HCM-OD Offshore Hydraulic Power Unit User Manual
Contents
1. E H Wachs Company 600 Knightsbridge Parkway Lincolnshire IL 60069 www wachsco com HCM OD Offshore Hydraulic Power Unit User s Manual E H Wachs Company Part No 14 MAN 10 Rev 2 1008 October 2008 Revision History Original October 2008 Copyright 2008 E H Wachs Company All rights reserved This manual may not be reproduced in whole or in part without the written consent of E H Wachs Company HCM OD Offshore Hydraulic Power Unit Part No 14 MAN 10 Rev 2 1008 E H Wachs Company Table of Contents Table of Contents Chapter 1 About the Offshore Hydraulic Power Unit 1 System Specifications a a ar er EN Be een 1 System Components nn ieee wee ene aed eens he 2 Chapter 2 Sale vices ho Fn se SG ei un neuen 7 Operator Safety 2 21 222 Done FROME ee Wee plea PDE na PEE RS 7 Safety Symbols ers eee ade ae end Rye bale ae oad danke eee ee 8 Protective Equipment Requirements ra ar AM 9 Safety Procedures ei N inate 9 Safety Labels u Art eee ee pe 11 Chapter 3 Operating Instructions ccc cece 13 Chapter 4 Parts List and Ordering Information 0 cc cece cece ce eeeees 17 Ordering Information u du eG bebe aa ieee per 17 Ordering Replacement P rls vermisste ee 17 Repair Information 2 2 42244 1 22 12422 Hl Sl be ua 17 Warranty Information eur we2. 1008 E H Wachs Company Chapter 2 Safety Operator Safety IMPORTANT This alert indicates a situation that if not avoided may result in damage to the equipment Protective Equipment Requirements WARNING Always wear impact resistant eye pro tection while operating or working near this equipment For additional information on eye and face protection refer to Federal OSHA regulations 29 Code of Federal Regula tions Section 1910 133 Eye and Face Protection and American National Standards Institute ANSI Z87 1 Occu pational and Educational Eye and Face Protection Z87 1 is available from the American National Standards Institute Inc 1430 Broadway New York NY 10018 CAUTION Personal hearing protection is recom mended when operating or working near this equipment Hearing protectors are required in high noise areas 85 dBA or greater The operation of other tools and equipment in the area reflective surfaces process noises and resonant struc tures can increase the noise level in the area For additional information on hearing protection refer to Federal OSHA regulations 29 Code of Federal Regulations Section 1910 95 Occupational Noise Exposure and ANSI 512 6 Hearing Protectors Safety Procedures All safety requirements listed below are those generally applicable to hydraulically powered machinery but are not intended to be an all inclusive list They are intended as guidelines only and wi
3. Rev 2 1008 HCM OD Offshore Hydraulic Power Unit 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 Company Retain the owner s registration record and warranty card for your information Return Goods Address Return equipment for repair to the following address E H Wachs Company 600 Knightsbridge Parkway Lincolnshire Illinois 60069 USA PARTS LIST The following table lists recommended service parts for the offshore HPU 18 Part No 14 MAN 10 Rev 2 1008 E H Wachs Company Chapter 4 Parts List and Ordering Information Parts List QTY DESCRIPTION Belt engine fan Cap dust hydraulic quick disconnect to fit male coupler Controller hydraulic flow Coupler hydraulic quick disconnect female wing Coupler hydraulic quick disconnect male no wing Coupler pneumatic crowfoot on starter Filter air engine intake Filter diesel fuel engine Filter oil engine Filter oil hydraulic Gasket water pump Gauge engine oil pressure Gauge engine water temperature Gauge hydraulic flow volume Gauge hydraulic pressure 3 kpsi Gauge thermometer hydraulic oil tank Hose air intake engine set of 2 w 4 clamps Hose fuel
4. 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 There is no safety labeling on the hydraulic power unit E H Wachs Company Part No 14 MAN 10 Rev 2 1008 11 HCM OD Offshore Hydraulic Power Unit 12 Part No 14 MAN 10 Rev 2 1008 E H Wachs Company Operating Instructions Chapter 3 Operating Instructions Perform the following checks before starting the HPU e Make sure the flow control lever is set to 0 e Make sure the engine oil is filled to the correct level e Make sure the engine coolant is filled to the correct level e Make sure the hydraulic tank is filled to the correct level e Make sure the suction shut off valve at the bottom of the tank is open e Make sure hydraulic hoses are securely connected to the HPU and to the tool you are operating e Make sure there is adequate fuel for the estimated oper ating time e Make sure the emergency shut off is pulled out 1 Attach a compressed air hose to the starter motor Be sure that the air supply is turned off Starter motor Starter fair connector Figure 3 1 Connect the air hose to the starter motor E H Wachs Company Part No 14 MAN 10 Rev 2 1008 HCM OD Offshore Hydraulic Power Unit Insert the safety locking pin to hold the air connector in pl
