DLS

An Archer Company

200 HP Catwalk HPU

Electric Driven Hydraulic Power Unit
Operation & Maintenance Manual
Serial Number 005102

Power Hydraulics, LLC.

133 N Goodman Rd
Lake Charles, LA 70615
Phone: (337) 436-6014
Fax (337) 436-6441
www.power-hydraulics.com
 TABLE OF CONTENTS

TABLE OF CONTENTS ................................................................................................................... 2

GENERAL DESCRIPTION .............................................................................................................. 3
SAFETY NOTICE ............................................................................................................................. 4
WARNINGS ...................................................................................................................................... 4
SPECIFICATIONS ............................................................................................................................ 5
CONTROLS & INDICATORS ......................................................................................................... 5
START UP PROCEDURES .............................................................................................................. 6
OPERATING INSTRUCTIONS ....................................................................................................... 7
HYDRAULIC OIL SPECIFICATIONS.......................................................................................... 10
HYDRAULIC MAIN SUPPLY VALVES ...................................................................................... 11
PREVENTIVE MAINTENANCE................................................................................................... 12
SERVICE PROCEDURES (FLUID & FILTERS).......................................................................... 14
LIFTING THE UNIT ....................................................................................................................... 17
TROUBLESHOOTING ................................................................................................................... 18
HYDRAULIC SYSTEM SCHEMATIC DIAGRAM ..................................................................... 19
PART IDENTIFICATION .............................................................................................................. 20
WEG MOTOR ―A‖ SCHEMATIC ................................................................................................. 21
WEG MOTOR ―B‖ SCHEMATIC .................................................................................................. 22
SCHEMATIC 1 ............................................................................................................................... 23
SCHEMATIC 2 ............................................................................................................................... 24
SPARE PARTS LIST ...................................................................................................................... 25
ELECTRICAL SCHEMATIC ......................................................................................................... 26
NOTES ............................................................................................................................................. 27

2
 GENERAL DESCRIPTION
This manual describes the function, operation, and maintenance of the Power Hydraulics Model
PH-ELEC-100 hp-Tandem-HPU. This Tandem 100 hp Electric Drive Hydraulic Power Unit is
comprised of the following systems and components:

Electric Motor System:

Tandem 100 hp electric motors with independent start/stop controls, and 10 hp cooler fan
motor and 1½ hp offline loop pump. The cooler fan and offline loop pump motors are
synchronized to start and stop with the 100 hp motors.

Hydraulic System:
Pressure compensated, variable volume, stroke limited—50 gpm pumps
Fixed displacement gear pump—30 gpm
Large capacity industrial oil cooler
400 gallon hydraulic reservoir and filtration system

Skid System:
6-Post, certified, removable, lift frame and bottom skid

Specifications:
Dimensions: Length 144.5‖ x Width 74‖ x Height 93‖ (3.67m L x 1.88m W x 2.36m H)
Weight (WET): 13,420 lbs (6,087 kg)
(DRY): 10,120 lbs (4,590 kg)

Cooling Fan

Hydraulic Fluid Reservoir

Motor

Control Panel

3
SAFETY NOTICE
Safety based on technical skill and years of experience has been carefully built into the Power
Hydraulics Model PH-ELEC-100hp-Tandem-HPU. Time, money and effort have been invested in
making this unit a safe product. The dividend realized from this investment is your own personal
safety.

It should be remembered, however, that power-driven equipment is only as safe as the person who
is at the controls. As the operator of this equipment, you are urged to observe the following rules:

 Do not exceed the maximum pressure for which the system is rated.
 Keep loose fitting clothing away from the rotating parts of the unit.
 Inspect all hanging brackets, lines, etc. to be sure they secure and tight before starting
up the unit.
 Inspect all of the above periodically during the operation.
 Do not stand at the unit during operation.
 Do not operate the unit with the relief valve set to cause the unit to exceed the 3000 psi
maximum operational setting of the control panel.
 Do not operate the unit if any unsafe conditions are present.

