHIGSSV3SOH I TTr z0 80
38. mers When a manual 1s 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 tandem pump hydraulic power unit 1s designed to oper ate with either two independent hydraulic circuits provid ing 8 gpm and 16 gpm flow or with one combined circuit providing up to 24 gpm flow A flow mode lever on the sys tem control panel switches the unit between independent and combined flow System Specifications e Dual pump providing 16 gpm 60 l m and 8 gpm 30 l m hydraulic circuits at 2200 psi 152 bar e Combined flow mode for up to 24 gpm 90 l m e Kubota V2203 diesel engine 48 1 HP 2800 rpm Arr start 3 4 14 taper pipe thread per ANSI B1 20 1 e Dry air cleaner e 16 gallon 61 liter diesel fuel tank e ATEX rated spark arrestor muffler e Safety air shut off overspeed valve E H Wachs Part No 14 MAN 12 Rev 2 0709 Gm NOTE A NOTE provides supple mentary information or oper ating tips Current versions of E H Wachs Company manuals are also available in PDF for mat You can request an electronic copy of this manual by emailing customer service at sales wachsco com Tandem Pump Offshore Hydraulic Power Unit User s M
39. n on hearing protection refer to Federal OSHA regulations 29 Code of Federal Regulations Section 1910 95 Occupational Noise Exposure and ANSI 812 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 avoiding risk of injury when followed by qualified experienced personnel These E H Wachs Part No 14 MAN 12 Rev 2 0709 Chapter 2 Safety Operator Safety 13 Tandem Pump Offshore Hydraulic Power Unit User s Manual WARNING Many types of machinery have parts that may start moving as soon as the hydraulic circuit is filled and pressurized This could result in injury to personnel or dam age to machinery WARNING Make sure all per sonnel are clear from the machin ery being operated before shutting down the HPU 14 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 1 Return all movable parts of the machinery being oper ated to their normal startup condition if possible before starting unit 2 Be sure all personnel product etc are clear of machinery before starting hydraulic unit 3 Check to make sure any hydraul
40. nn j bestet AVMESNYN LY rege e a SS 3313W MOTH WdO 0 650 2080 r J i 431139 HLIM dWNd YV3D vc0 090 dWNd INYA 318nOQ 1 ezoezoso z 431138 HLIM 33NIV3IS NOILONS 20 090 l Nous E WJEWONINVd Iwan JILVIN3HO2S W3LSAS INNVIDAH c JO Z s2reueups WEIS S 0 80 C1 000 v1 NdH 910usyo dund Wapue G3LN3A INN I01 INYA TIVA v I L9T L0 80 Bo dWAL HOH t ISOH 9 IST 0 80 EN IEEE dIN3L HOI ut T ISOH D ZGT EL0 80 9 Y HOW SN vHxa T 0S0 0 80 G YILYVIS uiv I 880 20 80 r uOLVOldan I GTI 20 80 N QLINY HSNd YILA VIS T 890 20 80 NE 2l AV IU Ulv I 690 0 80 AA NOILLdIYDS3G MO YJaWNN LYVd MAL DILVIW3H2S WILSAS DILYWNANd L 8 9 ADAN SNOGYUVZVH JO 1OHLNOO JHL Y XIGNSddV LYT OT6T Iu Vd YD 6c qu vaNvis VHSO 45S NOLLV WYOSNI 3HOIN HOJ LNAWdINOA ONIDIAYSS N3HM S34NA3 2 Oud 100 9 VE ANV LN O93 201 Gauin odd TIY MOTIOJ OL 34NS 38 u V8 Z 9 ISd 06 wd 99S IN32S 007 SLNSWSYIN 034 DL VWNINd CIANI WIN O 38 uiv GALVIN o8 NV3IO AlddNS d V8 OT ISd OCT G44 DXS LON OG i ONINHVM K quuessy J313W MOL TAN OSE EZO 80 CL 000 t I NdH 310ysyo dung w3puep 1HOIVALS dW ZT X W ZT MaLdvav I TTE 2080 L 06 dWr0 x fin YO MOST T OTE EL080 Ia dd v0 X dN ZT ONIHShB T 60 2080 S d4ZT XdWzl X Wezt aldavavi z t amp 9rez080 Ir Wd 0 ula MOH t amp 0 090 YA MOT LIO VA dOL z zeotos0 z NOlLdl
41. om the reservoir to keep the reservoir from draining Figure 4 4 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 1s running and change the filter when the gauge reads in the red zone above 25 psi 1 7 bar E H Wachs Part No 14 MAN 12 Rev 2 0709 Chapter 4 Maintenance Hydraulic System 39 Tandem Pump Offshore Hydraulic Power Unit User s Manual 40 Figure 4 5 Replace the hydraulic oil filter when the filter pressure gauge reads above 25 psi 1 7 bar Figure 4 6 Unscrew the hydraulic oil filter to replace it e Each time you drain the hydraulic reservoir check the strainer in the bottom of the reservoir and clean it 1f nec essary You can see the strainer with the reservoir cover removed Part No 14 MAN 12 Rev 2 0709 E H Wachs Ee E d a Figure 4 7 Remove the screws in the top of the hydraulic tank and remove the top to access and check the oil strainer L Strainer Figure 4 8 Remove the strainer by removing the out let piping and unscrewing the strainer from the outlet port e Change the hydraulic oil periodically especially if the oil looks dirty or discolor
