HYCON HPP09 Manuale di istruzioni
Hydrauli
c Powerpack
HPP09
HPP13 POR • HPP13 FLEX
HYCON A S
Juelstrupparken 11
DK-9530 Støvring
Denmark
Tel: +45 964 5200
Fax: +45 964 5201
Mail: hycon@hycon.dk
www.hycon.dk
1
Contents
Page
1. Safety Precautions ........................................................................................ 2
2. Filling up Hydraulic Oil................................................................................... 2
3. Technical Data HPP09 ................................................................................... 3
4. Technical Data HPP13 ................................................................................... 4
5. Starting Instructions...................................................................................... 5
6. Service and Maintenance............................................................................... 6
. Oil Types...................................................................................................... 6
8. Fault Location...............................................................................................
9. Mounting of Main Components ...................................................................... 9
10. Mounting of Tank........................................................................................ 14
11. Mounting of Pump ...................................................................................... 15
12. Mounting of Valve Block .............................................................................. 16
13. Replacement of Rubber Coupling ................................................................. 18
14. Replacement of Pump ................................................................................. 19
15. Dismounting of Drive Unit from Frame ......................................................... 21
16. Supplement for HHP13 FLEX........................................................................ 22
1 . Tool List ..................................................................................................... 25
18. Spare Parts Lists ......................................................................................... 26
2
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.
. 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 150 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 power-
pack.
•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.
3
3. Technical Data HPP09
Hydraulics
The HYCON HPP09 open centre hydraulic powerpack is designed in accordance with
the EHTMA category C, which prescribes a minimum performance of 20 l.p.m. at 138
bar. The HYCON powerpack is fully compatible with and sufficient for the common
European tools.
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 over-
heating.
Oil flow 20 l.p.m at 3300 r.p.m.
Working pressure nominal 120 bar
Pressure relief valve Set at 150 bar
Pump Gear pump
Oil temperature Max. 0° C
Hydraulic oil tank capacity Min. 5 litres/max. litres
Petrol tank capacity 6 litres
Hydraulic system compl. Max. 8 litres
Filter system (filter element) 25 Micron with by-pass
Engine Honda GX2 0QXB
9 HP 4-stroke petrol
with oil alert system
Petrol - normal or unleaded
Engine oil 1.1 litres
Guaranteed sound power level LWA 100 dB
Sound pressure level 1 m LPA 88 dB
Dimensions (LxWxH) 680x560x593 mm
Weight, without hydraulic oil 68 kg
4
4. Technical Data HPP13
Hydraulics
The HYCON HPP13 open centre hydraulic powerpack is designed in accordance with
the EHTMA categories C and D, which prescribe a minimum performance of 20 l.p.m.
at 138 bar and 30 l.p.m. at 138 bar, respectively. The HPP13 is available in two
versions:
•With POR system (Power On Request) that automatically reduces the engine
r.p.m. if the connected tool is not operated. This version is set to 20 or 30
l.p.m. from the factory.
•With manual flow adjustment. This powerpack can be set to 20 to 30 l.p.m.
on the front of the powerpack.
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
overheating.
Oil flow 20 l.p.m. at 2500 r.p.m.
30 l.p.m. at 3600 r.p.m.
Working pressure nominal 120 bar
Pressure relief valve Set at 150 bar
Pump Gear pump
Oil temperature Max. 0° C
Hydraulic oil tank capacity Min. 5 litres/max. litres
Petrol tank capacity 6.5 litres
Hydraulic system compl. 8 litres
Filter system (filter element) 25 Micron with by-pass
Engine Honda GX390QXB
13 HP 4-stroke petrol
with oil alert system
Petrol - normal or unleaded
Engine oil 1.1 litres
Guaranteed sound power level LWA 101 dB
Sound pressure level 1 m LPA 89 dB
Dimensions (LxWxH) 10x595x605 mm
Weight, without hydraulic oil 81 kg
5
5. Starting Instructions
Please observe the starting instructions on the front of the powerpack.
