HYCON HPP09, Workshop Manual

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 ...

Page 2: ...6 Service and Maintenance 6 7 Oil Types 6 8 Fault Location 7 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 17 Tool List 25 18 Spare Parts Lists 26 ...

Page 3: ...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 Rem...

Page 4: ... 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 70 C Hydraulic oil tank capacity Min 5 litres max 7 litres Petrol tank capacity 6 litres Hydraulic system compl Max 8 litres Filter system filter element 25 Micron with by pass Engine Honda GX270QXB7 9 HP 4 stroke petr...

Page 5: ... 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 70 C Hydraulic oil tank capacity Min 5 litres max 7 litres Petrol tank cap...

Page 6: ...ate 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...

Page 7: ... 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...

Page 8: ... 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...

Page 9: ...m pressure of the powerpack is too high Wrong adjustment of pressure relief valve Adjust pressure relief valve to 150 bar see instructions on page 7 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 T...

Page 10: ... 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 ...

Page 11: ... the coupling part on the pump fits into the rubber coupling if necessary turn the pump shaft until the parts fit Add Loctite 243 to the four threads on the coupling housing Mount the cooler over the pump and mount the four long screws through the cooler and the pump into the thread on the coupling housing Tighten the four screws with a torque of 15 Nm Place a spring washer on the shaft with the c...

Page 12: ...n 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 Mount the rubber dampers on the frame Screw in the screws with washers from below Mount the valve block on the frame Add Loctite 243 to the four threads ...

Page 13: ...crews with washers at one side it is easier to tighten the screws after dismounting the wheel Add Loctite 638 to the thread on the supporting leg and screw together the supporting leg and the rubber damper Mount the rubber damper on the frame with a screw and washer from below Mount the suction hose on the tank Mount the return hose on the filter housing Mount the hydraulic hose from the pump on t...

Page 14: ...nd 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 ...

Page 15: ...ighten 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 ...

Page 16: ...p 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: ... 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 an...

Page 18: ...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 o...

Page 19: ...ght The rubber coupling can now easily be replaced at the opposite side of the powerpack Turn coupling housing pump and cooler back into position To make sure that the rubber coupling is in the right position you can turn the fan until the coupling fits correctly Mount the four screws from the coupling housing to the engine and tighten the screws with a torque of 20 Nm Mount the POR hose on the va...

Page 20: ...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: ...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 and tighten them with a torque of 15 Nm Mount the fan and tighten the nut with a torque of 40 Nm Mount again the hydraulic hoses on the valve block Mount the hose from the tank on the pump Mount the POR hose on the valve block ...

Page 22: ... 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: ...e The tip of the cable must be in line with the upper edge of the eccentric plate Tighten carefully Dismount the air filter cover and the air filter Turn the lever to 30 l p m Mount the cable through cable plate and cable clamp on the engine and carefully tighten the screw on the inner cable Pull the outer cable backwards and fix the cable plate to the outer cable Mount again the air filter and th...

Page 24: ...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 fitt...

Page 25: ...24 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 ...

Page 26: ...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 ...