WPI WELLKIN 30000-S HDPU Guide

Model 30000-S DHPU
Casing and Tubing Tong Diesel Hydraulic Power Unit
Installation, Operation, Service and Parts Book Manual
WPI WELLKIN Inc.
8401 Industrial Dr.
Pearland, TX 77584
PH: [phone]
FX: [phone]
E-mail: [e-mail]
Web: www.wpiwellkin.com

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Terms and Conditions
1. All WPI WELLKIN packing slips and invoices must show Buyer's purchase order number.
2. All shipments MUST contain packing slips.
3. CONTRACT: This order will become a binding contract upon receipt by WPI WELLKIN of Buyer's
PO, receipt by Buyer of a written acknowledgement by WPI WELLKIN and receipt by WPI WELLKIN of a
down payment in the amount specified in the contract.
4. This contract may be modified as mutually agreed by the Buyer and WPI WELLKIN.
5. PAYMENT TERMS: The payment terms are specified on the commercial offer from WPI
WELLKIN. The Buyer agrees to the payment terms by acceptance of the bid.
6. DELIVERY: Time is of the essence. WPI WELLKIN will attempt to deliver the material early if
possible. WPI WELLKIN will make best efforts to supply all material on a timely basis. If the delivery
will run over the contract delivery date, WPI WELLKIN will notify the Buyer giving reason for delay.
The current delivery estimate is specified on the commercial offer. The Buyer agrees to the delivery
terms by acceptance of the bid.
When necessary, WPI WELLKIN will notify the Buyer in advance of completion of the order and Buyer
will appoint an authorized representative or employee to inspect the material on a date and site as
designated by WPI WELLKIN. Transportation, lodging and all other expenses portal to portal for Buyer
representative or employee to witness and accept the material is the expense of the Buyer.
All costs associated with preparation, crating, insurance and ocean freight of the goods to the final
destination to be at Buyer's expense.
7. CANCELLATION: This contract is considered to be special order and not subject to cancellation.
Both parties hereto shall be given consideration in case of delays in delivery caused by fire, strike, riot,
war, act of God, delay of carriers, governmental order or regulation, complete or partial shutdown of
plant by reason of inability to obtain sufficient raw materials or power or any other similar or different
contingency beyond the reasonable control of the respective parties.
8. WARRANTIES AND REMEDIES: WPI WELLKIN expressly warrants that all supplies, materials and
parts covered by this contract will conform to the specifications in the contract as applicable and will
meet or exceed industry standards for such equipment. WPI WELLKIN will supply Buyer with
operations manuals and parts books for the material where applicable. Certificates of Compliance are
available upon request.
MANUFACTURED ITEMS: WPI WELLKIN manufactured items must be free of material and
workmanship defects for a period of 12 months from the date of delivery. If any items fail
because of a manufacturing defect within that period of time, then that item will be replaced by
WPI WELLKIN. Expendable / wear items are not covered under warranty. Examples of such
items include, but are not limited to, the following - dies, inserts, brake bands, rollers, gears,
chains, filters, belts, flexible couplings, slip bodies, spider bowls.