42. plains how to operate and maintain the tan SYMBOLS AND WARNINGS dem pump hydraulic power unit It includes instructions for MANUAL UPDATES AND set up operation and maintenance It also contains parts REVISION TRACKING lists and diagrams to help you order replacement parts and EQUIPMENT DESCRIPTION perform user serviceable repairs HYDRAULIC FLUID OVERVIEW How TO USE THE MANUAL This manual is organized to help you quickly find the infor Throughout this manual refer mation you need Each chapter describes a specific topic on to this column for warnings using or maintaining the equipment cautions and notices with supplementary information 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 E H Wachs Part No 14 MAN 12 Rev 2 0709 1 Tandem Pump Offshore Hydraulic Power 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
43. pump Flowmeter malfunction Hefer 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 Pressure but no flow on either hydraulic circuit Obstruction in connected hydrau lic system Check connected hydraulic sys fem Flow control valve set to mini mum flow Increase flow setting on flow con trol valves 52 Part No 14 MAN 12 Rev 2 0709 E H Wachs Flow but no pressure on either hydraulic circuit No flow on only one hydraulic cir cuit Not cooling adequately E H Wachs Potential Cause Solution 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 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 Heat load exceeds cooler heat rejection Remove or decrease heat load and allow cooler to lower temper ature Cooler fans not spinning jammed fan blades Wit
44. s Manual Loud noise hazard and risk of eye injury Bar and eye protection must be wom Figure 2 2 Ear and eye protection caution label part no 90 401 03 16 Part No 14 MAN 12 Rev 2 0709 E H Wachs Chapter 3 Operating Instructions SETTING UP THE POWER UNIT 1 Position the HPU 1n 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 72 183 cm min Attach a crane to the lift eyes at all 4 corners Use a forklift in the frame channels Figure 3 1 Lift the HPU at the points shown E H Wachs Part No 14 MAN 12 Rev 2 0709 Chapter 3 Operating Instructions In This Chapter SETTING UP THE POWER UNIT START UP AND OPERATION X WARNING Use a 72 183 cm or longer sling to lift CN 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 17 Tandem Pump Offshore Hydraulic Power Unit User s Manual 2 Make sure the hydraulic tank oil level is visible m the sight gauge Figure 3 2 Make sure the hydraulic oil level is visible in the sight gauge on the front of the reservoir 3 Make sure the shut off valve at the bottom of the hydraulic reservior is open Should be in line with pipe Figure 3 3 Make sure the shut off valve at the bottom
45. s to the minimum setting and let the engine run at operating speed until the oil temperature has gone down Figure 5 21 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 If you need to stop the HPU immediately pull the emergency stop handle on the control panel Figure 3 22 Pull the emergency off handle if you need to shut down the engine immediately When you have completed the operation move the flow control levers back to the minimum flow setting E H Wachs Part No 14 MAN 12 Rev 2 0709 ER IMPORTANT Do not use the emergency stop for a normal engine shutdown Repeated use of the emergency stop could damage the engine 29 Tandem Pump Offshore Hydraulic Power Unit User s Manual Figure 3 23 Set the flow control levers back to the minimum flow setting before shutting down the HPU 3 Turn 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 24 Push the throttle button and push in the throttle to return the engine to idle 30 Part No 14 MAN 12 Rev 2 0709 E H Wachs Chapter 5 Operating Instructions Start Up and Operation 9 Toturn off the engine pull out the STOP handle Gm NOTE The STOP handle shuts off fuel to the engine and may take several
