Hydraulic Powerpack HPP06 HYCON A/S Juelstrupparken 11 DK-9530 Støvring Denmark Tel: +45 9647 5200 Fax: +45 9647 5201 Mail: hycon@hycon.dk www.hycon.dk
Contents Page 1. Safety Precautions... 2 2. Filling up Hydraulic Oil... 2 3. Technical Data HPP06... 3 4. Starting Instructions... 4 5. Service, Maintenance and Hydraulic Settings... 4 6. Oil Types... 5 7. www.hyconsupport.dk... 5 8. Fault Location... 6 9. Mounting of Main Components... 8 10. Mounting of Tank...11 11. Mounting of Pump...12 12. Mounting of Valve Block...13 13. Replacement of Rubber Coupling...15 14. Replacement of Pump...18 15. Dismounting of Drive Unit from Frame...20 16. Tool List...21 17. Spare Parts Lists...22 1
1. Safety Precautions 1. Read operating manual for powerpack and engine carefully before using the powerpack 2. Always use protective earplugs. The powerpack complies with the EU noise limits, but by daily long-lasting operation there is a risk of hearing defects. 3. Always connect hoses before starting. 4. Never add fuel and oil when the engine is running. 5. In case of non-operation or performance of service, always turn off the engine. 6. Never start the engine without side covers. 7. Operation of the powerpack without tool connected and with lever at ON may cause overheating of the system and damage to the powerpack. 8. When lifting the powerpack from a vehicle, we recommend the use of a crane. 9. The pressure relief valve is set at 110 bar from our plant. Never set it higher. 10. Always use filters with by-pass. The use of filters without by-pass may blow the hydraulic hoses and the filter cover. 2. Filling Up Hydraulic Oil To fill up with hydraulic oil, loosen the filter cover on top of the powerpack. Remove the filter element (see photo), and fill up with oil. When oil is showing at the bottom of the filter unit, there is enough oil on the powerpack. Insert the filter element again, mount the cover and the powerpack is ready for use. Please note: When connecting new extension hoses, it is necessary to fill up with extra 2 litres of oil. Therefore always top up the powerpack when connecting new extension hoses. 2
3. Technical Data HPP06 Hydraulics The powerpack is mounted with a pressure relief valve to avoid a too high pressure. Furthermore, the very efficient air cooling protects the powerpack against superheating. Oil flow Working pressure nominal Pressure relief valve Pump Oil temperature Hydraulic oil tank capacity 18 l.p.m at 3300 r.p.m. 100 bar Set at 110 bar Gear pump Max. 70 C Min. 5 litres/max. 7 litres Petrol tank capacity Hydraulic system compl. Filter system (filter element) Engine Guaranteed sound power level L WA Sound pressure level 1 m L PA Dimensions (LxWxH) Weight, without hydraulic oil 3.1 litres Max. 8 litres 25 Micron with by-pass Honda GX200QX7 6.5 HP (gross power) 4-stroke petrol with oil alert system Petrol - normal or unleaded Engine oil 1.1 litres 100 db 88 db 630x530x510 mm 54 kg 3
4. Starting Instructions Please observe the starting instructions on the front of the powerpack. Start: Stop: Check engine oil level Check hydraulic oil level at sight glass Connect hoses and tool Switch fuel tap to ON Activate choke Turn ignition switch to 1 Pull recoil starter Deactivate choke Move the lever to ON If the oil is cold, let the powerpack run for a couple of minutes before connecting the tool Move the lever to OFF Turn off the ignition switch Turn the fuel tap to OFF 5. Service, Maintenance and Hydraulic Settings Service/Maintenance Daily Weekly Yearly Engine oil Check 1 x replacement Hydraulic oil Check 1 x replacement Hydraulic oil filter *) Check hoses Air filter Fuel filter (tighten up if needed) 1 x replacement 1 x replacement 1 x replacement *) If the oil does not run down through the filter when removing the cover from the filter housing, the filter is clogged up and must be replaced. Use only filters with bypass. **) Refer to engine manual for further information. 4
6. Oil Types The HYCON powerpack uses standard hydraulic oil, i.e. all types of mineral oil and biodegradable oil, which comply with the following values: Recommended viscosity 20-40 cst Permitted viscosity 15-1000 cst Viscosity index Min. 100 Temperature area -20 to +70 C 7. www.hyconsupport.dk www.hyconsupport.dk is HYCON s homepage for our distributors and customers, giving various information, help and advice. Use the support page actively! You can download all our operating manuals and workshop manuals from the homepage. The manuals are available anytime and anywhere you need them. Contents of the support page: Technical Bulletins Spare Parts Lists Operating Manuals Workshop Manuals Oil Types You can have news about products, updates and technical bulletins sent automatically to your computer. For further info please visit the support page. If you have not yet got login and password, please contact our service department. 5