WARNINGS
Do not operate the unit until all warnings have been read and understood.

Power feed supply must be shut off before any maintenance is performed. Failure to follow this
warning can result in severe personal injury.

Do not operate unit unless all cover plates, guards, brackets, and pins are in place and positively
secured. Failure to comply with this warning could result in severe personal injury.

Do not stand on unit while unit is in operation. Failure to comply with this warning could result in
severe personal injury including loss of limb or death.

Keep hands and loose clothing away from any moving parts while unit is in operation or being
tested. Failure to follow this instruction could result in personal injury including loss of fingers,
hand or arm.

Do not operate the unit unless all parts are function properly and all safety devices are installed
correctly.

4
SPECIFICATIONS
Model 2011-PH Tandem 100 Electric Drive Hydraulic Power Unit

Motors
WEG 405TC 100 hp 3 Phase 480 Vac 60 Hz

Pump
Pressure Range: 0-4200 psi
Maximum Allowable Working Pressure: 3000 psi
Maximum Flow Rate: 50 gpm
Operating Temperature Range: 60-160°F
Type of Pump: Variable Displacement with pressure limiter

Skid Assembly:
Weight: ―WET‖ 13,420 lbs (6,087 kg)—— ―DRY‖ 10,120 lbs (4590 kg)
Dimensions: 144.5‖L x 74‖W x 93‖H——(3.67m L x 1.88m W x 2.36m H)

CONTROLS & INDICATORS

Motors: WEG 405TC 100 hp 3 Phase 480 Vac 60 Hz
Push Button Start/Stop
Pump:
 Pressure Indicator Gauge: 0-5000 psi liquid filled
 Relief valve: set to 3,400 psi
 Pressure Compensator Adjustment (set to 3,000 psi) located on the pump body
 Displacement Adjustment: 50 gpm

5
START UP PROCEDURES
A) First Time Start-up Procedure the operator should:
 Read and follow these instructions and ―Safety Precautions‖ before attempting to
operate the unit for the first time.
 Perform all of the operations listed below when preparing to operate a new or
overhauled unit, or a unit that has been in storage.

B) Unit Rig-up
 Remove any packing material and clean unit.
 Fill hydraulic fluid reservoir to the correct amount required.

C) Hydraulic Hoses
 Clean couplings.
 Connect hoses from the power unit to the tool.

D) Starting Sequence
1 Prior to startup: connect all supply, return lines.
2 Allow hydraulic unit to run 5-10 minutes.
3 Check for leaks and repair all leaks in system.
4 Push Start Button to start and Stop button to stop. (See below picture)

THE OPERATOR OF THIS EQUIPMENT MUST

 Caution: FOLLOW ALL SAFETY PERCAUTIONS WHEN
OPERATING THIS UNIT WITH SAFETY GLASSES,
HEAD GEAR AND HEARING PROTECTION

6
OPERATING INSTRUCTIONS
Typical Operating Procedures: Once the unit is running there are no other operations required.
Periodically check the hydraulic fluid levels on the dip stick to maintain the correct amount of
fluid.

7
9 6
1

4 8

5 2

Parts Identification:

1. Cooling Fan 4. Hydraulic Valves 7. Loop Pump/Cooling Fan Starter Panels

2. WEG 100 HP Motor 5. Supply Line 8. 100 hp Motor Starter Panel
3. Hydraulic Fluid Reservoir 6. Return Line 9. Lifting Frame

Operating Conditions: In general, electric motors are designed for operation up to an altitude of
1000m above sea level for an ambient temperature ranging from -4ºF (-20ºC) to 104ºF (40ºC). Any
variation is stated on the motor’s nameplate.

 The motor must start and operate smoothly. In case this does not occur, turn it off and
check all connections and the mounting before starting it again.
 In case there is excessive vibration, check if the fixing screws are correctly fastened. Check
also if the vibration comes from a neighbor machine. Periodical vibration checks must be
completed.
 Run the motor under rated load for a short period of time and compare if the running
current is in accordance to the nameplate current.

