wolverinesmallframegaspowerpacks_2

Operating Manual for

Small Frame

Hydraulic Power Packs

Wolverine Equipment is a Division of Concut, Inc.

Table of Contents General Instructions …………… 2 User Responsibilities …………… 2 Uncrating and Assembly …………… 3 Hydraulic System …………… 3 Engine and Fueling …………… 4 Operation in Closed Areas …………… 5 Battery …………… 5 Prohibition of Alternative Applications …………… 6 Adjustment of Controls – Engine …………… 6 Operating Hydraulic Power Unit …………… 6 Operation of Powered Equipment …………… 7 Hydraulic Oil Cooler …………… 8 Hydraulic Oil Tank …………… 8 Hydraulic Oil System Maintenance …………… 8 Suggested Engine Maintenance Guidelines …………… 10 Warranty …………… 11 Resource Guide …………… 12 Power Pack Diagrams and Parts …………… 13

Revised 9/6/2013

GENERAL INSTRUCTIONS This instruction manual describes the operating procedures, care, maintenance, adjustments, and safety precautions for proper use of Wolverine Equipment’s small frame hydraulic power packs. Most of this information pertains to all three versions of the power packs -- gas, diesel and electric. Specific instructions for a particular type of power pack may also be noted. This equipment is intended for industrial applications by experienced operators. It is to be operated in conformance with applicable federal, state, and local codes or regulations pertaining to safety, air pollution, noise, etc.

WARNING! IMPROPER USE OF THIS EQUIPMENT

OR IMPROPER MACHINE ALTERATIONS MAY BE EXTREMELY DANGEROUS

The operator is cautioned against using this machine before having read and fully understood the instructions presented in this manual and in the component manufacturers’ instructions provided separately. Those manufacturer instructions take precedence. USER RESPONSIBILITIES It is the operator’s responsibility to use this machine under safe working conditions and to be fully aware of requirements for operator safety and safety of co-workers, observers, and the public at large. The operator must be aware of machine’s capabilities and limitations and follow the safety precautions in each section of this manual. Periodic maintenance is required, in accordance with instructions herein, to promote safe and reliable operations. Care is to be taken by the operator to see that all of the safety features furnished with the machine are properly installed and operational. It is the responsibility of the operator to provide a safe working environment and to follow proper safety procedures when operating this equipment. Operators must

Revised 9/6/2013

use approved ear muffs or plugs, safety hat, eye protection, gloves, safety shoes, and any other personal protective equipment required for compliance with standard safety practices or federal, state and local codes and regulations. UNCRATING AND ASSEMBLY Uncrate the equipment carefully to prevent damage. This machine was inspected and operated before shipment and should not require any additional adjustments prior to its initial use. However, in the unlikely event of damage during shipment, the operator is advised to check out the machine by following the instructions of this manual in operating each of the equipment subsystems. HYDRAULIC SYSTEM The reservoir of the hydraulic power pack must be filled with fluid prior to start-up. A high quality petroleum based hydraulic oil with the following properties is recommended: anti-wear, low foaming, rust and oxidation inhibitors, wide temperature range. It should have a viscosity of approximately 300 SSU @ 100° F (ISO 68) for use in higher ambient temperature climates, regularly above 80° F; the oil should have a fluid viscosity of approximately 225 SSU @ 100°F (ISO 46). Check with local oil suppliers for availability. The oil must be kept free of contamination to avoid damage to system components. Quick disconnects must be cleaned before connection is made. Maximum allowable oil temperature at pump inlet is 180°F. Suggested maximum temperature is 150°F. The hydraulic system is compatible with components of some manufacturers. Wolverine Equipment may be able to supply information as to operational capabilities if sufficient specifications are available. SAFETY PRECAUTION

IMPROPER USE OF THE HYDRAULIC SYSTEM OR IMPROPER MACHINE ALTERATIONS MAY BE EXTREMELY DANGEROUS.

Revised 9/6/2013

INTRODUCTION OF CONTAMINANTS INTO THE SYSTEM WILL REDUCE COMPONENT SERVICE LIFE AND VOID ANY WARRANTY. ENGINE This machine may be equipped with a gasoline or diesel engine. MAKE SURE THE ENGINE CRANKCASE IS FILLED WITH OIL TO THE PROPER LEVEL. A dipstick is provided for gauging the oil level in the crankcase. Operating without oil will ruin the engine. FUELING Regular grade gasoline is to be used with gas equipment, although Premium grade can be used if necessary. Diesel fuel should be used with diesel engines. Add fuel to the tank only when the engine is stopped and cool and take care to prevent spilling fuel over any part of the equipment.

