Spare Parts / Specifications Manual DPU660-09 Diesel Hydraulic Power Unit • Specifications • Dimensional Drawings • Schematics • Assembly Drawings DRILLING & COMPLETIONS mccoyglobal.com mccoyglobal.
AUTHORISED USE ONLY Only authorised personnel who are deemed competent to operate, maintain, and repair this equipment may do so. © Copyright 2012 McCoy Corporation, including its wholly owned subsidiaries, (“McCoy”), all rights reserved. This document is the property of McCoy and is supplied as reference information for users of our products.
WARNING READ BEFORE USING EQUIPMENT This Spare Parts / Specifications Manual is intended to be used as a companion to the Operator’s Manual. DO NOT operate equipment without fully reviewing and complying with all safety guidelines outlined in the separate Operator’s Manual. Please contact McCoy Drilling & Completions customer service to obtain the appropriate Operator’s Manual if it has not been made available to you.
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Table of Contents Specifications.............................. 7 Schematics................................ 11 Assembly Drawings................... 15 mccoyglobal.
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Specifications Overall Equipment Dimensional Illustrations................................8 Specifications & Spare Parts........................................................9 mccoyglobal.
Specifications Overall Equipment Dimensional Illustrations 4,200 lbs (approx.) 1,905 kg (approx.) 50" 3 66 4 " 3 101 4 " ©2011 McCoy Corporation Page 8 mccoyglobal.
Specifications Specifications & Spare Parts Specifications Diesel Motor Output 114 HP @ 2,300 RPM Maximum Flow 60 GPM @ 1,000 PSI Maximum Pressure 3,000 PSI Hydraulic Oil Capacity 140 US GAL. Diesel Tank Capacity 42 US GAL. Operation Type Open loop for over-center valve Decibel Readings: 1.0 meter, 1 min 94 db (A), 97 db (C) Spare Parts Recommendations Qty Part Number Part Name 1 GNSH20-20 Dual Gear Pump 60GPM 2 P164697 Filter Elements 1 2.
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Schematics Power Unit Hydraulic Schematic..................................................12 mccoyglobal.
©2011 McCoy Corporation Page 12 14 13 LP HP 14 HYD. OIL RESERVOIR 4 3 7 FRONT GAGE Diesel Engine* DIESEL RESERVOIR HYDRAULIC SCHEMATIC 1 2 3.97 IN^3/REV EACH SECTION 30 GPM EACH SECTION AT 1800 RPM 3000 PSI MAX., 2500 RPM MAX. SAE C MTG.
mccoyglobal.com Page 13 1 1 1 1 1 1 1 3 2 7 8 9* 10 * 11 12 13 14 15 1508 1205 DT-45G HRES-150 DPU660-S1 1445 1440 BAC-5M25RCFF 7040HL-011 BAC-3M25RCFF 2070 GNSH20-20 F6L914 1458 2.
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Assembly Drawings DPU660-09 Diesel Power Unit Assembly.....................................17 mccoyglobal.
Assembly Drawings ©2011 McCoy Corporation Page 16 mccoyglobal.
Assembly Drawings DPU660-09 Diesel Power Unit Assembly Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 DPU660-05 DPU660-06 Part Number Quantity Quantity 1 1 DSKD-02 1 1 DBSKT-02 1 1 HRES-150 1 1 GNSH20-20 1 1 1 1 1 1 1 1 1 1 1 1 1 3 2 0 0 1 1 1 1 1 1 1 1 1 1 1 1 1 1 3 2 1 1 1 DPU660-S1 1440 1445 1458 2070 F6L914 7042HL-013 DT-45G 2.5 STRAINER 7040HL-011 7042HL-015 BAC-3M25RCFF BAC-5M25RCFF 1205 1508 HAK050017 DPU660-S2 KITFIT-DPU660 Description SKID FOR 6 CYL.
McCoy Drilling & Completions | Superior 4225 Hwy 90 East • Broussard, LA USA T: 337.837.8847 F: 337.837.8839 salesSuperior@mccoyglobal.
Operator’s Manual Hydraulic Power Unit • Commissioning • Operation • Maintenance • Troubleshooting • Decommissioning DRILLING & COMPLETIONS
READ BEFORE USING EQUIPMENT Personnel As a minimum, we recommend that all personnel operating or working in the vicinity of hydraulic equipment wear basic PPE (Personal Protective Equipment) such as eye, ear, head, hand, and foot protection. Only trained and competent users should be allowed to directly operate or operate around McCoy equipment. Safety guidelines suggested by McCoy are in no way intended to supersede the specific health and safety regulations outlined by the end user.
READ BEFORE USING EQUIPMENT Pinch / Touch Points All OEM warning stickers should be closely observed. Users of manually operated equipment should be properly trained in its use and be acutely aware of the potential hazards the equipment poses to them and surrounding personnel. McCoy recommends adopting a ‘touch point’ paint scheme to highlight areas which are acceptable to touch on the equipment.