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Replacement of parts will be accomplished at WPI WELLKIN's facility or at a designated service
point. WPI WELLKIN's liability is limited to replacement of defective parts only and does not
include the cost of labor, communications, transportation or handling connected to the
replacement of these parts. WPI WELLKIN will in no event be liable for consequential damages
or contingent liabilities arising out of the failure of any parts to operate properly. No expressed,
implied or statutory guarantee other than herein set forth is made or authorized to be made by
WPI WELLKIN.
DISTRIBUTED ITEMS: Items distributed by WPI WELLIN are subject to the warranty provided by
the Original Equipment Manufacturer (OEM). Upon request, WPI WELLKIN will furnish Buyer
with a warranty statement from the OEM for the applicable material. The OEM warranty will
start on the items' delivery date.
9. COMMISSIONING: On request, WPI WELLKIN can supply a representative for material
commissioning. The Buyer is responsible for portal to portal transportation costs and the current WPI
WELLKIN day rate.
10. BUYER’S PROPERTY: All equipment or material furnished by WPI WELLKIN shall be the
property of the Buyer after the WPI WELLKIN invoice is paid in full.
11. PATENTS: WPI WELLKIN holds the Buyer harmless from all claims, for infringement or alleged
infringement of any patents arising out of the sale or use of the goods furnished pursuant to this
contract.
12. INDEPENDENT CONTRACT: In the event that any goods ordered hereunder require in
connection with the installation thereof, the services of a contractor engaged by WPI WELLKIN or a
supervisor, engineer, or other employee connected with or employed by WPI WELLKIN, and WPI
WELLKIN agrees to furnish same, either with or without charge, such contractor, supervisor, engineer,
or other employee in performing such services shall not be deemed to be the agent or employee of the
Buyer.
13. INSURANCE: WPI WELLKIN agrees to carry General Operations and Liability Insurance and
other coverage as required in accordance with applicable state and federal laws of the U.S.A.
14. COMPLIANCE WITH LAWS: WPI WELLKIN warrants that in its performance of this contract it
will comply with all applicable Federal, State and Local laws, regulations, rulings and orders of the U.S.A.
15. ASSIGNMENT: This contract may not be assigned without the written consent of the Buyer and
any attempted assignment thereof shall be void.
16. PROPRIETARY INFORMATION: All plans, drawings, specification and the subject matter
contained therein and all other information given to WPI WELLKIN in connection with performance on
this Purchase Order involve valuable property rights of the Buyer and shall be held confidential by WPI
WELLKIN, shall remain the property of the Buyer and shall not be used by WPI WELLKIN for any
purpose other than those for which they have been prepared or supplied. WPI WELLKIN agrees that, as
far as possible, it will keep confidential the making of this order and the terms hereof. WPI WELLKIN
agrees not to use for publicity purposes any information as to notice of receipt of order, photographs,
drawings and/or materials in connection with performance of the Order without obtaining the prior
written consent of the Buyer.

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Table of Contents
Terms and Conditions...........................................................................................................................................................2
Warnings....................................................................................................................................................................................5
General Information ..............................................................................................................................................................7
Transportation and Installation........................................................................................................................................8
Operation................................................................................................................................................................................12
Appendices.............................................................................................................................................................................27
List of Figures
Figure 1: Transportation Points .......................................................................................................................................8
Figure 2: Engine Motor Oil ...............................................................................................................................................10
Figure 3: Engine Fuel Tank and Filters .......................................................................................................................10
Figure 4: Hydraulic Tank Level Gauge and Fill Location......................................................................................11
Figure 5: Quick Disconnects and Ball Valves Location..........................................................................................12
Figure 6: Control Panel......................................................................................................................................................13
Figure 7: Hydro-Throttle ..................................................................................................................................................14
Figure 8: Spring Starter.....................................................................................................................................................15
Figure 9: Engine Exhaust Components and Over Speed Shutdown.................................................................16
Figure 10: System Relief and Pump Sequence Valves...........................................................................................18
Figure 11: Heat Exchanger and Pump .........................................................................................................................19
Figure 12: Heat Exchanger Valves ................................................................................................................................20
Figure 13: Suction Strainer and Return Filter..........................................................................................................20
Figure 14: Shut Down Lever............................................................................................................................................21
List of Tables
Table 1: Troubleshooting the Power Unit Engine...................................................................................................22
Table 2: Troubleshooting the Power Unit Hydraulic Circuit..............................................................................24
Table 3: One Year Spares..................................................................................................................................................27

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Warnings
The Diesel Hydraulic Power Unit (DHPU) design integrates several safety features. However, the
power unit is only as safe as the operator using it. Therefore, it is imperative that the operator and
all other workers around the power unit observe the warnings below as well as read and
understand this manual. Failure to follow the instructions could result in death, serious injury or
equipment damage. The manufacturer is not responsible for any damages resulting from misuse
of the equipment. The risks and consequences of misuse are the responsibility of the user.
Observe, understand and follow all safety warnings.
This power unit is built strictly for generating hydraulic power for casing or tubing
tongs. Any use of the power unit contrary to the design is absolutely prohibited.
Never operate the power unit above the rated design pressure or engine speed.
Always check the pressure setting of the power unit before operating to prevent
equipment damage.
Never add, remove or convert equipment on the power unit without prior consent.
Never defeat or remove any of the power unit's integral safety features.
If a leak is observed, then halt the operation of the power unit and repair the leak
immediately.
Use the recommended interconnects hose size with the proper pressure rating.
Keep all body parts and clothing away from moving machinery.
Only trained personnel should operate, adjust or repair this equipment. No weld
repair on any components is allowed. Any attempts to repair these items by
welding will void all warranties and liability.
Use industrial safety regulations for proper ventilation of potentially poisonous
exhaust fumes when operating the power unit in a confined or enclosed space.
Prior to servicing the unit (maintenance, repairs, valve adjustment, etc.), shut down
and disconnect or kill power to the unit. Then, disconnect the hydraulic connections