8. Fault Location Start by checking the hydraulic settings HYCON Test Equipment Item No. 4040062 Before starting, check the oil level at the sight glass. Check the working pressure by means of the test equipment. The test equipment comprises a pressure gauge, a flow meter and a valve for adjustment of pressure. The pressure relief valve is placed on the right side of the valve block. 1. Connect the test equipment, start the powerpack and move the lever to ON. Then close the valve - the pressure gauge must show 110 bar. If the pressure relief valve does not show 110 bar, adjust the valve by loosening the lock nut and turning the adjustment screw in or out. In increases the pressure, and out decreases the pressure. Retighten the lock nut after adjustment. 2. When the pressure relief valve has been adjusted correctly, the working pressure must be set at 100 bar by means of the valve on the test equipment. At 100 bar, the oil flow should be 18 l.p.m. 3. The number of revolutions must not exceed 3300 r.p.m. at 18 l.p.m. If the number is higher, there may be dirt in the pressure relief valve, or the pump may be worn. r.p.m. meter Item No. 9992124 6
Problem Cause Solution Powerpack does not give the right oil flow, or r.p.m. is too high The maximum pressure of the powerpack is too high Hydraulic oil is foaming, and oil is leaking at the air filter on the filter housing Engine does not start Pressure relief valve may be clogged up or set incorrectly Pump is worn Wrong adjustment of pressure relief valve Leaking shaft seal in pump Oil level too low Heavy vibrations because of defective fan blade or defective rubber dampers Too much oil in tank Dismount pressure relief valve and clean with compressed air, or correct the setting of the valve Replace pump Adjust pressure relief valve to 110 bar (see instructions on page 6) Replace pump Add oil Replace defective parts Drain off oil from tank See engine manual 7
9. Mounting of Main Components Start by adding Loctite 243 to the four threads on the engine block. Then mount the flange on the engine block. Tighten the four screws with a torque of 20 Nm. Place the distance bushing on the shaft. Place the shaft key in the keyway on the shaft, and mount the coupling engine part on the shaft. Add Loctite 243 to the thread in the coupling part, and tighten the set screw with a torque of 5 Nm. Push the coupling housing in over the coupling. Mount the rubber coupling on the coupling engine part. 8
Add Loctite 243 to the four threads. Mount the pump with the coupling part into the coupling housing. It is important to fit the washer between pump and coupling housing perfectly into the frame on the coupling housing. Make sure that the coupling part on the pump fits into the rubber coupling (if necessary, turn the pump shaft until the parts fit). Mount the cooler over the pump, and mount the four long screws through the cooler, the pump and distance tube into the thread on the coupling housing. Tighten the screws with a torque of 20 Nm. Place a spring washer on the shaft with the curve towards the cooler (see photo). Place the shaft key in the keyway on the shaft. Mount the fan on the shaft, and place a spring washer on the shaft with the curve turned outwards. Mount the nut, and tighten with a torque of 40 Nm. 9
Place the tank in the frame. Mount the tank with four screws, washers and lock nuts. Mount the valve block on the frame. Add Loctite 243 to the four threads. Tighten the four screws. Mount the bypass hose on the filter housing. Mount the other end of the bypass hose on the valve block. Lift the drive unit into the frame, and tighten the four screws with washers. Mount the suction hose on the tank. Mount the return hose on the filter housing. Mount the hydraulic hose from the pump on the left fitting on the valve block (pressure). Mount the hydraulic hose from the cooler on the right fitting (return). 10
10. Mounting of Tank Grease the seal on the sight glass with silicone. Carefully mount the sight glass on the tank. Mount the threaded plug in the tank. Tighten carefully. Mount the hose on the filter housing and tighten the hose clip with an end cutter. Mount the filter housing into the tank (remember to mount the seal between tank and filter housing). Add Loctite 243 to the thread, and tighten the screws carefully. Add Loctite 542 and mount the hose fitting for the return line. Mount the hose fitting for the suction hose. Always remember the seal ring between hose fitting and filter housing. 11
11. Mounting of Pump Start by mounting the angle nipple at the right side of the pump. Mount the centering washer and the coupling part on the pump shaft. Tighten the nut with a torque of 20 Nm. Mount the hydraulic hose with banjo at the left side of the pump. Adjust the angle nipple and the hydraulic hose till they are at the same angle to each other as shown on the photo so that they do not get in contact with the cooler when it is mounted. 12