7
Master Power Disconnect
The master power disconnects to these motors are shown in the picture below with arrows. By
pressing the master power disconnect button the designated motor will stop.

To shut the entire unit down, the operator must press both RED buttons.

1 2

Parts Identification:
1. Engine shutoff button 2. Engine shutoff button

THE OPERATOR OF THIS EQUIPMENT MUST FOLLOW

 Caution: ALL SAFETY PERCAUTIONS WHEN OPERATING THIS
UNIT WITH SAFETY GLASSES, HEAD GEAR AND
HEARING PROTECTION

8
Start-Up Steps

1. Prior to startup connect all supply and return lines

2. Allow hydraulic unit to run 5-10 minutes
3. Check for leaks in system
4. Push GREEN buttons to start
5. Motors will start

Start Engine Shut-Off Engine

Stop the Motors

Normal Method
To shut down the engine according to normal procedures, follow these steps:
1. Return the pressure to OFF
2. Push both RED buttons on control panel which will shut off the motors and stop the power
unit

THE OPERATOR OF THIS EQUIPMENT MUST

 Caution: FOLLOW ALL SAFETY PERCAUTIONS WHEN
OPERATING THIS UNIT WITH SAFETY GLASSES,
HEAD GEAR AND HEARING PROTECTION

9
HYDRAULIC OIL SPECIFICATIONS
The hydraulic system fluid affects performance and service life of all other components of a
hydraulic system. Some of the factors especially important in the selection of oil for use in a
hydraulic system are:

 The oil must contain the necessary additives to ensure high anti-wear characteristics. Not
all hydraulic oils contain these in sufficient amounts.
 The oil must have proper viscosity to maintain adequate sealing and lubricating quality at
the expected operating temperatures of the hydraulic system.
 The oil must have rust and oxidation inhibition for satisfactory system operation.
 Viscosity of fluid is a measure of its resistance to flow as well as its ability to prevent
metal-to-metal contact of moving parts. It is recommended that the following maximum
and minimum viscosity ranges of the oil at start-up and during running be maintained:
o Nominal: 150-300 SUS at 1000°F (380°C)
o Running: 70-250 SUS
o At start-up: 4000 SUS maximum

It is recommended that you use an anti-wear type of heavy-duty industrial hydraulic oil.

4 5

3 2
Parts Identification:
1. Hydraulic Fluid Reservoir
2. Hydraulic Return Filters
3. Loop Filter
4. Loop Pump/Cooling Fan Starter Panel
5. Supply Side Filter

This unit is equipped with 4 hydraulic filters to keep the hydraulic system clean.

10
HYDRAULIC MAIN SUPPLY VALVES
Before starting the equipment, the operator must ensure that the hydraulic supply lines are in the
OPEN position.

OPEN CLOSED

Supply Valves
The picture above shows the location of the supply line blue-handled valves. Please note that one
is shown in the OPEN position and one in the CLOSED position; however, it should be OPEN
when running the unit.

The hydraulic supply line ball valve must be CLOSED during shipping or when servicing unit.

IT IS IMPERATIVE THAT THE HYDRAULIC RESERVOIR BE

 NOTE: FULL AND THE BALL VALVES BE OPENED PRIOR TO
OPERATING ANY OF THE HYDRAULIC EQUIPMENT ON THE
UNIT. FAILURE TO FULLY OPEN THESE VALVES MAY
RESULT IN EQUIPMENT FAILURE (NOT COVERED BY
WARRANTY) AND/OR INJURY TO PERSONNEL.

11
PREVENTIVE MAINTENANCE
General Maintenance Information
To obtain the long life and best performance from the unit, the operator must adhere to the
following instructions on preventive maintenance.