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from the power unit before performing any service. Allow the engine to cool down
before working around it to make repairs.
All personnel working around the power unit shall wear protective clothing
including but not limited to the following.
oHard hat
oEye protection
oSafety boots with steel toe
oSafety gloves
oEar protection
oCoverall
Never use excessive force when coupling the wing style quick disconnects to the
system.
Never disconnect any hose on the power unit when it is in operation. All hoses must
be pressure free before they are disconnected.
Use only the identified areas on the power unit for lifting the unit. Ensure that any
lifting equipment is rated for the power unit weight, and all equipment used in lifts
should be current with its inspection paper work.

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General Information
Description
The model 30000-S DHPU is an open frame type power unit designed to provide hydraulic
power to an open center circuit such as a casing tong, tubing tong or other open centered
circuits. The unit is self contained.
The DHPU is powered by an air cooled, 6 cylinder Deutz diesel engine. Attached to the
engine is a two section gear pump. Both sections provide fluid power for the casing circuit.
When the tubing tong circuit is active, fluid power only comes from one section of the gear
pump. There is an auxiliary hydraulic pump mounted on the engine to provide power for the
heat exchanger motor. Also included within the unit are the following items.
Instrument panel with engine speed, oil temperature and oil pressure
Spring start
Safety package with automatic over speed shutdown, emergency manual air intake
shutdown and spark arrestor
Shutdowns for low oil pressure, high oil temperature and fan belt break
30 gallon diesel reservoir with level gauge, drain port and filler breather
Hydraulic throttle
System relief valve set at 3000 PSI
Air/oil heat exchanger with hydraulic motor
100 gallon hydraulic reservoir with baffle, level gauge, oil temperature gauge,
cleanout cover, suction strainer with isolation ball valve, return filter, return pressure
gauge, drain port with ball valve and filler breather
Panel with 0 to 5000 PSI pressure gauges, control valves for standby/work and
casing/tubing modes
Oilfield type base skid with drip pan, drain ports, fork lift pockets and drag bar
Lift cage with hose basket
Aluminum box for small parts and tool storage
Specifications
Fluid Power
Tubing tong circuit 3000 PSI @ 30 GPM (207 bar @ 113 LPM)
Casing tong circuit 1500 PSI @ 60 GPM (103 bar @ 227 LPM)
Weight
Dry (Without fuel and hydraulic fluid) 4000 lbs (1814 Kg)
Wet (With fuel and hydraulic fluid) 4900 lbs (2223 Kg)
Connections (5100 Series wing style disconnect)
Pressure 1" Male
Return 1-1/4" Male
Dimensions
Length 120" (3048.0 mm)
Width 48" (1219.2 mm)
Height 62" (1574.8 mm)

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Transportation and Installation
Before any attempt is made to operate the power unit, the following section should be read,
understood and then followed.
Transportation
The power unit has several options for transportation as demonstrated in the picture below.
No special regulations apply to the transportation of the power unit.
Figure 1: Transportation Points
Lift Eyes
The power unit is designed to be lifted by the four lift eyes on top of the hose basket. When
lifted, a sling with four legs is required, and the sling must, at a minimum, be rated for the
gross weight of the power unit. The lifting equipment should also be inspected to ensure it is
in adequate condition. Normal rules and safety precautions apply when lifting the unit.
Drag Bars
Drag bars are located on each end of the power unit for conventional dragging of the unit on
and off of a flat bed truck.
Forklift Pockets
Incorporated into the base skid are two forklift pockets. Ensure the forklift used to lift the
unit has long enough forks to span the entire width of the pocket and is rated to lift the unit.
Hose Basket
The hose basket provides a storage area for the hydraulic hoses as well as spare
components.

