WPT POWER WPD-02 Bedienungsanleitung

Power Pump Drive

Installation & Maintenance Manual

Model WPD-02

 
 
WIM-PD-002_B 
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Table of Contents 
0 Signal Words & Definitions ..................................................................................................................................................................... 3 
0 Introduction........................................................................................................................................................................................... 4 
1 Product Description .......................................................................................................................................................................... 5 
0 Section View of Basic Unit, Parts List....................................................................................................................................................... 6 
0 Installation............................................................................................................................................................................................. 7 
1 Requirements for Proper Operation and Service Life......................................................................................................................... 8 
2 Installing the Unit.............................................................................................................................................................................10 
3 Coupling Replacement .....................................................................................................................................................................13 
0 Disassembly..........................................................................................................................................................................................15 
1 Remove PTO from Pump Drive.........................................................................................................................................................15 
2 Remove all Auxiliary Attachments....................................................................................................................................................15 
3 Remove Pump Drive for Disassembly...............................................................................................................................................15 
0 Assembly ..............................................................................................................................................................................................17 
1 Prepare and Install Main Shaft Assembly .........................................................................................................................................17 
2 Prepare and Install Intermediate Shaft Assembly.............................................................................................................................18 
3 Prepare and Install the Drive Gear Assembly....................................................................................................................................19 
4 Install Input Housing and Set the Axial Endplay................................................................................................................................20 
5 Finalize the Main Shaft Assembly.....................................................................................................................................................21 
6 Install Domed Covers, Head, Extension, and/or Auxiliary Equipment. ..............................................................................................21 
7 Internal Heat Exchanger Installation (if equipped)............................................................................................................................22 
8 Installing a head clutch (if equipped). ...............................................................................................................................................23 
9 Installing a circulation pump (if equipped)........................................................................................................................................24 
10 Installing a head PTO (if equipped). ..................................................................................................................................................24 
11 Installing a Blank Head Face Cover Installation (If needed). ..............................................................................................................24 
0 Maintenance.........................................................................................................................................................................................25 
1 Maintenance schedule.....................................................................................................................................................................26 
2 Oil Level Check.................................................................................................................................................................................27 
3 Approved Oil with Operating Speeds................................................................................................................................................28 
4 Oil Temperature Specification..........................................................................................................................................................28 
0 Heat Exchanger.....................................................................................................................................................................................29 
1 Typical Closed Loop Cooling System (if applicable).............................................................................................................................29 
2 Internal Heat Exchanger (if applicable) ..............................................................................................................................................29 
0 Circulation Pump Configurations............................................................................................................................................................30 
1 “Y” Side [Output] without extensions with WP3-02-003 pump .............................................................................................................30 
2 “Z” Side [input] with extensions with WP3-02-003 pump .......................................................................................................................31 
3 “Z” Side [input] without extensions with WP3-02-002 pump ..................................................................................................................32 
4 “Y” Side [Output] with extensions with WP3-02-002 pump.....................................................................................................................33 
0 Tables...................................................................................................................................................................................................34 
0 General Storage Guidelines ...................................................................................................................................................................35 
0 Trouble Shooting Guide.........................................................................................................................................................................36 

WIM-PD-002_B

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1.0 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.

“Danger”

Denotes the most serious injury hazard and is used when

serious injury or death WILL result from misuse or failure to

follow the specific instructions set forth in this manual.

“Warning”

Denotes when serious injury or death MAY result from

misuse or failure to follow the specific instructions set forth

in this manual.

“Caution”

Denotes when injury or product or equipment damage may

result from the misuse or failure to follow the specific

instructions set forth in this manual.

WIM-PD-002_B

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2.0 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.

Warning

Read these instructions thoroughly and review until you fully

understand all warnings and hazards before proceeding with

the work described in this manual. Failure to follow the

instructions in this manual can result in unreasonable exposure

to hazardous conditions and/or personal injury and/or death.

Warning

Use of improper tools and/or methods when installing or

servicing this unit can result in accidents causing injury and/or

death. Adequate lifting points are provided to safely handle

only the individual unit components. Lifting and handling of the

assembled will require the use of alternate methods.

WIM-PD-002_B

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2.1 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.

The input is connected to the flywheel of the engine through an elastic coupling which is

connected to the main shaft and consequently to the gears. On the output shaft a flywheel is

available. Thus, any equipment with SAE sizes 0 through 3 meeting J617 and SAE 11.5”through

18” meeting J620 can be installed.

When ordering replacement parts, use the part numbers from the Bill of Material and drawing

supplied with the brake. The most current documents may be obtained by contacting WPT or

an authorized distributor. When ordering parts, provide the assembly number and serial number

for the unit found on the brass tag affixed to the front of the brake. See the example shown in

the figure immediately below.

“F” style shown with circulation pump and heat

exchanger Engine side

“B” style shown with head extension.