1. The daily instructions pertain to routine or daily starting of a unit and not to new equipment.
2. The time intervals given in the instruction refer to actual operating hours of the unit.
3. Check hoses and connections daily for leaks, rubbing or looseness.
4. The dust caps and plugs provided must be used to protect the hose couplings.
5. Upon removal of each dust cap or plug from hose couplings, inspect each to see that
openings are free of any dirt.
6. Dip coupling in bucket of solvent to clean. (Do not submerge the hose.) If wiping must be
done, use a clean rag.
7. Make certain that no dirt gets into the couplings both at assembly and disassembly.
8. Hydraulic oil level should be checked DAILY. The reservoir should be maintained at a
level between the (2) fish eye sight glass.

WEG Motor Maintenance Information

Any service on electric machines should only be carried out when it is completely stopped and all
phases disconnected from the power supply.

General Motor Inspection

1. Check motor periodically.

2. Keep motor clean and ensure free air flow.
3. Check seals and replace them if required.
4. Check connections as well as supporting screws.
5. Check bearing condition and pay attention to 1) any excessive noise, 2) vibration, 3)
bearing temperature and 4) grease condition.
6. When a change, under normal conditions is detected, check the motor and replace required
parts.

**DO NOT REUSE DAMAGED OR WORN PARTS. REPLACE THEM BY NEW ONES
SUPPLIED BY THE FACTORY.

12
Motors are equipped with grease fittings
It is strongly recommended to grease the machine while running. This allows the grease renewal in
the bearing housing. When this is not possible due to rotating parts by the grease device (pulleys,
bushing, etc) that offer some risk to physical integrity of the operator, proceed as follows:

1. Clean the area near the grease nipple.

2. Put approximately half of the total grease and run the motor for 1 minute at full speed.
Then turn off the motor and pump in the rest of the grease.
3. The injection of all the grease with the motor in standstill can make the grease penetrate
into the motor, through the bearing housing inner seal.
4. Inspections intervals depend on motor type and on application conditions.

USE ONLY MANUAL GREASE GUN FOR LUBRICATION.

RECOMMENDED RELUBRICATION – MOBIL POLYREX EM GREASE

Compatibility of MOBIL Polyrex EM grease with other types of grease

Containing polyurea thickener and mineral oil, the MOBIL Polyrex EM grease is compatible with
other types of grease that contain:
 Lithium base or complex of lithium or polyurea and highly refined mineral oil.
 Inhibitor additive against corrosion, rust and anti-oxidant additive.
Note: Although MOBIL Polyrex EM is compatible with the types of grease given above, we do not
recommend mixing it with any other types of grease. If you intend to use a type of grease
different than those recommended above, first contact WEG.

BEFORE USING STANDARD MOTORS IN SPECIFIC AREAS OR ON SPECIAL

APPLICA TIONS, FIRST CONTACT THE GREASE MANUFAC TURER OR WEG

13
SERVICE PROCEDURES (FLUID & FILTERS)
Hydraulics

A) Filter Element Service

 The Strainer Filter Element should be cleared every 12 months.
 The Return Filter Element should be replaced when indicated by the differential pressure
gauge.
B) Hydraulic Fluid Service
 The hydraulic fluid needs to be replaced every six (6) months.
 Drain the hydraulic fluid reservoir by unscrewing the lower drain plug.
 Replace the plug and refill the hydraulic reserve reservoir with approved hydraulic fluid.
C) Hydraulic Filters: This Unit is equipped with convenient screw-in type hydraulic filters.

2
1
1

1
1
1
3
1
1

Part Identification
1. Hydraulic Return Filters 2. Supply Side Pressure Filter 3. Loop Filter

The hydraulic filter should be changed approximately every 500 hours or as needed. This is
imperative to proper operation of the unit.

THE HYDRAULIC FLUID MUST BE REPLACED EVERY 6

 Caution: MONTHS IN THE HYDRAULIC FLUID RESERVOIR TO BE
COVERED BY THE WARRANTY AND/OR INJURY TO
PERSONNEL.

14
Hydraulic Pumps
Powered by the WEG Electric Motor, the series of hydraulic pumps which are connected to the
motors, via a gear box, operate the unit.