46. set at idle and both flow control levers are set at the minimum flow setting 26 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 e 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 1n Table 2 Table 2 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 Two Circuit Mode Operation This section describes how to operate the HPU in two cir cuit mode You can use both circuits at the same time and independently control the flow on each circuit You will also use this mode to operate a single 8 gpm 30 I min or 16 gpm 60 l min circuit Turn on flow only to the circuit you are using Connect the hydraulic hoses to the appropriate circuit connectors shown in Figure 3 17 Part No 14 MAN 12 Rev 2 0709 E H Wachs Chapter 5 Operating Instructions Start Up and Operation rw Circuiti2 pressure Circuit 1 pressure Circuit 1 return ircuit 2 return Figure 3 17 For operating in two circuit mode con nect h
47. tenance Troubleshooting Symptom Potential Cause Solution 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 Engine starts but will not stay running 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 E H Wachs Part No 14 MAN 12 Rev 2 0709 51 Tandem Pump Offshore Hydraulic Power Unit User s Manual Hydraulic System Symptom Potential Cause Solution 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 the reservoir until oil is visible in the sight glass No flow and no pressure on The suction strainer in the bot either hydraulic circuit 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
48. tion Chapter 5 Parts List and Ordering Information ORDERING INFORMATION To place an order request service or get more detailed information on any E H Wachs products call us at one of the following numbers U S and Canada 800 323 8185 International 01 847 537 8800 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 E H Wachs Part No 14 MAN 12 Rev 2 0709 In This Chapter ORDERING INFORMATION DRAWINGS AND PARTS LISTS 55 Tandem Pump Offshore 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 Warranty Information Enclosed with the manual is a warranty card Please fill out the registration card and return to E H Wachs Retain the owner s registration record and warranty card for your information Return Goods Address Ret
49. urn equipment for repair to the following address E H Wachs 600 Knightsbridge Parkway Lincolnshire Illinois 60069 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 56 Part No 14 MAN 12 Rev 2 0709 E H Wachs e Y A o gi Y a COOLER AND FILTER ASSY FUEL TANK ASSEM BLY NUT 1 4 20 NYLOCK BHC S 1 4 20 X 5 8 SS18 8 WASHER 1 4 FLATSS18 8 HHCS 3 8 16 X 1 S518 8 NUT 3 8 16 HEX SS18 8 WASHER 3 8 FLAT SS18 8 3 8 SPLIT RING SS18 8 NE CNN 08 073 4024 1 ENG INE ASSEMBLY 7 0807334403 1 nic E pe 0807000 1 WELDMENLFRAME 0807231755 1 TOPCOVERASY 08073357 2 1W2NPTPUG 08 073 400 1 FRONTPANEL 08 073 403 08 073 415 90 130 06 Z O cc U N LLI e gt cc LLI ca gt 2 Z cc lt a LLI E 9 90055060 10 11 9015553 10 12 90172110 4 13 9017501 4 14 90 17551 4 EE m 3 MUY ESSE Ss Eom XS CG HHCS 1 2 13 X 1 0 SS18 8 WASHER 1 2 FLAT S518 8 WASHER 1 2 LOCK SS18 8 15 9017552 4 WASHER 1 10 1 G JH AN CH De s sMm G rrra ra rV o Tandem Pump Offshore HPU 14 000 12 Main Assembly Z JO sINEWOYDS uu 1s
50. ydraulic hoses to both circuits as described 2 Set the flow mode lever to the right to use both circuits at 8 gpm 30 l min and 16 gpm 60 l min maxi mum Figure 3 18 Set the flow mode lever to the right to operate the two circuits independently 3 Hold in the throttle button while pulling the throttle Gm NOTE until the engine is running at maximum Release the button and turn the throttle locking ring clockwise to lock the throttle Typically you can run the engine at maximum throttle throttle pulled out to physical stop E H Wachs Part No 14 MAN 12 Rev 2 0709 27 Tandem Pump Offshore Hydraulic Power Unit User s Manual c A E i ind Figure 3 19 Pull out the throttle to set the engine speed You can turn the locking ring clockwise to lock the throttle position A 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 Flow gauges Circuit 1 up to 8 gpm Circuit 2 up to 16 gpm Figure 3 20 Set the flow control levers to the desired flows When the HPU is in two circuit mode you can adjust the flows separately 5 Monitor the hydraulic oil temperature gauge below the sight glasss on the front and back of the reservor 28 Part No 14 MAN 12 Rev 2 0709 E H Wachs Chapter 5 Operating Instructions Start Up and Operation If the temperature exceeds 180 F 82 C set the flow lever
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