PTO side

Throughout this manual the terminology shown above may be used to refer to one side or the other.

Input side shall be known as “Z” side and the output side shall be known as “Y” side.

WIM-PD-002_B

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3.0 Section View of Basic Unit, Parts List

Section View

ITEM

DESCRIPTION

ITEM

DESCRIPTION

ITEM

DESCRIPTION

ITEM

DESCRIPTION

GEAR

BEARING

HHCS

LOCK WASHER

COVER

KEY

SHAFT, INTERMEDIATE

COUPLING

GASKET

WASHER

PLUG

HHCS

BEARING

SHCS

RETAINER

LOCK WASHER

O-RING

SHAFT, MAIN

SPACER

INPUT HOUSING

SPACER

O-RING

SHAFT, INTERMEDIATE

SEAL

RETAINER

SEAL

GEAR

VENT

HHCS

SET SCREW

SHIMS

BUSHING

WASHER

BEARING CARRIER

SHIELD

EYE BOLT

BEARING

GEAR

BEARING

CAP

COVER

HOUSING

OIL SEAL

HHCS

SEAL

HHCS

WASHER

PLUG

LOCK WASHER

HHCS

STUD

RETAINER

PLUG

WASHER

NUT

O-RING

FLYWHEEL

SHIM

WASHER

HUB

SIGHTGLASS

SHIELD

O-RING

HHCS

WIM-PD-002_B

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4.0 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.

Caution

Even though the units are properly set before shipment from the

factory, they should be checked for proper endplay before being

put into operation. See Section 6.4 for detailed instructions on

setting endplay.

Warning

Use only the proper quantity and grade of fasteners shown in the

drawings. Failure to do so may result in fastener failure and/or a

reduction in unit torque.

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4.1 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.

4.1.1 Check flywheel to housing face run out.

Mount the indicator base on the face of the flywheel and position the dial indicator tip

perpendicular to the flywheel housing mounting face. Rotate the flywheel 360 degrees while

holding pressure against the crankshaft thrust bearing. The total indicator reading should

not exceed:

SAE #3 Housing: 0.008 inches (0.20 mm)

SAE #2 Housing: 0.009 inches (0.23 mm)

SAE #1 Housing: 0.012 inches (0.30 mm)

SAE #0 Housing: 0.016 inches (0.41 mm)

4.1.2 Check flywheel housing bore run out.

Mount the indicator base on the face of the flywheel and position the dial indicator tip so its

movement is perpendicular to the pilot bore of the flywheel housing. Rotate the flywheel

360 degrees. The total indicator reading should not exceed:

SAE #3 Housing: 0.008 inches (0.20 mm)

SAE #2 Housing: 0.009 inches (0.23 mm)

SAE #1 Housing: 0.012 inches (0.30 mm)

SAE #0 Housing: 0.016 inches (0.41 mm)

WIM-PD-002_B

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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. The total indicator reading should not exceed:

11” Clutch: 0.007 inches (0.18 mm)

14” Clutch: 0.009 inches (0.23 mm)

18” Clutch: 0.011 inches (0.28 mm)

4.1.4 Check flywheel pilot bore 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 pilot ring inner diameter on the flywheel.

Rotate the flywheel 360 degrees. The total indicator reading should not exceed:

All Flywheel Sizes: 0.005 inches (0.13 mm)

CAUTION

NOTE: Consult PTO manual when installing PTO to pump drive.

WIM-PD-002_B

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4.2 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

check that flywheel is within SAE tolerances (see 4.1).

Following the provided technical specifications is recommended

for increased product life and safe operation.

WPT recommends performing

a transmission line torsional

vibration analysis. Especially

when the driven machine is

equipped with an additional

elastic coupling.

NOTICE: Thermal dissipation of the PPD is designed for an ambient temperature of 122°F [50°C]

max. Ambient temperature should be measured at a distance about 7.9-11.8 inch [20-30 cm]. For

ambient temperatures above 122°F [50°C], oil temperatures must be monitored. Design of engine

enclosure must be well vented.

Figure 1

4.2.2 Locate a dial indicator as per Fig. 1 and set it to zero to detect an eventual flywheel

housing deflection.

4.2.3 Mount the PPD on the flywheel housing of the engine keeping in mind to align the teeth

of the elastic coupling in the respective teeth of the driving ring.

To align the PPD housing and flywheel housing, use three threaded rods with adequate lengths,

mounted 120° apart on the flywheel housing.

To perform this operation, lift the assembly. In cases where the group includes a power take-off or

hydraulic coupling, support the assembly adequately to ease alignment.

4.2.4 Carefully release the lifting force and properly shim as shown on Fig. 1 in order keep the

dial indicator at zero. If indicator changes after bolts are tightened, re-shim until indicator

remains at zero.

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