HYDRAULIC

POWER 'UNIT'
Operation
and Service
Instructions

Sara Sae
Sara Sae

HYDRAULIC POWER 'UNIT'

Operation and Service
Manual

C u to m N m P .P E R A NA R N SE R V CE S
R ig N m -

S l d N um b -

Pu h d N um b 03/
C .11/
002.

Reference Reference Description

HYDRAULIC POWER 'UNIT'
This document contains proprietary and confidential SARA SAE
information which belongs to SARA SAE ; it is loaned for 7/1, Pritam Road
limited purposes only and remains the property of SARA Dehradun - 248001, India
SAE. Reproduction, in whole or in part; or use of this
design or distribution of this information to others is not
Tel +91 135 2672395
permitted without the express written consent of SARA Fax +91 135 2673109
SAE . This document is to be returned to SARA SAE upon WWW.SARASAE.COM
request and in any event upon completion of the use for
which it was loaned.
© SARA SAE

Document Number Rev.

1078
A
W W W .S A R A S A E .C
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 TABLE OF CONTENTS
1. E N E R A E SCR P N ,P W ER N
Introduction to Part 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Power Units, Overall description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
DPU-6530 Hydraulic Power Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
EPU-6530 Hydraulic Power Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Hydraulic System Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Specifications, EPU-6530 Power Untt, Electric Drive . . . . . . . . . . . . . . . . . . . . . . 6
Specifications, DPU-6530 Power Unit, Diesel Drive . . . . . . . . . . . . . . . . . . . . . . . 7

2. N S A A N ,P W ER N
General Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

3. P E R A N ,P W ER N
General Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Operating Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Operating-Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

4.S E R V C N ,P W ER N
Daily Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Pressure Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Adjustment Procedure, Diesel Power Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Adjustment Procedure, Electric Power Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

5. R ES N AN R E P A R ,P W ER N
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

6.P A R S S ,P W ER N ......................................22

List of Illustrations
F ig u
1-1 DPU-6530, Hydraulic Power Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1-2 EPU-6530, Hydraulic Power Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1-3 EPU-6530 Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1-4 Hydraulic Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2-1 DPU-6530 Power Unit Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2-2 EPU-6530 Power Unit Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3-1 Control Panel, DPU-6530 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3-2 Engine Control Circuit Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
6-1 DPU-6530 Power Unit, Major Components . . . . . . . . . . . . . . . . . . . . . . . . . . 22
6-2 EPU-6530 Power Unit, Major Components . . . . . . . . . . . . . . . . . . . . . . . . . . 23
6-3 Hydraulic Components (DPU-6530 or EPU-6530) . . . . . . . . . . . . . . . . . . . . 25

List of Tables

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 bl
1-1 Specification, EPU-6530 Hydraulic Power Unit . . . . . . . . . . . . . . . . . . . . . . . . 6
1-2 Specifications, DPU-6530 Hydraulic Power Unit . . . . . . . . . . . . . . . . . . . . . . . 7
3-1 Control and Indicator Functions, DPU-6530 . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5-1 Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
6-1 DPU-6530 Power Unit, Parts List - Figure 6-1 . . . . . . . . . . . . . . . . . . . . . . . . 22
6-2 EPU-6530 Power Unit, Parts List - Figure 6-2 . . . . . . . . . . . . . . . . . . . . . . . . 23
6-3 Part List, Hydraulic Components (DPU-6530 or EPU-6530) . . . . . . . . . . . . . 24

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 Section 1
General
Description,
Power Unit