12. Mounting of Valve Block Add Loctite 542 to the two threads at the left, and tighten the pipe plugs firmly. Add Loctite 542 to the thread at the side of the valve block, and tighten the pipe plug. Mount two roll pins on the valve block with the groove turned upwards and a roll pin on the spool. Mount the retaining ring and the O-ring on the spool. Mount the O-ring in the hole in the valve block. Mount the check valve with the holes turned upwards. Screw in the check valve completely. Add Loctite 542 to the upper part of the thread, and mount the hose fitting. Mount the two seal rings and fittings on the valve block. 13
Mount the two seal rings and fittings at the front of the valve block. Carefully mount the small nozzle in the fitting, and then mount the fitting with a seal ring on the valve block. Add copper grease to the thread on the pressure relief valve. Mount the pressure relief valve on the valve block, and tighten it with a torque of 40 Nm. Grease the spool and the hole in the valve housing, and carefully mount the spool in the valve housing. After pushing the spool through the valve housing, always check for remnants of the O-ring placed around the spool. If there are remnants, replace the O-ring to make sure that the spool function is completely tight. Mount the retaining ring at the back end of the spool. Mount the seal rings on the two fittings, and then mount the flat-face couplings. 14
13. Replacement of Rubber Coupling To replace the rubber coupling, the drive unit must be removed. Dismount the two hydraulic hoses from the valve housing. The fittings can be plugged to prevent oil from running out of the valve housing. Remove the suction hose from the pump, and dismount the return hose from the filter housing (there is oil in the suction hose be careful it does not run out). Loosen the four screws that hold the drive unit and lift it out. Dismount nut and spring washer, and remove the fan. Dismount shaft key and spring washer, and unscrew the four screws that hold the cooler and pump along with the distance tube. 15
Replace the old rubber coupling by a new one. Add Loctite 243 to the four threads. Mount the pump with the coupling part into the coupling housing. It is important to fit the washer between pump and coupling housing perfectly into the frame on the coupling housing. Make sure that the coupling part on the pump fits into the rubber coupling (if necessary, turn the pump shaft until the parts fit). Mount the cooler over the pump, and mount the four long screws through the cooler, the pump and distance tube into the thread on the coupling housing. Tighten the screws with a torque of 20 Nm. Place a spring washer on the shaft with the curve towards the cooler (see photo). Place the shaft key in the keyway on the shaft. Mount the fan on the shaft, and place a spring washer on the shaft with the curve turned outwards. Mount the nut, and tighten with a torque of 40 Nm. 16
Lift the drive unit into the frame, and tighten the four screws with washers. Mount the suction hose on the tank. Mount the return hose on the filter housing. Mount the hydraulic hose from the pump on the left fitting on the valve block (pressure). Mount the hydraulic hose from the cooler on the right fitting (return). 17
14. Replacement of Pump To replace the pump, the drive unit must be removed. Dismount the two hydraulic hoses from the valve housing. The fittings can be plugged to prevent oil from running out of the valve housing. Remove the suction hose from the pump, and dismount the return hose from the filter housing (there is oil in the suction hose be careful it does not run out). Loosen the four screws that hold the drive unit and lift it out. Dismount nut and spring washer, and remove the fan. Dismount shaft key and spring washer, and unscrew the four screws that hold the cooler and pump along with the distance tube. 18
Dismount the cooler and replace the pump. It is important that the coupling part on the pump is fitted correctly in the rubber coupling. It is also important to fit the centering washer between pump and coupling housing completely into the frame on the coupling housing. Mount the cooler with the four screws through cooler and pump, tighten them with a torque of 20 Nm. Mount the fan, and tighten the nut with a torque of 40 Nm. Remount the hose from the tank on the pump. Remount the hydraulic hoses on the valve block. 19
15. Dismounting of Drive Unit from Frame Dismount the four screws on the frame that hold the valve block. Dismount the two hoses on the filter housing. Dismount the hose on the pump. Dismount the four screws under the engine. The entire drive unit can now be removed, and it is easy to do major repairs. 20
16. Tool List n m c o d k a l j g i f h b e a. 1/2 torque wrenches, sizes 5-50 Nm/10-100 Nm b. 3/8 sockets, sizes 10, 13 mm, 1/2" sockets, sizes 19, 22 mm c. 1/2" sockets, sizes 14, 21, 22, 24, 30 mm long d. Reversible ratchets, 3/8 / 1/2 e. Hex head socket drivers 3/8, sizes 4, 6 mm f. Extension bar 3/8 g. Combination spanners, sizes 2x10, 14, 17, 27 mm h. Hex head wrenches, sizes 5, 6 mm i. External circlip plier j. End cutter k. Pipe wrench, size medium l. Small flat screwdriver m. Silicone n. Lubricating grease o. Plastic scraper 21