General About This Manual Hazard Notification Maintenance & Service This manual is intended to give users general guidelines on operating and working around McCoy equipment, as well as to encourage good maintenance practices which will extend product life. Throughout this manual, important notifications and warnings appear intended to alert the user of potential danger or practices which must be observed. It is imperative that all notice or warning boxes be observed.
AUTHORISED USE ONLY Only authorised personnel who are deemed competent to operate, maintain, and repair this equipment may do so. © Copyright 2012-2013 McCoy Corporation, including its wholly owned subsidiaries, (“McCoy”), all rights reserved. This document is the property of McCoy and is supplied as reference information for users of our products.
Thank You. We at McCoy would like to thank you for entrusting our equipment to meet your Drilling & Completions needs. This manual is intended to give users general guidelines on operating and working around McCoy equipment, as well as to encourage good maintenance practices which will extend product life. Contacting McCoy McCoy Drilling & Completions 4225 Hwy 90 East • Broussard, LA USA T: 1.337.837.8847 F: 1.337.837.8839 dcsales@mccoyglobal.
Table of Contents Section 1 1-1 Component Identification 1-1.1 Basic Electric Power Unit Component Identification 1-1.2 Basic Diesel Power Unit Component Identification 1-1.3 Basic RP Style Console / Power Unit Component Identification 1-1.4 Connection Panel Item Identification Section 2 2-1 Status Monitoring 2-1.1 Operating Temperature 2-1.2 Operating Pressure 2-2 Commissioning 2-2.1 Making Up / Breaking Out Hydraulic Connections 2-2.2 Moving and Placing the Unit 2-2.
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Basic Identification Section 1 1-1 Component Identification 1-1.1 Basic Electric Power Unit Component Identification 1-1.2 Basic Diesel Power Unit Component Identification 1-1.3 Basic RP Style Console / Power Unit Component Identification 1-1.4 Connection Panel Item Identification mccoyglobal.
Basic Identification 1-1 Component Identification 1-1.1 Basic Electric Power Unit Component Identification G H I A B F J C D E K M N ©2012 McCoy Corporation L A. B. C. D. E. F. G. H. I. J. K. L. M. N.
Basic Identification 1-1 Component Identification 1-1.2 Basic Diesel Power Unit Component Identification D E F G A B C H mccoyglobal.com I J K N L M A. B. C. D. E. F. G. H. I. J. K. L. M. N.
Basic Identification 1-1 Component Identification 1-1.3 Basic RP Style Console / Power Unit Component Identification A. B. C. D. E. F. G. H. I. J. K. L.
1-1 Component Identification Basic Identification 1-1.4 Connection Panel Item Identification ●●Load Sense: Connection point to connect the load sense feature of the power unit’s hydraulic pump.
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Commissioning & Operation Section 2 2-1 Status Monitoring 2-1.1 Operating Temperature 2-1.2 Operating Pressure 2-2 Commissioning 2-2.1 Making Up / Breaking Out Hydraulic Connections 2-2.2 Moving and Placing the Unit 2-2.3 Ventilation Considerations 2-2.4 Initial Start-Up 2-2.5 Extreme Cold Weather Start-Up Procedure 2-3 Operation 2-3.1 General Operation Notes 2-3.2 Depressurization Procedure mccoyglobal.
Commissioning & Operation 2-1.1 Operating Temperature 2-1 Status Monitoring 2-1.2 Operating Pressure 1500 1000 77 500 150 50 bar psi ●● ISO68 hydraulic oil is designed to operate at a temperature range of 130 degrees F (55 degrees C) to 170 degrees F (77 degrees C), in order to maintain proper viscosity of 100 SSU. The use of an oil cooler may be required if the operating temperature reaches the maximum temperature.
2-2 Commissioning Commissioning & Operation 2-2.1 Making Up / Breaking Out Hydraulic Connections ●●Before connecting any hydraulic joint, always inspect hoses for damage and any dirt or contaminants. Clean as necessary with compressed air or an approved cleaning solvent in combination with a lint-free cloth. mccoyglobal.com Fully make up connection to ●●Wing type hydraulic disconnects should almarked point on male fitting ways be fully made up to the connection line on the joint.
Commissioning & Operation 2-2 Commissioning 2-2.2 Moving and Placing the Unit ●●For additional information regarding proper rigging and overhead lifting , refer to OSHA, ASME B30.9-2006. For additional information on load bearing devices, see OSHA 1910.184, ANSI/ASME B30.9 ”SLINGS”, ANSI/ASME B30.10 ”HOOKS” and ANSI/ASME B30.26 “RIGGING HARDWARE”.
2-2 Commissioning Commissioning & Operation 2-2.3 Ventilation Considerations ●● When operating diesel power units in an enclosed environment, assure that the unit is placed in an area with sufficient ventilation to assure that exhaust fumes do not accumulate. WARNING If the power unit is to be placed within an enclosed area, it is imperative that sufficient ventilation be maintained. Local mechanical codes should be consulted when considering indoor placement locations and setups.