5. line out to engine Hose fuel line return Hose hydraulic bypass return Hose hydraulic pump discharge Hose hydraulic pump suction tank to pump Muffler Oiler pneumatic on starter Pin crowfoot connector w lanyard Plug dust hydraulic quick disconnect to fit female coupler Pully fan idler Pump hydraulic Pump water engine Spark arrester body engine exhaust Spark arrester disc engine exhaust Starter pneumatic Valve emergency shutoff engine air intake Valve hydraulic bypass HP 3 4 ball lever Valve pneumatic auto close starter PIP PIP IN JP IP IR IP IP TRIP Ir RP Ir IP IP IR IP IP IR IR IP IP TRIP IP IR Ir r JP IR IR IP IR E H Wachs Company Part No 14 MAN 10 Rev 2 1008 19 HCM OD Offshore Hydraulic Power Unit 20 Part No 14 MAN 10 Rev 2 1008 E H Wachs Company
6. 8 If you need to stop the tool immediately push in the emergency shut off on the engine shut the engine off immediately Q When you have completed the operation move the flow control lever back to 0 Shut the engine off using the stop lever under the throttle Figure 3 6 Push the stop lever to the left to shut off the engine 16 Part No 14 MAN 10 Rev 2 1008 E H Wachs Company Chapter 4 Parts List and Ordering Information Chapter 4 Parts List and Ordering Information ORDERING INFORMATION To place an order request service or get more detailed information on any E H Wachs Company 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 when ordering Repair Information Please call us for an Return Material Authorization number before returning any equipment for repair or fac tory service We will advise you of shipping and handling When you send the equipment please include the following information e Your name company name e Your address e Your phone number e A description of the problem or the work to be done In This Chapter ORDERING INFORMATION PARTS LIST E H Wachs Company Part No 14 MAN 10
7. PONENTS E H Wachs Company Part No 14 MAN 10 Rev 2 1008 HCM OD Offshore Hydraulic Power Unit e Approximate weight 1200 lbs 545 kg with fuel and hydraulic oil For detailed information on the diesel engine see the manu facturer s manual that is supplied with it SYSTEM COMPONENTS The following figures illustrate the components of the power unit Lift eye Hydraulic Fuel tank pump Hydraulic oil filter Diesel Hydraulic oil engine reservoir Frame with drip pan Figure 1 1 Major components of the hydraulic power unit Part No 14 MAN 10 Rev 2 1008 E H Wachs Company About the Offshore Hydraulic Power Unit System Components Emergency shut off push in Temperature oil pressure gauges Fuel filter Radiator and fan Figure 1 2 Major components on the front side of the diesel engine Muffler Air cleaner Oil filter Starter motor air Starter air connector Figure 1 3 Major components on the back of the die sel engine Some configurations have the air connec tor coming straight out rather than on a 90 elbow E H Wachs Company Part No 14 MAN 10 Rev 2 1008 3 HCM OD Offshore Hydraulic Power Unit Figure 1 4 Hydraulic fittings on the HPU Quick disconnects shown units can also be fitted with wing connectors Flow control lever Pressure gauge Figure 1 5 Hydraulic controls on the HPU The flow control lever is adjustable on a scal
8. ace Activate air supply pressure Put the flow control valve in the closed position and open the bypass valve on the pressure output to bypass the hydraulic circuit to the tank Flow control valve in closed posi tion Bypass valve in open posi tion Figure 3 2 The photo shows the flow control valve in the closed position and the bypass valve in the open position This is the configuration for starting the engine Pull the starter air supply handle to operate the starter and turn over the engine Release the handle as soon as the engine starts 14 Part No 14 MAN 10 Rev 2 1008 E H Wachs Company Operating Instructions Figure 3 3 Pull the starter handle to engage the starter motor When the engine starts release the han dle 5 Adjust the throttle on the engine for the desired work ing RPM 6 To operate the tool close the bypass valve on the pres sure output as shown in Figure 3 4 7 Move the flow control lever to the desired gpm i valve opened to desired flow level Bypass valve in closed position Figure 3 4 The photo shows the controls positioned for operating the HPU The bypass lever is closed and NOTE The recommended continu ous engine speed is 3000 rom maximum E H Wachs Company Part No 14 MAN 10 Rev 2 1008 15 HCM OD Offshore Hydraulic Power Unit the flow control lever is set to the desired flow level shown fully open in the photo