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ID Tag
Each unit has an identification tag installed on the skid. Use the ID tag information (weight,
model, serial number, etc.) for transportation documentation.
Installation
Once the power unit is on location, then the installation process gets the unit ready for
operation.
Location of the Unit
Remember the following points when positioning the power unit for installation.
The physical space required for the unit is detailed in the general specifications page.
Consideration should also be given for access around the power unit for startup
procedures and maintenance activities.
The power unit should be located on an area that is relatively flat. Installing the unit
on an incline could adversely affect the fluid levels of the motor oil and hydraulic
fluid.
Also, take into account the location of the power unit to keep it as close as possible to
the equipment in order to reduce pressure losses in the line. Pressure losses from
long hose lengths can reduce the system performance and generate significant heat.
Ensure the exhaust and intake air paths are unobstructed. The engine exhaust should
be directed towards a well ventilated area and pointed away from any operator
positions.
If located near an operator, then proper safety equipment such as ear protection
should be worn by all personnel near the unit.
The diesel power unit incorporates several safety devices. However, this combustion
engine driven power unit is neither designed nor certified as an explosion proof
system.
The unit will require diesel fuel, engine oil and hydraulic fluid to be added or
removed during operation or maintenance. Take precautions when adding new
fluids to avoid spills and dispose of used fluids according to the applicable local
environmental laws.
Engine System Inspection
Examine the following areas on the diesel engine after the unit is in its final position. Do not
inspect the engine while it is running. Review the included engine manuals for detailed
instruction.
With the power unit on level terrain, check the motor oil level using the dipstick. The
level should be between the minimum and maximum marks. Add motor oil to the
inlet if the level is below the minimum mark. Refer to the engine manual for the type
of motor oil required. As a general rule, use SAE 10W-30 motor oil for average
ambient operating temperatures below 45°F (7°C), SAE 15W-30 for 45° to 85°F (7° to
30°C) operation and SAE 15W-40 for operation above 85°F (30°C). If the oil level is
above the maximum mark, then drain the motor oil level out of the outlet.
It may be necessary to purge the fuel system from air that may have been introduced
during transportation, during repair/maintenance work or if the system ran until the
fuel tank was empty. If air bubbles are in the fuel system, the power unit will have

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difficulty running or may not run at all. See the figure below for the location of the
priming pump. Reference the engine manual for procedures to bleed the fuel system.
Figure 2: Engine Motor Oil
Check the fuel level in the diesel tank. Add fluid through the fluid fill port.
Commercial grade diesel fuel should be used. Refer to the engine manual for details
on summer or winter grades of diesel fuel. When filling the tank, do not spill any fuel
and avoid letting contaminants enter the tank. The following photo shows the fuel
tank location.
Refer to the engine manual for service and maintenance schedules for the motor fuel
filter and oil filter. These filters ensure the purity of the fuel and oil reaching the
engine systems. If necessary, then replace the filters per the instructions in the
manual prior to operation.
Figure 3: Engine Fuel Tank and Filters

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Remove all debris and coarse dust from the collector prior to starting the engine. The
previous photo shows the location of the dust collector. Review the service and
maintenance section of the engine manual for further instructions.
Check the oil condition and level in the oil bath air cleaner. If the oil needs
replacement, then follow the instructions for cleaning and replacement in the engine
manual. The cleaner is detailed in the previous photo.
Hydraulic System Inspection
The following steps review the hydraulic system to ensure it is ready for operation.
Check the fluid level of the hydraulic tank. For operation, the fluid level should be
seen in the level gauge as detailed in the following photo. If the level is low, then add
hydraulic fluid through the filler/breather until the level reaches the top of the level
gauge. When the filler/breather cap is removed, take care to avoid the passage of
contaminants into the hydraulic reservoir. A premium hydraulic fluid is
recommended for use such as Shell Tellus® 32 for average ambient operating
temperatures below 45°F (7°C), Shell Tellus® 46 for 45° to 85°F (7° to 30°C)
operation and Shell Tellus® 68 for operation above 85°F (30°C).
The level gauge has a built in thermometer that displays the temperature of the oil in
the reservoir. The power unit should not be operated when the oil temperature is
above 160°F (71°C).
Open the louvers on the heat exchanger prior to operation. They are closed for
transport to protect the heat exchanger core.
Figure 4: Hydraulic Tank Level Gauge and Fill Location
Ensure the suction line ball valve is in the open position. Starting the unit with the
ball valve closed will cause serious damage to the hydraulic pump. The ball valve is
mounted on the suction port of the tank.