WARNING IN THE EVENT OF FUEL SPILLAGE, DO NOT ATTEMPT TO START THE ENGINE OR OPERATE ANY ELECTRICAL COMPONENT UNTIL THE SPILLED FUEL HAS BEEN REMOVED. MAINTAIN AN APPROVED FIRE EXTINGUISHER READILY AVAILABLE IN THE EVENT OF FIRE. SAFETY PRECAUTION DO NOT OVERFILL THE FUEL TANK. ALWAYS LEAVE ENOUGH SPACE FOR EXPANSION DUE TO ENVIRONMENTAL HEATING. The operator is advised to defuel the tank during temporary storage within an enclosed area. This will reduce chances of fire.

Revised 9/6/2013

OPERATION IN CLOSED AREAS The operator is cautioned not to use diesel or gas equipment within enclosed spaces. Fumes from the engine contain carbon monoxide, a poisonous, odorless and invisible gas, which, if breathed by operator or other occupants of the enclosed space, causes serious illness and possibly death. Enclosed spaces include all areas where natural ventilation is restricted, such as buildings, truck enclosures, and access paths between buildings. Open skyways, windows and doorways are not sufficient for preventing this hazard.

WARNING DO NOT OPERATE ENGINE WITHIN ENCLOSED OR CONFINED SPACES. FOR ELECTRIC POWER UNITS ONLY Refer to instructions on motor to ensure proper motor rotation. The pump is single-directional and will not operate if rotation is in the wrong direction. BATTERY A 12-volt dry charged battery is installed in the machine. SAFETY PRECAUTION THE SULFURIC ACID ELECTROLYTE IS CORROSIVE. READ AND FOLLOW ALL SAFETY PRECAUTIONS AND INSTRUCTIONS ON THE ELECTROLYTE. HAVE RUNNING WATER INSTANTLY AVAILABLE FOR FLUSHING. IF THE ELECTROLYTE SHOULD COME IN CONTACT WITH THE BODY, CLOTHING, BATTERY, ETC, NEUTRALIZE WITH BAKING SODA OR AMMONIA SOLUTION. THOROUGHLY RINSE AND EMPTY

Revised 9/6/2013

ACID CONTAINER WITH WATER AND BAKING SODA BEFORE DISCARDING. PROHIBITION OF ALTERNATIVE APPLICATIONS Use of this equipment as a vehicle for transporting personnel or equipment is hazardous. No attempts to use the equipment for this purpose should be allowed. This equipment was designed for a single purpose. Its modification for alternative uses is not recommended and may cause an unrecognized hazard to the operator. ADJUSTMENT OF CONTROLS – ENGINE Review the engine manual provided with the power unit for details of control actions. The governor is adjusted at the factory to provide an idle speed of 1000 RPM and a maximum (no load) speed of 3600-3800 RPM. OPERATING POWER UNIT The following procedures must be adhered to when starting and operating the power unit.

1. Connect hydraulic hoses to power unit. Connect tool to hoses. The flow valve must be set at the off position .

2. Pull out throttle control. Start engine - choke if necessary. 3. Idle engine at 1000 RPM gradually increasing speed to 2000 RPM over a 2-

3 minute period to warm engine. 4. Turn knob counter clockwise on flow valve to engage flow. 5. Gradually increase engine speed from 2000 RPM to 3600 RMP over a 2-3

minute period to warm hydraulic system. 6. The power units are equipped with positive displacement gear pumps. All

tools must be equipped with an open-centered valve.

Note: The power unit has been factory adjusted to provide correct pressure relief (approximately 2350 psi).

Revised 9/6/2013

OPERATING PRECAUTION

IT IS IMPERATIVE THAT THE QUICK – DISCONNECTS BE CLEAN WHEN CONNECTING HOSES AND DEVICES. FAILURE TO THOROUGHLY CLEAN WILL RESULT IN PREMATURE FAILURE OF SYSTEM COMPONENTS.

SAFETY PRECAUTION PRIOR TO USE, THE OPERATOR MUST KNOW THE HYDRAULIC REQUIREMENTS AND LIMITATIONS OF THE DRIVEN EQUIPMENT TO BE OPERATED AND THE APPROPRIATE ADJUSTMENTS MUST BE MADE ON THE CONTROLS. FAILURE TO DO SO, OR THE INTRODUCTION OF OTHER CONTROL DEVICES, MAY CAUSE SYSTEM HEATING OR MAY RENDER THE SYSTEM INOPERATIVE.

OPERATION OF POWERED EQUIPMENT

Before running any tools or equipment with the Wolverine power pack, review the instructions supplied with that equipment. Instructions must be followed to ensure the correct connection and operation of each individual piece of equipment. Equipment supplied by Wolverine Equipment will be capable of being connected correctly and will be compatible with this power pack, provided neither has been modified from original factory configuration. With equipment from other manufacturers, it will be necessary to determine the following:

1. Correct direction of flow through the equipment. 2. Correct pressure and flow required by the equipment. 3. Compatibility of any valving or circuitry and quick disconnects. Some

hand-held equipment, such as handsaws or hammers, utilize trigger controls which are operated frequently. These valves must be of the open center type for correct operation.