9. e of 0 to 10 Part No 14 MAN 10 Rev 2 1008 E H Wachs Company About the Offshore Hydraulic Power Unit System Components Figure 1 6 Hydraulic suction shut off valve shown in the open position Turn the lever perpendicular to the fitting to shut off hydraulic oil supply to the pump Figure 1 7 The hydraulic oil temperature fill level gauge is on the front of the reservoir E H Wachs Company Part No 14 MAN 10 Rev 2 1008 5 HCM OD Offshore Hydraulic Power Unit 6 Part No 14 MAN 10 Rev 2 1008 E H Wachs Company Chapter 2 Safety 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 e READ THE OPERATING MANUAL Make sure you understand all setup and operating instructions before you begin INSPECT MACHINE AND ACCESSORIES Before starting the machine look for loose bolts or nuts leaking lubricant rusted components and any other physical conditions that may affect operation Properly maintaining the machine can greatly decrease the chances for injury e ALWAYS READ PLACARDS AND LABELS sure all placards labels and sticke
10. ll assist in avoiding risk of injury when followed by qualified experienced personnel These E H Wachs Company Part No 14 MAN 10 Rev 2 1008 HCM OD Offshore Hydraulic Power Unit 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 IN sonnel are clear from the machin ery being operated before shutting down the HPU 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 hydraulic connections which may have been removed replaced or disconnected during shut down have been reconnected securely before starting hydraulic unit Before starting the unit perform all equipment checks described at the beginning of the operating instruc tions in Chapter 3 5 there are tools or machinery being operated by the HPU that may move when hydraulic flow or pressure are turned off block or lock these parts in
11. 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 e a hydraulic line failure either with the unit running or shut down pump or motor failure e movement of machine components during normal oper ation or resulting from a component malfunction or fail ure 8 Avoid locating equipment in any environment for which it was not designed and which may create a dangerous operating condition such as an explosive 10 Part No 14 MAN 10 Rev 2 1008 E H Wachs Company Chapter 2 Safety Safety Labels 10 11 atmosphere e g gas dust high heat e g molten metal furnace chemicals extreme moisture etc Avoid bodily contact with such fluids Some hydraulic fluids may be irritating or injurious to the eyes and skin Check with your fluid suppliers to obtain this information Use only E H Wachs parts and materials when servic ing the equipment Substitute parts or materials could produce a hazardous operating condition When piping your equipment use only materials of adequate size
12. r ei Hirte see 18 Return Goods Address an nal neben 18 Parts DASE tw wae el Bae ne ee Bee Rae 18 E H Wachs Company Part No 14 MAN 10 Rev 2 1008 1 HCM OD Offshore Hydraulic Power Unit ii Part No 14 MAN 10 Rev 2 1008 E H Wachs Company About the Offshore Hydraulic Power Unit Chapter 1 About the Offshore Hydraulic Power Unit The HCM OD is a rugged skid mounted hydraulic power unit designed to operate Wachs offshore cutting machinery and other hydraulic equipment It features a diesel engine with air starter and disk type spark arrestor and provides 15 gallons per minute gpm flow output at 1500 psi 57 at 103 bar The unit has adjustable flow control with built in relief valve and flow meter SYSTEM SPECIFICATIONS e Kubota D905 diesel engine 23 HP 3600 rpm e Air start Dry air cleaner e 7 5 gallon diesel fuel tank e Disc type spark arrestor 40 gallon hydraulic tank 3 4 NPT female pipe ports fitted with quick discon nects matched at factory with purchased accessories 20 gpm 1250 psi 76 lpm 86 bar hydraulic output at 3000 rpm recommended operating speed Inline flow meter e 0 3000 psi 207 bar pressure gauge e Steel tubular frame with drip pan e Centralized lifting eyes e Approximate dimensions height 46 1168 mm length 60 5 1537 mm width 32 813 mm In This Manual SYSTEM SPECIFICATIONS SYSTEM COM
13. rs 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 In This Chapter OPERATOR SAFETY SAFETY LABELS Look for this sym IN bol throughout the manual It indicates a personal injury hazard E H Wachs Company Part No 14 MAN 10 Rev 2 1008 HCM OD Offshore Hydraulic Power Unit 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 e KEEP WORK AREA CLEAR Keep all clutter and nonessential materials out of the work area Only people directly involved with the work being performed should have access to the area Safety Symbols A This icon is displayed with any safety alert that indicates a personal injury hazard Z WARNING This safety alert indicates a potentially hazardous situation that if not avoided could result in death or serious injury Z 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 10 Rev 2
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