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Summary of Contents for HYCON HPP09
- Page 1 Hydraulic Powerpack HPP09 HPP13 POR • HPP13 FLEX HYCON A/S Juelstrupparken 11 DK-9530 Støvring Denmark Tel: +45 9647 5200 Fax: +45 9647 5201 Mail: hycon@hycon.dk www.hycon.dk...
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Page 2: Table Of Contents
Contents Page Safety Precautions ..................2 Filling up Hydraulic Oil................... 2 Technical Data HPP09 ................... 3 Technical Data HPP13 ................... 4 Starting Instructions..................5 Service and Maintenance................6 Oil Types...................... 6 Fault Location ....................7 Mounting of Main Components ..............9 10. -
Page 3: Safety Precautions
1. Safety Precautions Read operating manual for powerpack and engine carefully before using the powerpack. 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. Always connect hoses before starting. Never add fuel and oil when the engine is running. -
Page 4: Technical Data Hpp09
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. -
Page 5: Technical Data Hpp13
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: •... -
Page 6: Starting Instructions
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” •... -
Page 7: Service And Maintenance
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... -
Page 8: Fault Location
8. Fault Location Start by checking the hydraulic settings Before starting, check the oil level at the sight HYCON Test Equipment glass. Item No. 4040062 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. - Page 9 Problem Cause Solution Powerpack does not give Pressure relief valve may be Dismount pressure relief valve the right oil flow, or r.p.m. clogged up or set incorrectly and clean with compressed is too high air, or correct the setting of the valve Pump is worn Replace pump...
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Page 10: Mounting Of Main Components
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. - Page 11 Add Loctite 243 to the four threads, and tighten the screws with a torque of 20 Nm. Mount It is important to fit the the pump with the coupling part into the coupling housing. washer between pump and coupling housing perfectly into the frame on the coupling housing.
- Page 12 Mount the fan on the shaft, and place the spring washer on the shaft with the curve turned outwards. Mount the nut and tighten with a torque of 40 Nm. Add Loctite 243 to the two threads on the frame, and mount the bolts. Place the tank in the frame. Mount the tank with four screws, washers and lock nuts.
- Page 13 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 place the drive unit on the two rubber dampers. Tighten the four screws with washers (at one side it is easier to tighten the screws after dismounting the wheel).
- Page 14 Mount the hydraulic hose on the cooler and the other end on the right fitting on the valve block. Make sure the hoses do not bend. Mount the suction hose from the tank to the pump. Mount the return hose on the cooler. Finally mount the suction hose from the POR cylinder on the valve block.
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Page 15: Mounting Of Tank
10. Mounting of Tank Grease the seal on the sight glass with silicone. Carefully mount the sight glass on 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). -
Page 16: Mounting Of Pump
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. -
Page 17: Mounting Of Valve Block
12. Mounting of Valve Block Re. HHP13 FLEX, please refer to section 16 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. - Page 18 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.
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Page 19: Replacement Of Rubber Coupling
13. Replacement of Rubber Coupling Unscrew the four screws from the coupling housing to the engine. Dismount the POR hose from the valve housing. Turn the coupling housing, the pump and the cooler out to the right. The rubber coupling can now easily be replaced at the opposite side of the powerpack. Turn coupling housing, pump and cooler back into position. -
Page 20: Replacement Of Pump
14. Replacement of Pump Dismount the fan. Dismount the POR hose on the valve block. Dismount the hose on the cooler from the tank. Let the oil run out. Dismount both hydraulic hoses on the valve block. Dismount the four screws, which are mounted through cooler and pump. You can now push the cooler forward and remove the pump. - Page 21 important Mount the pump in the coupling housing. It is that the coupling part on the important pump is fitted correctly in the rubber coupling. It is also to fit the centering washer between pump and coupling housing completely into the frame on the coupling housing.
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Page 22: Dismounting Of Drive Unit From Frame
15. Dismounting of Drive Unit from Frame Dismount the four screws on the frame holding the valve block. Dismount the two hoses on the filter housing. Dismount the hose on the pump. Dismount the four screws under the engine. Dismount the supporting leg under the frame. The entire drive unit can now be removed, and it is easy to do major repairs. -
Page 23: Supplement For Hhp13 Flex
16. Supplement for HPP13 FLEX Mounting of special parts for HPP13 FLEX Mount the outer cable. The end of the cable must be in line with the upper edge of the cable plate. Mount the cable in the cable clamp on the eccentric plate. The tip of the cable must be in line with the upper edge of the eccentric plate. - Page 24 Mounting of special parts on valve block for HPP13 FLEX Add Loctite 542 to the two threads to 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.
- Page 25 Add Loctite 243 to the two threads on the valve block, and mount the cable plate with two screws. Mount the cable clamp on the cable plate. Mount the screw with hole through the eccentric plate.
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Page 26: Tool List
17. Tool List 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.
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