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 1 General Description

Section 1
General Description, Power Unit
N R C N PAR transport of a hydraulically operated tong,
and a metal rack provides for storage of
Part I describes the function, the interconnecting hoses. A centrally-
operation and maintenance of the SARA located lifting eye facilitates hoisting the
DPU-6530 Diesel Driven Power Unit and unit to the drill floor or to other desired
the EPU-6530 Electrically Driven Power location.
Unit. Although the manual is designed to
cover these specific units, the same E P -6530 Y R A C P W ER
general principles apply to other power N .the EPU-6530, Figure 1-2 is a skid-
units in the SARA line. The major mounted hydraulic power unit driven by an
variations between units consist chiefly ofelectric motor. The unit consists of the
type of drive (electric or diesel) and electric drive and starter; hydraulic
hydraulic volume. In particular, functions reservoir which encloses the hydraulic.
and parts of the hydraulic system are pump and pressure regulating
practically identical from unit to unit. components; a heat exchanger with
blower, blower motor, and starter; and
P W E R N S , VE R A hoses for interconnection to the tong or
E SCR P N other equipment to be powered. The unit
components are installed on a skid having
a centrally-located lifting eye to facilitate
Overall descriptions of the two
hoisting the unit to the drill floor or to
power units are presented in the two sub-
another desired location. Figure 1-3 is an
topics which follow, Because the hydraulic
electrical schematic of the EPU-6530 unit.
functions of the two units are almost
identical, these are covered in a separate
topic titled Hydraulic System Function. Y RA C S YS E
F NC NS
Refer to the Parts List, Section 6 for
locations and part numbers of the power Except that the electric unit has a
unit components, a['ld refer to the engine heat exchanger not normally present on
manufacturer's manual for service and diesel units, the hydraulic systems are
repair of the diesel engine. functionally identical for diesel and
electrically driven power units. The heart
P -6530 Y R A C P W E R of the hydraulic system is a two section
hydraulic pump having a high-volume,
N .
low-pressure section and a low-volume,
high pressure section with associated
The DPU-6530, Figure 1-1, is a unloading and relief valves. In operation,
skid mounted hydraulic power unit driven both pump sections provide pressure to
by a diesel engine. The unit consists of the the tong until 1,000 PSI is obtained. When
diesel engine, hydraulic reservoir, pump, this pressure is attained, the low pressure
and other components mounted on a skid. section is unloaded and the high pressure
A mount- is provided for storage' and

W W W .S A R A S A E .C
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 l o m tio
section continues to deliver hydraulic
pressure to the tong until the desired
pressure is obtained at the tong. Should
the required torque be higher than the
capability of the tong and power unit
combination, the high pressure pump
section will relieve at the maximum
pressure for the power unit (normally
2,500 to 3,000 PSI) and the tong will
develop no higher torque.
Figure 1-4 is a schematic diagram
of the hydraulic system for the electrically
driven EPU6530 system. The schematic
for the DPU-6630 Diesel Unit is identical
except that the latter does not have the
heat exchanger. As indicated in the
diagram, all the hydraulic components
except toe hoses and the heat exchanger
are located in the, hydraulic reservoir.
During operation, hydraulic fluid
from the reservoir is drawn through the
strainer to enter both sections of the
hydraulic pump. The motor drive the pump
at approximately 1,500 RPM, delivering
full volume from both sections of the pump
until the load on the tong requires 1,000
pounds of pressure. At this point, the
unloader valve in the output of the low-
pressure side of the pump opens and
unloads the flow from that pump section
back to the reservoir. A check valve in the
manifold between the two pump sections
inhibits the high pressure from bypassing
through the unloader valve. At this point,
only the high-pressure section delivers
pressure to the tong, and the volume is
decreased so that the tong slows down.
The unloader valve is a pilot-
operator bypass valve which operates
from the output pressure of the power unit.
The pilot line from the unloader valve is
connected from a port on the relief valve
through a hose to a port on the unloader
valve. When the output pressure reaches
the set pressure as controlled by the
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General Description 2
unloader valve control knob, the unloader
valve opens the flow path from the low-
pressure section of the pump back to the
reservoir.
In of Duration, as spon as the
pressure reaches the setpoint (nominally
1,000 PSI), only the high-pressure side
delivers fluid under pressure to the tong or
other device being operated. The power
unit continues to deliver hydraulic
pressure to the tong until sufficient
pressure is obtained or until the maximum
output pressure set by the high-pressure
relief valve is obtained. When the
maximum pressure is obtain, the high-
pressure relief valve bypasses the excess
flow back to the hydraulic reservoir and
"no higher pressure may be developed at
the tong. When the pressure again drops
below 1,000 PSI, the pilot line permits the
unloader valve to be reset and· the
sequence starts over.
In practice, the operator runs the
tong in high speed until maximum
pressure is reached then shifts the tong to
low speed and again lets the pressure
build up until the required torque is
developed. Under normal operating
conditions, sufficient torque is developed
for the task being performed before the
maximum pressure of the power unit is
achieved.
In the schematic diagram note· that a heat
exchanger is located in the return fluid line
from the tong. Such heat exchanger is
normally used with the electric unit
because the motor operates continuously
at full speed developing considerable
heat. A spring-loaded check valve permits
the return flow to bypass the exchanger
should the heat exchanger clogged.
A heat exchanger normally is not used in
diesel power units because the pump
W W W .S A R A S A E .C
 3 General Description

