50HP ELECTRIC

POWER UNIT
Revised December 2005
50HP ELECTRIC POWER UNIT Table Of Contents

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1

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Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1
Equipment Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
Lubricant Specs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4

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Hydraulic Fluid Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5
Hydraulic Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6
Component Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1
Setup and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1
Data Sheets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1
Gear Pumo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1
3000 PSI Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4
Filler Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5
Level Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.6
Sump Strainer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7
Filter Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.8
Filter Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9
OIl Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.10

IDENTIFICATION OF OF WARNINGS AND OTHER NOMENCLATURE OF

IMPORTANCE USED IN THIS MANUAL
Farr Canada uses three subsets to describe items in three degrees of importance.
The highest level of urgency is called a CRITICAL WARNING, and is identified with an excla-
mation point, is red in color, and is surrounded by a double black box. A CRITICAL WARNING
denotes an item of extreme importance, and failure to heed a warning may result in bodily
injury, death, severe equipment damage, or any combination of these.
A STANDARD WARNING is identified with an asterisk, and contains information critical to the
correct assembly or operation of the unit. A STANDARD WARNING may also serve to alert the
user to a potential low-level injury hazard. A STANDARD WARNING is also surrounded by a
double black box, but is amber in colour.
An ALERT is identified by black text within a double black box. An alert contains specific infor-
mation of note that pertains to the correct assembly or operation of the unit.

! This is how to identify a critical warning

* This is how to identify a standard warning

This is how to identify an alert

ii Section Contents Technical Manual - December 2005

 Introduction 50HP ELECTRIC POWER UNIT

Congratulations on the purchase of your new FARR 50 HP Electric Power Unit. This unit is designed
to provide you with years of outstanding performance. Simple maintenance and care will extend its life
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and insure a continuing level of excellence, performance and reliability.

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This manual will provide you with the information necessary to adequately care for your new equip-
ment. Performing the simple maintenance procedures in this manual will extend its life and ensure
continuing excellent performance and reliability.

Replacement parts are readily available from FARR Canada Ltd. in Edmonton Alberta. However, many
of the consumable parts are common items, and are likely to be found in supply stores or parts depots.
In the event you require parts not available to you locally, please do not hesitate to contact our service
department.

FARR 50 HP Electric Power Units are designed to supply GPM/PSI to customer specifications. The
power units are designed with an air-cooled heat exchanger, and are equipped with a level gauge to
ensure proper oil levels.

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50HP ELECTRIC POWER UNIT

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iv Section Contents Technical Manual - December 2005

 Specifications 50HP ELECTRIC POWER UNIT

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65-1/4”
94-3/4”

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50HP ELECTRIC POWER UNIT Specifications

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54”

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 Specifications 50HP ELECTRIC POWER UNIT

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Flow @ Operating Pressure 45 GPM @ 1000 PSI
15 GPM @ 2500 PSI
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Dimensions: 94-1/2" L x 68" H x 54" W
Weight: 4020 lbs. EMPTY
5640 lbs. FULL

Electric Motor: WEG W21 Severe Duty 50 HP-NEMA 326TC Frame

1775 RPM @ 60Hz
Power Requirements: 208 - 230 VAC 116A (Full Load) 3P
460 VAC 57.8A (Full Load) 3P

Electric Switchbox: ADALET Severe Duty Enclosure

Model: XCBSMQN4

Oil Capacity: 135 US Gallons

Heat Exchanger: Thermal Transfer Products AOHMR-30-1-60-FB

Max. Operating Pressure 300 psi
Max Operating Temperature: 400 Deg. F

Gear Pump:
Model: Parker-Commercial P51B142BIOR22-11COK17-1
Displacement, 2-1/4” gear: 5.74 in3 / rev.
Max Pressure, 2-1/4” gear: 2500 PSI
Displacement, 1-3/4” gear: 4.46 in3 / rev.
Max Pressure, 1-3/4” gear: 3000 PSI