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Verify the interconnect hoses or piping is adequate for the maximum flow generated
from the power unit. Undersized lines will lead to a buildup of heat and a decrease in
system performance. A hose set can be purchased separately with connectors
matching the power unit installed.
For quick installation and to reduce spills on connection, the power unit is equipped
with quick disconnects. Never connect or disconnect the lines when the power unit is
running. Before connecting the quick disconnects to the unit, ensure that the faces of
the connectors are free from debris. Remove any particles with a lint free rag. Dust
plugs and caps are included with the connectors to prevent contamination during
transportation and storage. Connect the pressure and return lines using the quick
disconnects. The connectors are threaded with a wing style construction. Full thread
engagement must be met before the integral check valve in the connector is forced to
open. The following photo shows the location of the pressure and return quick
disconnects.
Figure 5: Quick Disconnects and Ball Valves Location
Operation
The DHPU is a simple unit that provides pressure and flow for an open center hydraulic circuit such
as a tong. This unit is not intended to work in conjunction with closed center valves. Closed center
valves have the pressure port blocked in the neutral position. Heat builds up in the system quickly
as the full flow of the system is dumped over the system relief since the flow cannot return to tank
through the valve.
The prime mover for the hydraulic pump is the diesel engine. The engine rotates the pump shaft at
the speed selected and the torque output is dictated by the load on the pump. This model has two
fixed displacement gear pumps coupled to the engine. The first gear pump has two sections and
provides hydraulic power to the open centered circuit. The other single section pump's purpose is
to supply power to the heat exchanger's motor. It is mounted on the engine's auxiliary pad.

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The following sequences assume the necessary installation steps have been completed, and the unit
is ready for start up.
Modes
The DHPU has the following modes of operation. Ensure the arrow on the selector handle
aligns with the black lines on the panel when changing modes as shown in the picture.
Standby Mode
When the ball valve is in the standby position, the flow from the pump is diverted back to
tank bypassing the tong circuit. The unit can also be placed in standby mode when long
breaks are expected in operation. Oil still flows through the heat exchanger, but the unit will
generate less heat because flow is at zero pressure instead of the loop's back pressure.
Tubing Mode
The power unit should be in tubing mode when started or when a tubing tong is to be
operated. In this mode, flow from the rear section of the pump is diverted internally in the
pump back to the suction port allowing only the front section to provide flow to the circuit.
The maximum pressure allowed in the circuit is dictated by the relief valve mounted directly
on the pump. Tubing mode provides lower flow but higher pressure than casing mode.
Figure 6: Control Panel

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Casing Mode
The power unit should be in casing mode when a casing tong is to be operated. Casing mode
allows both pump sections to contribute flow to the hydraulic circuit, so a higher flow at a
lower pressure is available. Once the load on the system increases past a factory preset
point, the rear section of the pump is shifted out of the circuit and circulates fluid internally
(tubing circuit mode). Therefore, less flow leaves the pump, but the maximum pressure that
can be achieved is higher. This high/low feature allows for faster use of the casing tong with
light loads while still providing high pressures for making/breaking of the connection.
Idle Mode
The power unit is equipped with a hydro-throttle as shown in the figure below. When the
system pressure exceeds the set point, the internal piston will extend thereby increasing the
motor speed. The cylinder is pushed back by the spring when the pressure drops back down
below the set point putting the engine into an idle mode to lower the motor's fuel
consumption. The set pressure is typically set around 500 to 800 PSI. This setting should be
higher than the back pressure experienced through the interconnect hoses and tong valve in
neutral. The setting can be adjusted if the back pressure is higher or lower. Refer to the
hydro-throttle cut sheet in the engine section.
Figure 7: Hydro-Throttle
Start Up
Ensure that the installation section has been followed and that the tong control valve handle
is in neutral. Review the included engine operation and Murphy panel manuals also prior to
operation. Make sure that the fan belt break trip lever and the Sentinel are reset. The
function of the Sentinel is described in the safety features section. To reset the valve, turn
the trip lever to clockwise. Refer to the previous picture for the location of these
components.