F ig u 1-1. i l d u li P o it

F ig u 1-2.E l ti l d u li P o it

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 l o m tio General Description 4

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 5 General Description

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 l o m tio General Description 6

does not operate at full speed S P E C F C A N S , E P -6530 P W E R

continuously, and thus excessive heat is N ,E E C R C R V E
normally not generated in the hydraulic
fluid. But heat exchanger on DPU can also The specifications for the EPU-6530
supplied. (If required by the customer) electrically driven power unit are
presented in Table-1-1.

b l 1-1,S i i tio ,E P -6530 d u li P o it

im io : o to .............................................1,500 RPM,
................................................. Explosion Proof
Width .............................................40 Inches (1 02cm)

Length ...........................................94 Inches (239 cm)

Height ............................................63 Inches (160 cm)

d u li u t u t:
W ig h t: 70 GPM @ 1,000 PSI
265 Umin @ 70.3 Kg/cm2
Approximately .............................*3,460 Jbs .
................ .....................................(1569.4 Kg.) 30 GPM@ 3,000 PSI
125 Umin @ 210.9 Kg/cm2
k C it ............................70 gal. - 525 Ibs .
.............................................. (265 L.) (238 Kg.) tE x h g :

El ti lR qu i m t : Tube and Shell - Four-pass, fresh or salt water,

60 P it ..................................Amp. 164 @ 230 volts
.............................................. Amp. 82 @ 460 volts
50 P it ..................................Amp. 142 @ 230 volts
.............................................. Amp. 72 @ 480 volts
pressure to 250 PSI (oil) and 150 PSI (water).
Temperature at 350°F. in both tube and shell,
Requires 5 GPM of 100°F cooling water.

S t t .........................................Explosion Proof
*(without tong and hydraulic fluid)

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 7 General Description

SP E C F CA NS, P -6530
The specifications for the DPU-6530 diesel driven power unit are presented in Table .1-2:

b l 1.2,S i i tio , P -6530 d u li P o it

im io :
R t d C o ti u o u . .P .:
Length ................................ 122" (310 em) 2000 R.P.M. - 80 S.H.P.
1800 R.P.M. - 73 S.H.P.
Width .47" (119 em) 1500 R.P.M. - 61 S.H.P.

Height 74" (188 em)

W ig h t: d u li u t u t:
Approximately *3788 Ibs. 70 GPM @ 1,000 PSI
(7(l3 Kg/em)
.......................................... (1720 Kg)

E gi W ig h t ........ 940Ibs. (410 Kg) 30 GPM @ 2,500 PSI

(175.8 Kg/em)
d u li k C it :
110 gal. - 825 Ibs. R t d RP -1,800
(416 L) (375 Kg)

i lF u lC it : A o x .F u l C o um tio @ 1,800 R .P . .
36 gal. - 270 Ibs.
4.5 gal/hr
(136 L) (123 Kg)
(17 L/hr)
*(without tong, hydraulic & diesel fluid)