Revised 9/6/2013

HYDRAULIC OIL COOLER Most power units are equipped with an oil/air cooler. Power units which are equipped with water/oil heat exchangers must be supplied, when used, with a minimum of 4 GPM (7 LPM) water flow. The water supply hose is connected to the cooler and then routed either to the driven tool or to a convenient drain point on the job site. Routing the water to a drain normally provides higher cooling capacity where required. It is recommended the heat exchanger be used at all times. HYDRAULIC OIL TANK Hydraulic oil tanks are marked with a maximum and minimum oil level. DO NOT EXCEED MAXIMUM LEVEL! Hydraulic oil needs room for expansion when hot; over-filling may cause the hydraulic tank to rupture. PLEASE NOTE: If the hydraulic oil level is near or below the minimum oil level mark the power unit will completely shut off and will not re-start until the unit’s hydraulic oil level is restored to the maximum oil level. HYDRAULIC OIL SYSTEM MAINTENANCE

Suggested Maintenance Schedule for Hydraulic Oil System

Every 200 Hours

• Change Filter

Every 400 Hours

• Change Hydraulic Oil

Revised 9/6/2013

CAUTION MAXIMUM OPERATING TEMPERATURE FOR THE HYDRAULIC SYSTEM IS 180°F. MINIMUM FOR PROPER TOOL OPERATION IS 125°F.

WARNING IT IS THE OPERATOR’S RESPONSIBILITY TO CONNECT, MOUNT OR OPERATE THIS UNIT AND ANY DRIVEN EQUIPMENT IN A CORRECT AND SAFE MANNER. INCORRECT OPERATION OR MODIFICATION OF THIS SYSTEM MAY BE EXTREMELY HAZARDOUS.

Revised 9/6/2013

GUIDELINES FOR MAINTENTANCE OF DIESEL AND GAS ENGINES USED IN WOLVERINE POWER PACKS Note: These guidelines are superseded by any instructions provided by the engine manufacturer.

Suggested Engine Maintenance Schedule

Weekly

• Check filter minder.

After First 25 Hours

• Change oil filter and oil• Service/replace low-profile precleaner if needed1.

Every 50 Hours

• Replace low-profile air cleaner element1. • Change oil. Oil filter is recommended1. • Remove cooling shrouds and clean cooling areas1. • Check heavy-duty air cleaner element. • Replace fuel filter. • Check oil cooler fins; clean as necessary.

1 Perform these procedures more frequently under severe, dusty, dirty condition. Refer to engine manufacturer maintenance guidelines for more information.

Revised 9/6/2013

EQUIPMENT AND PARTS WARRANTY Wolverine Equipment warrants all equipment manufactured by it against defects in workmanship or materials for a period of one (1) year from the date of shipment to Customer. The responsibility of Wolverine Equipment under this Warranty is limited to replacement or repair of defective parts at Wolverine Equipment’s Kent, Washington location, or at a point designated by it. If after inspection, such parts appear to us to have been defective in material or workmanship, such parts will be replaced. Expense for transportation and labor are borne by Customer. In no event shall Wolverine Equipment be liable for consequential or incidental damages arising out of the failure of any product to operate properly. Integral units such as engines, hydraulic motors, batteries, transmissions, etc., are excluded from this Warranty and are subject to the prime manufacturer’s warranty. THIS WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED, AND ALL SUCH OTHER WARRANTIES ARE HEREBY DISCLAIMED.

Wolverine Equipment 6815 South 220th Street, Kent, Washington 98032 (253) 867-6209 fax (253) 867-6213

Revised 9/6/2013

Wolverine Equipment

Small Frame Hydraulic Power Packs

Resource Guide

Wolverine Equipment Concut, Inc. 6815 S. 220th St. Kent, WA 98032 Customer Service 253-867-6209 Email: [email protected] Website: wolverinequipment.com Kohler Engines Customer Service: 800-544-2444 Website: kohlerengines.com Kubota Engine For Authorized Dealers and Service: 800-532-9808 Website: kubotaengine.com Techtop Industries, Inc. Main Phone: 678-436-5540 Email: [email protected] Website: techtopind.com Leeson Electric Main Phone: 262-377-8810 Website: leeson.com