Commissioning & Operation 2-2.4 Initial Start-Up 1. Remove any shipping restraints that may be present on the equipment 2. Ensure adequate lubrication, oil, and fuel (if applicable) levels. ●● Fill hydraulic reservoir with specified hydraulic oil. Ensure suction isolation valve is open. ●● Fill chain drive case with specified gear oil. ●● Lubricate all grease fittings with specified bearing grease. ●● See any third party component’s operator’s manual for manufacturer specific start up instructions. 3.
2-3 Operation Commissioning & Operation 2-3.1 General Operation Notes ●●When shutting down the unit under normal operation, always use the nominal shut down method (either by means of a starter box or engine pull level) and not the ESD (Emergency Shut Down) switch. ESD switches should only be used in emergency situations as daily use may damage engine components.
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Fluids, Lubrication, & Torque Section 3 3-1 Hydraulic Oil 3-1.1 Hydraulic Fluid Specifications 3-1.2 Hydraulic Fluid Maintenance 3-2 Fastener GeartrainTorque GreaseSpecifications 3-2.1 Fastener GeartrainTorque GreaseSpecifications Specifications 3-3 Bearing Grease 3-3.1 Bearing Grease Specifications 3-4 Fastener Torque Specifications 3-4.1 Fastener Torque Specifications mccoyglobal.
Fluids, Lubrication, & Torque 3-1.1 Hydraulic Fluid Specifications When replacing hydraulic fluid, always use a fluid that meets or exceeds the standards displayed in the table provided. Use of unapproved hydraulic fluid may lead to equipment damage. Use the following standards when selecting hydraulic fluid for use in CLINCHER® brand equipment. NOTICE It is imperative that ONLY hydraulic fluid that meets the standards listed on this page be used in your hydraulic equipment.
3-1 Hydraulic Oil Fluids, Lubrication, & Torque 3-1.2 Hydraulic Fluid Maintenance When implementing hydraulic equipment into a schedule of regular service, it is essential to adopt a regimented, properly administrated hydraulic fluid maintenance schedule. Many costly hydraulic system repairs can be drastically reduced or completely eliminated this way.
Fluids, Lubrication, & Torque 3-4.1 Torque 3-2.1 Fastener Fastener Torque Specifi cations Specifications Most fasteners and threaded components listed should be coated with Never-Seez® or equivalent prior to assembly. Certain fasteners or components require the application of Loctite® before installation. It is important to first reference the corresponding assembly drawing to obtain such information. All tapered pipe thread connections be sealed and locked using Loctite 569™ hydraulic sealant.
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Inspection & Maintenance Section 4 4-1 Maintenance 4-1.1 Maintenance Considerations 4-1.2 Daily Inspection & Maintenance 4-1.3 Decommissioning 4-1.4 Storage 4-1.5 Recommissioning mccoyglobal.
Inspection & Maintenance 4-1.1 Maintenance Considerations NOTICE When carrying out these maintenance procedures, hydraulic fluid and industrial lubricants will be expelled or rinsed off of the equipment. Ensure adequate containment is in place to prevent environmental contamination. Equipment systems utilizing exterior electrical components must be hand washed. Never directly spray electrical cables or equipment with a high pressure wash. All third party components (engine, pump, heat exchanger, etc.
4-1 Maintenance Inspection & Maintenance 4-1.4 Storage prior to storage. Prepare areas to be painted to ensure they are free of grease, dirt, or solvent. Touch up with appropriate paint. Allow sufficient time for paint to dry before proceeding. 8. Perform a complete lubrication of all externally accessible grease fittings on equipment. 9. Connect a low-pressure air supply line (10 PSI or less) to the hydraulic supply line, and force a small amount of the remaining hydraulic fluid from the valve assembly.
Inspection & Maintenance 4-1 Maintenance 4-1.5 Recommissioning ●●The following procedure is to be carried out when removing equipment from storage and into a working environment. This procedure assumes that the equipment in question has been decommissioned in accordance with the steps listed in this manual. 1. Remove all protective plastic wrapping. Dispose of any desiccant packs. 2. Wipe excess grease or heavy oil from exposed cylinder rods (if applicable). 3.
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Troubleshooting Section 5 5-1 General Troubleshooting mccoyglobal.
Troubleshooting 5-1 General Troubleshooting Problem Action Key Insufficient System Pressure F Flush hydraulic fluid & replace CH Check fluid levels, add as necessary CL Clean / clear debris L Inspect for fluid leaks, repair as necessary R Repair or replace IN Inspect, realign / adjust / re-calibrate to correct value LU Lubricate components Hydraulic Pump Making Excessive Noise High Operating Temperature Excessive Wear to Hydraulic Components • • • • • • • • • • • • • • • • • • • • • ©
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