Parts Identification:

1. Vickers 50 gpm pumps (2)

2. Vickers 30 gpm pump

THE HYDRAULIC FLUID MUST BE REPLACED EVERY 6

 Caution: MONTHS IN THE HYDRAULIC FLUID RESERVOIR TO BE
COVERED BY THE WARRANTY AND/OR INJURY TO
PERSONNEL.

15
Hydraulic Fluid Cooling System
This Unit is equipped with a hydraulic fluid heat exchanger. This heat exchanger is located in
front of the WEG electric motors. Air is pushed through the cooling tower and exhausts to the
outside of the unit in order to helping remove heat from fluid and the unit.

3
1
2 1
1
1

1
1
1
Parts Identification

1. Heat Exchanger 2. Fan Motor 2. Hydraulic Fluid Reservoir

THE HYDRAULIC FLUID MUST BE REPLACED EVERY 6

 Caution: MONTHS IN THE HYDRAULIC FLUID RESERVOIR TO BE
COVERED BY THE WARRANTY AND/OR INJURY TO
PERSONNEL.

16
LIFTING THE UNIT
The skid has been designed to be capable of lifting. Lifting of the skids is accomplished by bolting
on four (4) lifting eyes to each unit the reinforced lifting plates. Lifting of these units should be
done via a correctly-rated-for-weight spanner bar and certified lifting slings.

The lifting locations are as follows:

HPU Skid – Lifting

Moving of Skid Units on Trailers

1) Carry out full visual check of the unit prior to moving

2) Disconnect all supply hoses
3) Shut off hydraulic fluid supply lines

THIS UNIT IS A CERTIFIED SKID. IT IS CERTIFIED TO 2 TIMES

 NOTE: ITS WEIGHT. THE SKIDS ARE CLEARLY MARKED WITH
LIFTING CERTIFICATIONS ON THE CRASH FRAME.

17
TROUBLESHOOTING

Problem Probable Cause Corrective Action

Low hydraulic fluid
Fill reservoir to "full" repair/replace as
No response to controls supply
required
Hydraulic hose leak

Slow operation Low system pressure Set pump to: 200psi min/ 3000psi max

18
HYDRAULIC SYSTEM SCHEMATIC DIAGRAM

19
PART IDENTIFICATION

Motor WEG 405 100 Hp 3 Phase 480 Vac 60 Hz

Characteristics
Output: 100 HP Full Load Amps: 250-226/113 A
Poles: 4 Efficiency (100%): 95.4
Frequency: 60 Hz Power factor (100%): 0.87
Torque: 291 ft-lbs Insulation: F
Voltage: 208-230/460 V Noise: 75 dB(A)
Frame: 404/5T No load current: 86.0/43.0 A
RPM: 1780 In Rush (Times): 8.7

20
WEG MOTOR “A” SCHEMATIC

21
 WEG MOTOR “B” SCHEMATIC

Visual Index

3.2

7.0

3.6
3.3

8.2
4.2
4.2

3.5

8.3 3.1 5.1

5.2 3.4

Table of Contents Description

3.1 Grounding lugs
3.2 Eyebolts
3.3 End shields
3.4 Drain plugs
3.5 Nameplate
3.6 Cooling system
4.1 Fan cover
5.1 Shaft
7.0 Bearings
8.2 Terminal box
8.3 Sealing system

22
SCHEMATIC 1

23
SCHEMATIC 2

24
 SPARE PARTS LIST

Item Qty Description Part #

1 2 Electric Motor 100 Hp
2 2 Hydraulic Pump
3 2 Check Valve
4 2 Isolation Valve
5 2 Gauge Isolator
6 2 Pressure Gauge
7 1 High Pressure Filter
8 1 Return Filter
9 1 Electric Motor 1 1/2 Hp
10 1 Hydraulic Pump
11 1 Pressure Filter
12 1 Air/Oil Cooler

25
ELECTRICAL SCHEMATIC

26
NOTES

27