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The engine is equipped with a spring starter. Review the complete starter instructions
found in the engine section. In brief, to start the power unit:
Put the standby/work ball valve in the standby position.
Wind the crank handle in a clockwise direction until white or red springs are visible
through the inspection window (white = warm engine, red = cold engine).
Pull the trip lever to start the engine.
Repeat the above steps if the engine does not start. Pull the reset knob before turning
the crank handle. It could take 3 attempts to get the engine started.
Turn the standby/work ball valve to the work position.
Figure 8: Spring Starter
Observe the engine speed, oil temperature and oil pressure gauges. The engine speed will be
approximately 1400 RPM when the unit is in idle mode and 2100 RPM otherwise. Consult
the engine manual for acceptable ranges for the oil temperature and pressure.
Observe the oil pressure gauges. The system pressure gauge (located on the control panel)
will show a low value when the hydraulic oil is circulating directly back to tank. Higher
pressure readings will only occur when the tong is operated. Check the pressure gauge on
the return filter assembly at start up. As the filter collects more debris, then the pressure
drop across the filter increases. If the indicator on the pressure gauge is in the red area, then
the return filter element needs replacement.

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Safety Features
The power unit is equipped with several safety features, which are explored in more detail in
the following sections.
Engine Silencer
The exhaust from the engine is routed through a silencer (muffler) to reduce the engine
noise. See the location of the silencer in the picture below.
Engine Spark Arrestor
After the silencer, the exhaust is routed through a spark arrestor. The spark arrestor, as
seen below, uses centrifugal force to separate solids from exhaust gas. The manufacturer
recommends inspecting and cleaning out the spark arrestor every 1000 operating hours or
three times per season, whichever time period is less. The inspection should include a visual
check for holes, cracks or metal corrosion. If any of the above conditions are found, then
replace the spark arrestor. Also, ensure the mounting clamp is securely tightened.
The spark arrestor and exhaust are wrapped with a thermal blanket to help prevent the
operator from accidentally touching the unit during operation. This area should not be
touched even though it contains this safety precaution.
DO NOT SET TOUCH THE EXHAUST SYSTEM COMPONENTS DURING OPERATION OF
THE POWER UNIT AS IT HEATS UP TO DAMAGING TEMPERATURES. THIS HEAT IS
RETAINED EVEN AFTER THE POWER UNIT IS TURNED OFF. VERIFY THE UNIT IS COOL
BEFORE WORKING AROUND THE EXHAUST SYSTEM.
Figure 9: Engine Exhaust Components and Over Speed Shutdown
Over Speed Shutdown
If the unit over speeds during a runaway condition such as the intake of gas, then the unit
will automatically shut down when the speed exceeds the factory setting of 2400 RPM. The
engine should not be restarted again until the area is declared safe for operation. The
location of the over speed shutdown is shown in the previous photo. For maintenance and
setting instructions, review the over speed shutdown manual.

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Emergency Stop Manual Shutdown
The unit has an emergency stop manual shutdown. Pulling and holding the handle, detailed
in the control panel photo, closes off the air intake to shut the engine down. Use this method
for emergency situations, not for routine operation. The engine should not be started again
until the area is declared safe for operation. The proper way to stop the unit is detailed in
the shut down section.
Fan Belt Break
If the fan belt breaks on the engine, the ruptured piece will trip a spring loaded bar that is
connected to the engine fuel injection pump control rod. Once tripped, the engine
immediately stops. This safety feature prevents the motor from overheating if the cooling
fan stops turning due to a belt break. See the Hydro-Throttle figure for the location of the
spring loaded bar.
Low Oil Pressure/High Oil Temperature Shutdown
The power unit is set to shut down if the oil pressure gets too low or if the oil temperature
gets too high. The Sentinel diesel protection system valve controls the when the engine is
shut down by cutting off the fuel. The location of this valve is seen in the Hydro-Throttle
figure. For more information, refer to the cut sheet in the engine section of the manual.
System Relief Valve
The system hydraulic pressure relief valve (RV-1 on the hydraulic schematic) is shown in the
following photo. This valve limits the maximum pressure from the power unit hydraulic
pump. It is factory set to relieve at 3000 PSI. To adjust the valve setting, loosen the jam nut
at the bottom of the valve stem. Turn the knob clockwise to increase the pressure setting
and counter clockwise to reduce the setting. Lock the jam nut back down after adjusting the
valve setting. To develop pressure in the circuit, either the tong needs to grip and stall on a
tool joint or the pressure line can be removed at the quick disconnect (while the unit is off).
DO NOT SET THE RELIEF VALVE HIGHER THAN THE POWER UNIT DESIGN PRESSURE
OR THE ALLOWABLE PRESSURE TO THE COMPONENTS.
Components
The following sections will explain the major components in the hydraulic system to help the
user familiarize themselves with the operation of the power unit. Examine the hydraulic
schematic in conjunction with the text below. The assembly drawings will also help identify
the physical locations of the components.
Hydraulic Pump
In the schematic, the hydraulic pump is referenced by HP-1. The pump is a fixed
displacement gear pump with two sections, which is connected to the motor (DM-1) using a
pump adapter (PA-1) and pump coupling (PC-1). The pump has an integral high/low circuit
as previously discussed. The valve is factory set at 1500 PSI (103 bar) and should not be