Max Contamination 20/18/15 ISO/DIS 4406 (NAS Class 9)

Level

Relief Valve Setpoint 2500 PSI

Unloading Valve Setpoint 1000 GPM

Filtration System
Spin-On Filter SDF Series Filter Head: SDF-2215-25-1-V
Replacement Cartridges: SF6707 6 micron

Technical Manual - December 2005 Section Contents 1.3

50HP ELECTRIC POWER UNIT Specifications

Use an EP synthetic grease that meets or exceeds the following specifications:

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Thickener Lithium Complex

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NLGI consistency grade 2
NLGI performance grade GC-LB
Penetration - ASTM D 217 (25°C [77°F] 265-295 minimum
0.1 mm) worked 60 strokes
Dropping point, °F[°C] - ASTM D2265 550 [288] minimum
High temperature life, hours - ASTM D 3527 160 minimum
Oxidation stability, psi - ASTM D 942 (100 hr/300 hr) 0/3
Water washout, percent - ASTM D 1264 1.8 max
Rust and corrosion - ASTM D 1743 pass
Oil separation, percent loss - ASTM D 1742 1.1 max
(24 hours, 25°C [77°F]
Leakage, g lost - ASTM D 4290 1.0 max
Four ball wear test, mm scar - ASTM D 2266 0.40 max
Fretting wear, mg - ASTM D 4170 3.4 max
Four ball EP, kgf - ASTM D 2596
Weld point 400 minimum
Load wear index 50 minimum
Timken OK load test, lbs - ASTM D 2509 50
Low temperature torque, N*m - ASTM D 4693 1.3 max
(-40°C [-40°F])
LT-37 pumpability, g/min 360/7
(60°F/0°F [16°C/-18°C])
Copper corrosion - ASTM D 4048 1B
Disc brake wheel bearing specifications
Ford ESA-M1C 198A Yes
Chrysler MS-3701 Yes
Oil viscosity: 40°C [104°F], cSt 151
100°C [212°F], cSt 19.2
Flash point, °F[°C] - ASTM 92 450[232]

1.4 Section Contents Technical Manual - December 2005

 Specifications 50HP ELECTRIC POWER UNIT

Use a premium quality hydraulic fluid that meets or exceeds the following specifications:
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Typical Density (kg/m3) 878

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Viscosity - cSt @ 40 °C 68.8
- cSt @ 100 °C 8.7
Viscosity Index 97
Pour Point °F [°C] -22 [-30]
Flash Point °F [°C] 432 [222]
Colour, ASTM 1.5
Neutralization Number 0.40
Rust Protection - Distilled Water No Rust
- Sea Water No Rust
Hydrolytic Stability - Cu Mass Loss, mg/cm2 0.04
Copper Corrosion Test 1A
Filterability: Denison - Wet & Dry Pass
Afnor - Wet & Dry Pass
Cincinatti Milacron Spec Approved P69
Denison HF-0: Approved
Denison P-46 Piston Pump: Pass
Denison T6C Vane Pump: Pass
Vickers 35VQ25 Vane Pump Test: Pass
104/105C Vane Pump Test: No Data Available
Vane pump test total ring and vane wear, mg. <10
Oxidation Stability
Turbine Oil Stability Test Life, hours 2500+
Rotary Bomb Oxidation Test, minutes 325
FZG Spur Gear Test, Failure Load Stage (FLS) 12

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50HP ELECTRIC POWER UNIT Specifications

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1.6 Section Contents Technical Manual - December 2005

 Component Identification 50HP ELECTRIC POWER UNIT

1 2 3 4 5
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6 7 8 10 9

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50HP ELECTRIC POWER UNIT Component Identification

11 12

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10

13

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 Component Identification 50HP ELECTRIC POWER UNIT

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15

16

6 7

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50HP ELECTRIC POWER UNIT Component Identification

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 Component Identification 50HP ELECTRIC POWER UNIT

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15

18

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50HP ELECTRIC POWER UNIT Component Identification