Start: •
••
• 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, you should let the powerpack run for a couple of
minutes before connecting the tool.
Stop •
••
• Move the lever to “OFF“
•Turn off the ignition switch
•Turn the fuel tap to “OFF”
Powerpack with adjustable flow:
The desired oil flow can be set on the front of the
powerpack. A marking is engraved in the lever.
Turn the lever to the right until the marking is
opposite the required flow
The pressure relief valve setting will be the same
on all flows.
6
6. Service and Maintenance
Service Maintenance
Daily Weekly Yearly
Engine oil Check 1 x replacement
Hydraulic oil Check 1 x replacement
Hydraulic oil filter *) 1 x replacement
Check hoses (tighten up if needed)
Air filter **) 1 x replacement
Fuel filter **) 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 by-
pass.
**) Refer to engine manual for further information.
7. 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 + 0° C
7
8. Fault Location
Start by checking the hydraulic settings
Before starting, check the oil level at the sight
glass.
Check the working pressure by means of the
test equipment. The test equipment com-
prises 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 150 bar.
If the pressure relief valve does not show 150 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 20 (30) l. p.m.
On the powerpack with POR, the flow is adjusted by loosening the POR cylinder
in the bracket and pushing it to the left (higher flow) or to the right (lower flow).
On the powerpack with adjustable flow, the flow is regulated by adjusting the
position of the throttle cable.
3. The number of revolutions must not exceed 3400 r.p.m. for the HHP09 at 20
l.p.m. and 3800 r.p.m. for the HHP13, when the powerpack is set at 30 l.p.m. If
the number is higher, there may be dirt in the pressure relief valve, or the pump
may be worn.
HYCON Test Equipment
Item No. 4040062
r.p.m. meter
Item No. 9992124
8
Problem Cause Solution
Pressure relief valve may be
clogged up or set incorrectly
Dismount pressure relief valve
and clean with compressed
air, or correct the setting of
the valve
Powerpack does not give
the right oil flow, or r.p.m.
is too high
Pump is worn Replace pump
The maximum pressure of
the powerpack is too high
Wrong adjustment of
pressure relief valve
Adjust pressure relief valve to
150 bar (see instructions on
page )
Leaking shaft seal in pump Replace pump
Oil level too low Add oil
Heavy vibrations because of
defective fan blade or
defective rubber dampers
Replace defective parts
Hydraulic oil is foaming,
and oil is leaking at the air
filter on the filter housing
Too much oil in tank Drain off oil from tank
Engine does not start See engine manual
9
9. Mounting of Main Components
Dismount the three screws on the recoil cover. Mount the bracket for the POR cylinder with
screw and nut. Then re-mount the recoil cover on the engine. Mount the POR cylinder in the
bracket. Make sure to position the POR hose behind the wires and trough the rubber eye.
Mount the shaft key on the engine shaft. Mount the coupling engine part on the shaft.
Add Loctite 243 to the thread in the coupling part. Tighten the set screw with a torque of 5
Nm. Mount the rubber coupling on the coupling engine part. Mount the coupling housing
over the coupling.
Altri manuali per HPP09
2
Questo manuale è adatto per i seguenti modelli
2
Indice
Altri manuali HYCON Gruppo di alimentazione
HYCON
HYCON HPP18V FLEX Manuale utente
HYCON
HYCON HPP13D Manuale utente
HYCON
HYCON FLEX HPP14V Manuale utente
HYCON
HYCON HPP09 Manuale utente
HYCON
HYCON HPP06 Manuale utente
HYCON
HYCON HPP18E FLEX Manuale utente
HYCON
HYCON HPP18E FLEX Manuale utente
HYCON
HYCON HPP09 Manuale utente
HYCON
HYCON HPP27VMF Manuale utente
HYCON
HYCON HPP18E FLEX Manuale utente