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adjusted in the field. However, the following procedure can be used to set a replacement
cartridge in the field.
DO NOT ATTEMPT TO ADJUST THE PUMP SEQUENCE VALVE WHILE THE UNIT IS
RUNNING.
DO NOT INCREASE THE SEQUENCE VALVE SETTING PAST 1500 PSI.
Figure 10: System Relief and Pump Sequence Valves
The pump's sequence valve can be seen in the previous picture. With the unit off, remove
the cap from the end of the cartridge stem. To adjust the valve setting, loosen the jam nut on
the cartridge valve stem. Turn the screw clockwise to increase the pressure setting and
counter clockwise to reduce the setting. Lock the jam nut back down after adjusting the
valve setting. Upon completion, tighten the cap back onto the cartridge stem.
To check the valve setting, block the pressure port by disconnecting the pressure line at the
quick disconnect. Loosen the jam nut on the system pressure relief valve (RV-1). Lower RV-
1's pressure setting all the way by turning the set screw counter-clockwise. Next, start the
power unit. Increase the system pressure by turning the RV-1 set screw clockwise. Around

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1500 PSI, the pump should shift from high flow to low flow. If it does not shift at 1500 PSI,
then shut down the power unit and repeat the adjustment on the HP-1 sequence valve.
Continue this trial and error method until the correct setting is achieved. The maximum
valve setting is determined by the maximum power the motor can deliver. Increasing the
valve setting would increase the required torque from the motor at a higher flow (more
power); raising it too high would cause the motor to stall.
Relief Valve
A relief valve (RV-1) is directly bolted onto the pump's output. This valve limits the
maximum pressure on the circuit as mentioned in the system's safety feature section.
Heat Exchanger and Heat Exchanger Hydraulic Pump
The unit incorporates an air over oil heat exchanger (HX-1) driven by a hydraulic motor.
The heat exchanger always runs as long as the power unit motor is running. The hydraulic
pump (HP-2) for this circuit is mounted on the motor's auxiliary pad as shown below.
Figure 11: Heat Exchanger and Pump
Heat Exchanger Motor Flow Control Valve
Flow to the heat exchanger hydraulic motor is limited by the control valve (FCV-1) shown in
the following photo. This valve keeps the speed of the heat exchanger fan constant no
matter if the engine is at full or idle speed. This valve is non-adjustable.
Heat Exchanger Motor Relief Valve
The pressure on the heat exchanger hydraulic motor is restricted by the relief valve (RV-2).
This valve is set during the initial test and should not be adjusted in the field.

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Figure 12: Heat Exchanger Valves
Suction Strainer
The suction strainer (STR-1) is mounted inside the reservoir. The strainer filters the
hydraulic fluid going to the pump inlet.
Return Filter
Before fluid reenters the reservoir, it passes through the return filter (FL-1).
Figure 13: Suction Strainer and Return Filter
Shutdown
The proper way to stop the engine is to rotate the shut down lever on the fuel injection
governor by pushing it towards the spring on the fan belt break trip lever. Closing the valve
cuts off the fuel from the engine and immediately stops it. Ensure the following prior to shut
down.