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Related Manuals for WPT POWER WPD-02
Summary of Contents for WPT POWER WPD-02
- Page 1 Power Pump Drive Installation & Maintenance Manual Model WPD-02...
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Page 2: Table Of Contents
Table of Contents Signal Words & Definitions ..................................3 Introduction ......................................4 Product Description ..................................5 Section View of Basic Unit, Parts List ............................... 6 Installation ......................................7 Requirements for Proper Operation and Service Life ......................... 8 Installing the Unit .....................................10 Coupling Replacement ..................................13 Disassembly ......................................15 Remove PTO from Pump Drive .................................15... -
Page 3: Signal Words & Definitions
Signal Words & Definitions Throughout this manual there are several safety messages that must be read and adhered to in order to prevent possible loss of equipment and/or personal injury and/or loss of life. The three signal words are “Danger”, “Warning” and “Caution”. They are used to indicate the severity of the hazard and are preceded by a safety alert symbol. -
Page 4: Introduction
Introduction Warning Forward this manual to the person or persons responsible for the installation and/or operation and/or maintenance of the product described herein. Without access to this information, faulty installation, operation and/or maintenance may occur, which could result in equipment damage, personal injury and even death. -
Page 5: Product Description
Product Description The PPD is a multi-pump drive that attaches to the engine similar to a power-take off and distributes the power to one or two heads. Each head has the possibility to mount two pumps. With a flange adapter, a Type D, 4-hole mount is available. On the engine side flange, there are Type B, 2-hole, and Type C, 2- and 4-hole mounting pads. -
Page 6: Section View Of Basic Unit, Parts List
Section View of Basic Unit, Parts List Section View ITEM DESCRIPTION ITEM DESCRIPTION ITEM DESCRIPTION ITEM DESCRIPTION GEAR BEARING HHCS LOCK WASHER COVER SHAFT, INTERMEDIATE COUPLING GASKET WASHER PLUG HHCS BEARING SHCS RETAINER LOCK WASHER O-RING SHAFT, MAIN SPACER INPUT HOUSING SPACER O-RING SHAFT, INTERMEDIATE... -
Page 7: Installation
Installation Warning Follow safety guidelines utilizing lockout tag out procedures before and during all installation and maintenance procedures. Warning Ensure that proper rated lifting devices & procedures are followed when installing, working, or maintaining unit. Failure to do so may result in equipment damage, personal injury and even death. -
Page 8: Requirements For Proper Operation And Service Life
Requirements for Proper Operation and Service Life Flywheel and flywheel housing alignment inspection. It is strongly recommended that dial indicator checks be made (as shown) prior to installation of the Pump Drive, especially on new engines or when a previous Pump Drive failure might indicate an alignment problem. - Page 9 4.1.3 Check flywheel face run out. Mount the indicator base on the flywheel housing and position the dial indicator tip so its movement is perpendicular to the face of the flywheel. Position the indicator tip near the drive ring mounting bolt circle diameter. Rotate the flywheel 360 degrees while holding pressure against the crankshaft thrust bearing.
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Page 10: Installing The Unit
Installing the Unit 4.2.1 Mount driving ring of the elastic coupling on the flywheel. NOTE Before mounting the PPD onto the engine, it is important to WPT recommends performing check that flywheel is within SAE tolerances (see 4.1). a transmission line torsional vibration analysis. - Page 11 4.2.5 Mount the pumps on the heads, inserting the respective adapters for type B or C. For type B, a reducing ring with respective O-rings are required. For type D (non-engine side only) an adapter flange is required to be mounted to the head. Utilize pump manufacturers recommended grease on both internal and external splines of the adapter CAUTION The PPD is supplied without oil.
- Page 12 CAUTION 4.2.12 Strike the output end of clutch shaft with a soft face hammer (brass) to relieve bearing preloading caused by installation, see sketch below (appearance in some models vary). CAUTION 4.2.13 Torsional vibrations must be managed with proper coupling selection, regardless of its position in the drivetrain.