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2.6 Section Contents Technical Manual - December 2005

 Component Identification 50HP ELECTRIC POWER UNIT

Item Description Qty Part Number Page

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1 Power Unit Basket Assembly 1 1487-100-00 2.1

2 Hydraulic Fluid Tank Assembly 1 1487-200-00 2.1, 2.4
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3 Tank Level Gauge 1 07-0492A 2.1
4 Electrical Control Box 1 90-1002 2.1
5 Hydraulic Fluid Cooler c/w Hydraulic Motor 1 08-0195 2.1, 2.4
6 50HP Electric Motor 1 02-0268W 2.1
7 50 HP Combination Starter 1 2.1
8 Unloading Manifold 1 08-0153 2.1
9 Skid Assembly 1 1487-00-00 2.1
10 Filter Element 2 02-0317 2.1, 2.5
11 3000 psi Pressure Gauge (Low Pressure, Hi Volume 1 02-0245 2.2, 2.6
12 3000 psi Pressure Gauge (Hi pressure, Low Volume) 1 02-0245 2.2, 2.6
13 Hydraulic Fluid Supply 1 2.2
14 Hydraulic Fluid Return 1 2.2
15 Gear Pump 1 07-0212 2.3, 2.5
16 Remote Control 1 90-2000 2.3, 2.4
17 2” Shutoff Valve 2 08-1155 2.4, 2.5
18 Dual Return Filter Head 1 02-0315 2.1, 2.2, 2.5
19 Hydraulic Motor - Oil Cooler 1 2.6
20 Fluid Pressure Dump Valve 1 2.6
21 Oil Cooler Motor Shutoff Valve 1 2.6

Other applicable part numbers:

Qty. Description Part No.

2 Suction Strainer 02-0272
1 Ball Valve 08-0338
1 Relief Valve 08-0193
1 Check Valve 07-0616
1 Sequence Valve 07-0614
1 Flow Control Valve 07-0617
1 Filler Breather 08-0340
1 Pump/Motor Adapter 08-0152B
1 Coupling Half 02-0113A
1 Coupling Half 02-0114
1 Unloading Manifold Stand 1487-150-00
1 Electrical Control Panel Stand 1487-200-00

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50HP ELECTRIC POWER UNIT Component Identification

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2.8 Section Contents Technical Manual - December 2005

 Setup & Operation 50HP ELECTRIC POWER UNIT

Unpack and inspect your power unit for shipping damage. The operation of this equipment has been
thoroughly tested and inspected at the factory, and observation of a few simple guidelines will ensure
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trouble-free operation.
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1) Fill oil tank with your selection of hydraulic fluid. Fill to roughly halfway up the level gauge, leaving
adequate room in the tank for fluid expansion. See Section 1 for Farr Canada’s recommendations
for hydraulic lubricants and fluids.

!
Do not start power unit before turning the bypass
valve handle to the “start” (fully counter-clockwise)
position. Substantial damage to the pump may occur.

2) Connect hydraulic lines to tong before starting power unit. The possibility of cross-connecting the
high pressure supply hose and the low pressure return hose has been eliminated by using a 1”
high pressure hose and a 1-1/4” return hose. These hose couplings are self-sealing, and care
should be taken to ensure complete engagement to prevent partial closure of the check valve in
the coupling. Ensure that the nut (female) side is completely made up onto the male connector
- there is a line on the male fitting that indicates complete make-up. Snug the female fitting right
up to the line.
(See following illustration)

dis-assembled

Make up female fitting

to marked line

assembled

3) Turn the bypass valve handle to the “start” position (fully CCW).

Bypass valve handle in

“START” position.

Technical Manual - December 2005 Section Contents 3.1

50HP ELECTRIC POWER UNIT Setup & Operation

4) Turn fluid bypass handle to the “RUN” position to circulate fluid to the tong.

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5) Open the control valve for the cooling fan motor fluid supply. In most cases this valve will be at
lease partially open while running pipe, unless the ambient temperature is 0o C or lower.