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 l o m tio Installation 8

Section 2
Installation
Power Unit

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 9 Installation
Section 2
Installation, Power Unit
GENERAL CONSIDERATION
In applications where electrical power is
limited or not available: a diesel unit is employed.
Where a power or line power is available to operate
a power unit, the electrically driven unit is normally
used. The selection of a power unit, of course,
depends upon the job to be accomplished.
SPACE C NS ERA NS.
Use of a hydraulic power unit requires
consideration of the space available, distance from
tong or other device to be driven, handling
equipment required to lift the unit, etc. The
dimensions of the DPU-6530 unit are shown in
Figure 2-1 and the dimensions of the EPU-6530
unit are shown in Figure 2-2. Within practical
limitations, hoses may be ordered in the length
required for a particular service. The handling
capacity for lifting the unit may be determined from
the weights given in the specifications.
P W ER C NS ERA NS.
While the diesel power unit required no
external electrical source, the electrically driven
power unit requires a source of line power or rig
power capable of delivering the amperages stated
at the voltage given in Section I, specifications.
NS A N E P W ER N 3. Route the hydraulic hoses to the tong in such a
Before transporting the power unit to the
installation site, be sure the tong is properly.
positioned on the mount and securely fastened.
Also be sure that the hoses, if provided, are coiled
and placed in the hose rack, or otherwise coiled
and, placed so as not to be damaged in transit.
Transport the power unit with mounted
tong to the job site. Then" observing the proper
precaution for the weight of the unit, use a crane or
other appropriate lifting device to set the power unit
into its working position. The cargo hook of the
lifting device must be secured to the lifting eye of
the unit.
Remove the tong from the mount, and
hong the tong in the position required to makeup or
break-out the pipe to be worked. Refer to the
manual on the particular tong for tong installation
and instructions.
W W W .S A R A S A E .C
C NNEC N E Y RA C NES.
The hydraulic couplings, Figure 6-3, contain check
valves to prevent loss of hydraulic fluid when the
lines are disconnected. Proper tightening of the
hydraulic hose connectors opens these check
valves. In making up the connections, you must be
sure that the connectors are fully tightened in order
to open the check valves and avoid blockage at the
connectors.
Connect these hoses in accordance with
the following steps :
1. Hook up pressure hose to 1-inch fitting on
power unit by forcing connectors together
while turning the fitting.
2. Hook up return hose from tong to 1-14 inch
connector on power unit, as for 1inch fitting
above.
CAUTION
To be sure connectors are completely tight, first
tighten each connector until travel is restricted
and the end of thread travel appears to be
reached. Then try to tighten the connector
further to be sure first restriction was not a false
tightness. Finally, continue to tighten the lifting
until connection is tight. Failure to tighten the
return hose will cause back pressure and lead
to seal failure in the hydraulic motor.
manner that they will not become fouled with
rig equipment or other equipment and that they
will not be likely to become damaged or
endanger personnel moving about the rig or
worksite.
4. Refer to the instruction manual for the
particular tong, and connect the hydraulic
hoses-to the tong.
5. Perform the pre-operating sequence as out-
lined in Section 3, making any necessary
adjustment.
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 l o m tio Installation 10