Revised 9/6/2013

Power Pack Diagrams and Parts

Revised 9/6/2013

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PARTS LISTDESCRIPTIONSTOCK NUMBERPART NUMBERQTYITEM

Frame, Power PackP0301WEI-PPF11Bracket, Flow Control ValveP0210WEI-0208-FV12Rear GrillP0215WEI-0108-RG13Battery TrayP0208WEI-0208-BB14Front GrillP0214WEI-0108-FG15Oil Filter BracketP0212WEI-0208-OFBKT16Oil filterP22892199 10C17Tire, Reliance 13 x 5.00-645722145722128Hydraulic Tank02-359-12302-359-12319Hydraulic Tank BracketP0213WEI-0208-HT-BKT110Bracket, Quick DisconnectsP0211WEI-0208-QK-DB111Foot Pad SupportP238Foot Pad Support212Crosby Eyebolt 1/2-13 UNC 9900217113Fuel Tank, 6-1/2 GallonA007405210-9901114Strap, Fuel TankH094WEI-1207-STRAP215Heat ShieldP0218WEI-0208-SHIELD116Bracket, Fuel TankH095WEI-425X1BKT217Kohler Engine, 25-30 HPPCH 730 0040 / PCH 750 0050ko4246780036118Kohler Engine CH-960 38-40 HPPCH 980 0002 / PCH 1000 0002ko42983310981193/8-16 Hold Fast KnobP02174R946220Hydraulic Flow Control ValveA0250M3303405600000121Indicator Plate, Control ValveP0220WEI-PPF-CVIP122CoolerA008Cooler Assembly123Strap, Battery Holldown ShortP0209WEI-0208-BS124Strap , Battery Holdown, LongWEI-0208-LBSWEI-0208-LBS125BATTERY 25-30 HP P0105 / 30-40 HP P0206P0105 / P0206mt-mx-5 (370 CCA)126Pump Adapter 3-1/2"A009G33 PMM ADAPTER1127Pump P67R (20 HP), P68R (25-30 HP), P69R (38-40 HP)P67R, P68R, P69RHydraulic Pump128Filter HeadFEF-30-12-10-RV25FEF-30-12-10-RV25129Hose, Pump to Hyd. Tank:1F301F301130Hose, Cooler to Hyd. TankF303F303131Hose, Return Quick Disconnect to Hyd. FilterF302F302132Hose , Hyd. Filter to CoolerF302F3021331.5" Dia SS Hose ClampP221Hose Clamp 1501341.250" Dia SS Hose ClampP220Hose Clamp 0125135Parker Triple-Lok Male NPT Bulkhead Connector, 8-8 WFTX-SA044Parker Triple-Lok Male NPT Bulkhead Connector, 8-8 WFTX-S236Parker Bulkhead Locknut, 8 WLN-S8WLNSParker Bulkhead Locknut, 8 WLN-S2371/4-20 X 3/4 UNC Hex BoltA200HexBoltScrewInch638Type A Plain WasherA201ANSI B18.22.1-1965, R19906391/4 Std NC Nylock NutA203Nylock Nut1040Type A Plain WasherA201ANSI B18.22.1-1965, R19902413/8 x 1 1/4 Hex Bolt Screw InchA204HexBoltScrewInch2423/4" X 26" ZINC PLATED STEELP0216Handle243Slide on round grip. Smooth RubberP23497065K53P234244Cooler to ValveF305F305145Pump to Flow ValveF304F304146Flow Valve to Make QdF307F307147Plastic pull tieA400Cable_Tie_Panduit_PLT_formed148Plastic pull tieA400Cable_Tie_Panduit_PLT_formed149Plastic pull tieA400Cable_Tie_Panduit_PLT_formed1501/4- 20 x 1 1-2 inch hex bolt with washerA2051/4- 20 x 1 1-2 inch hex bolt with washer651Hex Bolt 10-32 x .75 self tappingA206WNBSN 1-00501752

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Flow Valve11INDUSTRIAL FITTING TUBE TO PIPE 1/2"F0088-8_ftx-s16INDUSTRIAL FITTING ELBOW, TUBE TO PIPE 1/2" TubeF0H38-8_vtx-s17INDUSTRIAL FITTING ELBOW, TUBE TO PIPE 1/2 Tube 90 Degf0108-8_ctx-s.stp18

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Hydac Fan1 1" to 3/4 inch FittingF100712-16_f5ox-s2 1" TO 1/2" ReducerF00512-8 TRTXN1 1/2 Tee Male 37° Flare,37° Flare SwivelF0018_r6x-s1

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NONE111 NONE12 NONE213 12_c5ox-s.stp14STRAIGHT THREAD CONNECTION 37 Deg. Flare 8-10-5OX-S15

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Hose, Pump to Hyd. Tank:1F301F30111Hose, Cooler to Hyd. TankF303F30312Hose, Return Quick Disconnect to Hyd. FilterF302F30213Hose , Hyd. Filter to CoolerF302F30214Cooler to ValveF305F30515Pump to Flow ValveF304F30416Flow Valve to Make QdF307F30717

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wolverinesmallframegaspowerpacks_2

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