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Control handle for fan
motor is on side of
manifold block.

* Normal operating temperature for hydraulic fluid is

60o C to 80o C.

Pump inlet to P1 AND P2 is combined to give maximum flow at low pressure (45 GPM @ 1000 psi)
(see hydraulic schematic). When the load pressure increases to the unloading valve setting, the high
flow (low pressure) module of the pump is bypassed from P1 to the recovery tank, which allows the
majority of system power to be used for the high pressure module of the pump. The system relief
valve provides protection by limiting the maximum pressure in the system line. This allows for fast and
efficient crossover, giving rapid advance and high power compaction with the most economic usage of
system components and energy requirements.

When inlet pressure exceeds the setting of the main relief valve, the pilot section opens. This pilot flow
causes a pressure imbalance across the main section spool causing it to open, allowing relief flow
to tank. When “vented”, pilot flow is referenced directly to tank, bypassing the pilot section, this flow
through the vent port causes a pressure imbalance, opening the main section and dumping the pump
at minimum pressure drop. The over-all effect is limited pressure in the system.

3.2 Section Contents Technical Manual - December 2005

 Maintenance 50HP ELECTRIC POWER UNIT

Farr Canada power units are designed to provide years of trouble-free service. A few simple precau-
tions will help extend the life of your equipment and avoid unscheduled maintenance.
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FILTER REPLACEMENT
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Replace sediment / particle filters after 100 hours of initial use, then a minimum of once per every 250
hours - more often if the power unit is continuously used in a dusty environment. The filter head may
be equipped with an indicator gauge. If so, the gauge should be checked routinely; if the arrow on the
gauge approaches the “red zone”, the filter canisters should be replaced even if the recommended
interval has not been reached. See Page for recommended replacement canisters.

HYDRAULIC FLUID

Hydraulic fluid that is unused for a long period of time, or is repeatedly heated to high temperatures
(above 80o C) should be tested annually by a qualified laboratory. “Cracked” fluid can result in signifi-
cantly reduced performance.

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50HP ELECTRIC POWER UNIT

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 Data Sheets - Gear Pump 50HP ELECTRIC POWER UNIT

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Technical Manual - December 2005 Section Contents 5.1

50HP ELECTRIC POWER UNIT Data Sheets - Gear Pump

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5.2 Section Contents Technical Manual - December 2005

 Data Sheets - Gear Pump 50HP ELECTRIC POWER UNIT

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Technical Manual - December 2005 Section Contents 5.3

50HP ELECTRIC POWER UNIT Data Sheets - 3000 PSI Gauges

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5.4 Section Contents Technical Manual - December 2005

 Data Sheets - Filler Breather 50HP ELECTRIC POWER UNIT

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Technical Manual - December 2005 Section Contents 5.5

50HP ELECTRIC POWER UNIT Data Sheets - Level Gauges

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5.6 Section Contents Technical Manual - December 2005

 Data Sheets - Sump Strainer 50HP ELECTRIC POWER UNIT

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Technical Manual - December 2005 Section Contents 5.7

50HP ELECTRIC POWER UNIT Data Sheets - Filter Head

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5.8 Section Contents Technical Manual - December 2005

 Data Sheets - Filter Elements 50HP ELECTRIC POWER UNIT

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Replacement Canister

Technical Manual - December 2005 Section Contents 5.9

50HP ELECTRIC POWER UNIT Data Sheets - Oil Cooler

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5.10 Section Contents Technical Manual - December 2005

 Data Sheets - Oil Cooler 50HP ELECTRIC POWER UNIT

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Technical Manual - December 2005 Section Contents 5.11

50HP ELECTRIC POWER UNIT Data Sheets - Oil Cooler

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5.12 Section Contents Technical Manual - December 2005

 Data Sheets - Oil Cooler 50HP ELECTRIC POWER UNIT

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Technical Manual - December 2005 Section Contents 5.13