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 11 Installation

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 l o m tio Operation 12

Section 3
Operation,
Power Unit

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 13 Operation

Section 3
Operation, Power Unit
GENERAL OPERATION
Operation of a hydraulic power unit consists of
performing the pre-operational checks and
adjustments and starting up the power unit. Once
the pow~r unit is started, it requires very little
attention, and the crew can devote their attention
to operating the tong or other hydraulically
powered device.
P E R A N C N R S AN
N CA R S . The operating controls and
indicators differ considerably between the units
due to the fact that the DPU-6530 is powered by
the diesel engine.
P -6530 C o t o l d di to
The controls and indicators for the DPU-6530 are
located on a control panel as illustrated in Figure
3-1. The functions of the controls and indicators
are given in Table 3-1. A schematic of the engine
control circuit is illustrated in Figure 3·2.
EP -6530 C o t o l d di to
The only operating control on the electrically
operated hydraulic power supply is the main
power switch on the motor starter enclosure.
PERA N PR CE RE
To operate the hydraulic power unit, .
proceed as follows :
1. Verify that power unit pressure setting have
been performed in accordance with
.instructions in Section 4.
2. Verify that tong to be operated is connected as
instructed in Section 2.
W ARN N
Be sure that tong control lever is in neutral
position and that personnel are clear of the
tong jaws before operating power unit.
3. If power unit is diesel operated, be sure that
pre-operating checks have been performed as
specified in engine manufacturer's
instructions.
4. For diesel driven power unit, start up diesel
engine as described in following topic, or for
electrically operated power unit, turn on power
circuit breaker on motor starter.
5. Permit hydraulic fluid to circulate sufficiently
long to reach operating temperatures
(nominally 15 minutes).
E gi S t t-u P o du . To
start the diesel engine refer to Figure 3-1 and
proceed as follows:
1. Open manual bypass. (Figure 6-1, Item 3)
.
2. Insert starter key, turn clockwise to detent and
check that alternator failure lamp is on.
3. Push start button and hold until engine starts
firing.
NOTE
.
Do not leave starter motor running for more
than 10 seconds. Also, battery life will be
prolonged if an interval of about one minute is
allowed between successive starting
attempts.
4. The alternator failure lamp should be now
have gone out. Allow engine to idle a few
minutes.
5. Close manual bypass (Figure 6-1, Item 3).
E gi S h u t-d o P o du .
Do not shut the engine down suddenly from full-
load running, but let it idle for some time to allow for
temperature balance.
1. Operate stopping lever on injection pump until
engine comes to stop, wherafter alternator
failure lamp will light up.
2. Turn starter key fully anti-clockwise and pull out
switch key.

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 l o m tio Operation 14

b l 3-1,C o t o l d di to F u tio , P -6530

CONTROL OR INDICATOR FUNCTION

1. Tachometer Monitors Engine RPM.

2. Oil pressure gauge and shut- Monitors engine oil pressure and shuts down engine if oil
pressure drops below 20 PSI.

3. Ammeter Monitors engine charging circuit.

4. Temperature gauge Monitors engine cylinder temperature and shuts down engine
if temperature exceeds 280°F.

5. Key switch Provides power to engine control circuit.

6. Engine shutdown indicator Button moves to extended position upon engine malfunction.
Must be reset before engine can be restarted.

7. Hourmeter Indicates elapsed time engine has been in service.

8. Blank

9 Alternator Indicates malfunction in charging circuit.

10. Engine start button Push switch energizes engine starter.

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 15 Operation

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 l o m tio Operation 16

Section 4
Servicing,
Power Unit

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 17 Operation

Section 4
Servicing, Power Unit
Servicing the power unit consists of A J S EN P R CE RE,
inspection, lubrication, and adjustments. For ESE P W ER N . The pressure
diesel driven units, servicing also includes adjustment procedure for the diesel power unit is
servicing the diesel engine according to the as follows:
manufacturer's instructions, Should servicing
reveal requirements for repair, refer to the 1. Install pressure gauge (0 to 5000 PSI, 0 to
appropriate portions in Sections 5 and 6. 351.5 Kg/cm2) in plug port of the pilot cap on
the relief valve. (Item 3).
A Y NSPEC N
2. Turn adjustment knob (3A) on relief valve
The power units should be inspected at the until there is no spring " compression on
start of every job. Inspect the power unit needle valve.
according to the following steps and perform any
necessary maintenance or repair: 3. Turn adjustment knob on unloader valve (Item
4) until there is no spring compression on
1. For diesel driven unit, inspect diesel engine
needle valve.
in a c c o r d a n c e w i t h m a n u f a c t u r e r ' s
instructions.
W ARN N
2. Inspect mechanical, electrical,· and hydraulic
Be sure all personnel are clear of the tong
components for any obvious damage.
jaw area.
3. Inspect hydraulic system for any leaks, broken
or worn hoses, etc. 4. Start engine.

R CA N 5. Shift tong to high gear and set tong control

lever to operate tong.
Most hydraulic components are located
in the hydraulic tank and surrounded by hydraulic
NOTE
fluid so that no lubrication of these components is
required. Tong will not begin to operate until sufficient
pressure has been obtained from the power
PRESS RE A J S EN S unit.