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Page 13: Coupling Replacement
Coupling Replacement Instructions for replacing an input coupling. 4.3.1 Please refer to the equipment manual for proper steps on how to remove peripheral items such as belts, guards, etc. 4.3.2 Remove the Power Pump Drive (PPD) assembly from the machine and place on flat, sturdy work surface. - Page 14 4.3.9 Attached new drive ring to the engine flywheel using new hardware. • Refer to torque chart in the back of the instructions or torque to engine manufactures recommended setting. 4.3.10 Attach the new coupling to In-put splined hub using the twelve (12) provided hex head cap screws (item 4).
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Page 15: Disassembly
Disassembly Warning Follow safety guidelines utilizing lockout tag out procedures before and during all installation and maintenance procedures. Warning Ensure that proper rated lifting devices & procedures are followed when installing, working, or maintaining unit. Failure to do so may result in equipment damage, personal injury and even death. Remove PTO from Pump Drive 5.1.1 Remove drive shaft or belts from PTO output shaft. - Page 16 Disassembly Main Shaft 5.4.1 Remove “Y” side output flywheel by removing SHCS from center. 5.4.2 Remove hardware holding flange adapter. 5.4.3 Remove hardware to remove bearing carrier. 5.4.4 Remove output main bearing. 5.4.5 On “Z” side remove hardware to remove shaft retainer. 5.4.6 After shaft retainer is removed coupling maybe removed.
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Page 17: Assembly
Assembly Prepare and Install Main Shaft Assembly 6.1.1 Press the main shafts output seal into the main shafts output bearing carrier. Press until flush with the front face. 6.1.2 Install the large main shaft bearing’s outer race with rollers into the main shaft’s output bearing carrier. -
Page 18: Prepare And Install Intermediate Shaft Assembly
6.1.17 Heat (170°F ± 20°F)/demagnetize and install main shaft gear onto main shaft. Make sure it is firmly seated against the bearing with a press. 6.1.18 Let the assembly cool, then proceed to the next step. 6.1.19 Heat (170°F ± 20°F)/demagnetize and install the inner race for the main shafts input bearing, onto the main gear. -
Page 19: Prepare And Install The Drive Gear Assembly
6.2.5 Using a soft-faced mallet, drive the intermediate shaft into the intermediate and bearing. Be sure the gear is seated firmly against the retaining ring. 6.2.6 Let the assembly cool. 6.2.7 Heat (170°F ± 20°F)/demagnetize and install the inner race onto the upward facing end of the intermediate shaft. -
Page 20: Install Input Housing And Set The Axial Endplay
Install Input Housing and Set the Axial Endplay. 6.4.1 Press the seal into the input housing. Press until flush with the machined face. 6.4.2 Make sure the output housing (y-side) is face down on a flat surface. 6.4.3 Install bearing spacer / oil baffle: 6.4.4 Install the Shims. -
Page 21: Finalize The Main Shaft Assembly
Finalize the Main Shaft Assembly 6.5.1 Apply Kluber Altemp Q NB 50, or equivalent, to the splines on the input end of the main shaft. 6.5.2 Install the splined hub. 6.5.3 Press the O-ring into the groove between the splined hub and splined shaft using a blunt smooth tipped tool. -
Page 22: Internal Heat Exchanger Installation (If Equipped)
requirement, tighten the remaining bolts in a crisscross pattern. Repeat this twice to verify the torque. (Repeat steps in 8.5 for each domed cover to be installed) 6.6.6 If installing a head or head extension, complete this set of steps. If not, skip this set of steps. -
Page 23: Installing A Head Clutch (If Equipped)
6.7.5.4 Install the O-ring followed by the brass part with bevel, making sure the beveled end is facing the O-ring. 6.7.5.5 Install nut and tighten until assembly is made up solid. NOTE: Be careful not to twist the internal heat exchanger while tightening this end. Use a jerking motion to tension the nut if necessary. -
Page 24: Installing A Circulation Pump (If Equipped)