The following procedure presumes that 6. Close relief valve just enough to rotate tong ..
the power unit is being operated to power a
hydraulic tong. However, should you wish to 7. Rotate tong approximately 15 minutes to
adjust the relief valves without a tong installed, circulate air out of system and bring oil to
you may improvise a pressure loop including a operating temperature.
method for closing off the flow to develop back
pressure in the power unit.
CA N

Refer to Figure 6~3 fOJ component
location. The adjust~ent procedure, with tong
installed is given separately below for the diesel
power unit and the electric power unit.
Do not attempt step 8 until hydraulic fluid
is thoroughly warmed.
Stop engine and remove one-inch pressure line from
tong 0 that pump discharge is blocked from coupling.

W W W .S A R A S A E .C
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 l o m tio Servicing 18

9. Start engine. The hydraulic throttle W ARN N

should stroke and pressure gauge
should read approximately 150 to 200 Be sure that all personnel are clear of tong
PSI (10.5 to 14.0 Kg/cm2). jaw area.

10. Turn unloader adjustment knob (Item 4A) 4. Turn motor on.
until unloader valve closes. When
unloader valve closes, you will hear 5. Shift tong to high gear and operate tong
engine load up. The reading on pressure control lever.
gauge indicates the setting of valve.
N E
11. Increase system relief valve setting to Tong will not operate until sufficient system
1,000 PSI. Note than unloader valve will pressure is obtained.
open again while pressure is being
'increased as evidenced by decreased· 6. Rotate tong approximately 15 minutes to
load on engine. circulate pir out of system and bring oil to
operating temperature.
12. Increase unloader setting until unloader
valve closes again. At this point:' unloader CA N
valve is'- adjusted correctly. Lock
unloader valve knob." Do not attempt step 7 until hydraulic fluid is
thoroughly warmed.
13. Adjust relief valve (Item 3A) to desired
system pressure setting (2,500 to 3,000 7. Stop electric motor and remove oneinoh
/ PSI, 175.7 to 210.9 Kg/cm2). pressure line from tong so that pump
discharge is blocked at coupling.
A J S EN P R CE RE;E EC R C
P W ER N . The pressure adjustment 8. Turn motor on (pressure gauge should be
procedure for the electric power unit is as approximtely 150 to 200 PSI, 10.5 to 14.0
follows : Kg/cm2).

1. Install pressure gauge (0 to 5000 PSI, 0 to 9. Turn relief valve adjustment knob until
351.5 Kg/cm2) in plugged part of pilot cap maximum desired pressure is reached.
on relief valve (Item 3). (2,500 to 3,000 PSI, 175.7 to 210.9
Kg/cm2). Lock knob into position.
2. Turn adjustment knob (Item 3A) of relief
valve counterclockwise until there is no 10. Install gauge in gauge port of unloading
spring compression on needle valve. valve. 11.

3. Turn adjustment knob (Item. 4A) of 11. Turn unloading adjustment knob until
unloading valve counterclockwise until desired' unloading pressure is obtained
there is no spring compression on needle (1,000 PSI, 70.3 Kglcm2). Lock knob into
valve. position.

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Section 5
Troubleshooting,
Repair and
Overhaul

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Section 5
Troubleshooting,
Repair and Overhaul
This section contains instructions for REPA R
troubleshooting, repair and overhaul of theIn general, repair consists of replacing
tong. After any major repair or overhaul, worn or broken parts. When a part is
the tong should be serviced as outlined in determined to be faulty, either. through
Section 4. inspection or through an operational
check, you should remove the part and
R ES N replace it with a new part according to the
Power troubleshooting consists of locating procedures and instructions in the
observed symptoms on the Trouble- following topics. The component parts are
shooting Chart, Table 5-1, determining the illustrated and identified in Section 6.
probable cause, and correcting the
problem as suggested.

b l 5-1. o u b l h o o ti g C h t
SY P PR A E CA SE C RREC VE A C N

o d u li P u Relief valve setting on tong Reset Relief valve in control valve.