6.8.6 Wipe excess sealant. (Repeat steps in Error! Reference source not found. for each head clutch to be i nstalled) Installing a circulation pump equipped). 6.9.1 See Section 9 for option layout configurations. Rotation and direction of flow varies in each configuration. -
Page 25: Maintenance
Maintenance Warning Do not allow unqualified personnel to install, adjust and/or repair the unit. Faulty workmanship could result in faulty installation, dangerous operation of the Unit, repeated costly maintenance and greatly shorten the life of the Unit. Warning Do not perform maintenance work on the unit, without making sure that the machinery will remain in a safe position. -
Page 26: Maintenance Schedule
Maintenance schedule • Initial oil replacement is recommended after the first 300 hours of operation. • Replace oil every 1000 working hours or six months whichever comes first. • Check magnetic plug during every oil change for any evidence of metal shavings and grease bushings in heads with Klüber paste ALTEMP Q NB 50, or equal. -
Page 27: Oil Level Check
Oil Level Check 7.2.1 Dipstick Version When equipped with a dipstick, ensure the machine is off and is on solid level ground. Remove the dipstick and wipe away any oil on the dipstick. Reinsert the dipstick until fully seated. Slowly remove the dipstick. If oil level is low, add oil and continue checking until it reaches the Max Fill line (see illustration). -
Page 28: Approved Oil With Operating Speeds
Approved Oil with Operating Speeds Castrol Shell Alpha MW 220 SP 220 Shell Omala Oil 220 Alpha MW 100 SP 100 Shell Omala Oil 100 Alphasyn T 220 Shell Omala Oil HD 220 Alphasyn T 100 Shell Tivela Oil WB 220 Alphasyn PG 220 Shell Tivela Oil WA 150 Mobil... -
Page 29: Heat Exchanger
Heat Exchanger Typical Closed Loop Cooling System (if applicable) Internal Heat Exchanger (if applicable) COOLING WATER SUPPLY Max Flowrate: 7.9 gal/min [30 l/min] COOLING WATER SUPPLY Min Flowrate: 4.0 gal/min [15 l/min] COOLING WATER SUPPLY Max Pressure: 145 psi [10 bar] Estimated Pressure Drop: 1.0 psi [0.07 bar] COOLING WATER SUPPLY-TO- RETURN. -
Page 30: Circulation Pump Configurations
Circulation Pump Configurations “Y” Side [Output] without extensions with WP3-02-003 pump WIM-PD-002_B Page 30 of 38... -
Page 31: Z" Side [Input] With Extensions With Wp3-02-003 Pump
“Z” Side [input] with extensions with WP3-02-003 pump WIM-PD-002_B Page 31 of 38... -
Page 32: Z" Side [Input] Without Extensions With Wp3-02-002 Pump
“Z” Side [input] without extensions with WP3-02-002 pump WIM-PD-002_B Page 32 of 38... -
Page 33: Y" Side [Output] With Extensions With Wp3-02-002 Pump
“Y” Side [Output] with extensions with WP3-02-002 pump WIM-PD-002_B Page 33 of 38... -
Page 34: 10.0 Tables
10.0 Tables Caution: Torque values on assembly drawings override torque values on these charts. TORQUE VALUES FOR METRIC SOCKET HEAD AND HEX HEAD CAPSCREWS 4.6 Class 8.8 Class Lubricated** Lubricated** Bolt Bolt Size Size lbf•ft lbf•in N•m lbf•ft lbf•in N•m lbf•ft lbf•in N•m... -
Page 35: 11.0 General Storage Guidelines
11.0 General Storage Guidelines Upon receipt of parts or assemblies, they should be inspected for corrosion or other related damage. If any problem is detected, contact vendor. It is the owner’s primary responsibility to store and protect the PPD product. Products should be stored in a manner that it is protected from the environment and outside sources, which may include but are not limited to the following: •... -
Page 36: 12.0 Trouble Shooting Guide
12.0 Trouble Shooting Guide Problem Possible Cause Remedy Output main seal damaged Inspect and replace seal as needed Fluid Leaks Input main seal damaged Oil level too high Inspect oil level and drain as needed Foaming in Pump Drive Case Incorrect oil type Verify approved oil is used Oil level low... - Page 37 This Page Intentionally left Blank WIM-PD-002_B Page 37 of 38...
- Page 38 WPT Power Corporation 1600 Fisher Road - Wichita Falls, TX 76305 P.O. Box 8148 - Wichita Falls, TX 76307 Ph. 940-761-1971 www.WPTpower.com WIM-PD-002_B Page 38 of 38...
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