Debris in relief valve on tong Remove relief valve and clean.

Debris in relief valve in power unit Remove relief valve-pilot

section and clean.

Manual Pilot open on diesel Close manual valve.

unit.

Excessive pump wear Replace pump gears.

Plugged suction strainer Clear Suction strainer.

o F lo F om P o it Relief valve stuck open Inspect valve for debris under seat.

Unloader valve not closing Check unloader valve pilot line.

Low engine RPM Reset engine RPM.

Suction strainer plugged Clean suction strainer.

d u li il h ti g Electric power unit-exchanger Check for plugged exchanger or

bypassed spring in exchanger bypass.

Ex i V ib tio Faulty coupling Replace coupling.

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 21 Servicing

Section 6
Parts List

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Section 6
Parts List, Power Unit
This section contains lists for the includes a heat exchanger not used on
Figure 6.1 Illustrates the Diesel Power Unit diesel unit, the hydraulic components are
DPU-6530, and the major components of identical for the diesel unit and the
this power unit are listed in table 6-1. electrical unit. The hydraulic components
Figure 6-2 illustrates the Electric Power are illustrated in Figure 6.3 and listed in
Unit EPU-6530, and the major Table 6.3.
components of this power unit are listed in
Table 6-2. The Engine Control Panel for DPU-
6530 is illustrated in Figure 3-1 and the
Except that the electrical power unit components are listed in Table 3-1.

b l 6-1. P -6530 P o it,P t i t F ig u 6-1

N E PAR N E SCR P N
AN Y

1 101906 KIRLOSKAR, Diesel Engine 1

2 101051 Tyre Coupling 1

3 101509 Filler & Breather Assembly 2

4 REF Hydraulic Components (see Table 6-3)

5 REF Control Panel (See Table 3-1)

6 104179 Return Line Filter 1

Not Shown 102491 Tube & Shell Type Heat Exchanger 1

Not Shown 104313 Pressure Gauge 0-5000 PSI 1

7 102708-5 Hose 1-1/4" x 5 Ft. Return Line 1

Not Shown 103594 Valve Temperature Control 1

(For Type & Shell Type Heat Exchanger)

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b l 6-2.E P -6530 P o it,P t i t F ig u 6-2

N E PAR N E SCR P N
AN Y

1 101898 Electric Motor (60 HP), 440 Volts, 50 Hz 1

2 104871 Electric Starter (60 HP), 440 Volts, 50 Hz 1

3 101501 Tyre Coupling 1

4 102491 Heat Exchanger (Tube & Shell Type) 1

5 101506 Heat Exchanger (Fins Type) 1

6 REF Hydraulic Components (See Table 6-3)

Now Shown 101509 Filler & Breather Assembly 1

Now Shown 104179 Return Line Filter 1

Now Shown 104313 Pressure Gauge 0-5000 PSI 1

Now Shown 102708-5 Hose 1-1/4" x 5 Ft, Return Line 1

Not Shown 103594 Valve Temperature Control 1

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Troubleshooting, Repair and Overhaul 24

b l 6-3.P t i t, d u li C o m o t P -6530 o E P -6530

N E PAR N E SCR P N
AN Y

1 104878-N Pump 1

2 101508 Suction Strainer 2

3 106518 Relief Valve 1

4 101875 Unloading Valve 1

5 101883 Check Valve 1

6 102377 50'-1" Pressure Hose Assembly 1

7 102379 50'-1.1/4" Return Hose Assembly 1

8 102538 1/4" x 24" Hose Assembly MP to MP 1

9 101040 1" Female Coupling 1

10 101073 1" Dust Plug 1

11 101039 1-1/4" Female Coupling 1

12 101074 1-1/4" Dust Plug 1

Optional 102377-1 60'-1" Pressure Hose Assembly

Optional 105207 60-1/4" Return Hose Assembly

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 25 Troubleshooting, Repair and Overhaul

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