Harken HYDRO POWER UNIT 1 User manual

Please read these instructions carefully before installing, servicing, or operating the equipment.
This manual may be modified without notice. See: www.harken.com/manuals for updated versions.
PLEASE SAVE THESE INSTRUCTIONS
The Hydro Power Unit pictured above is for display purposes only. Actual system purchased may vary.
HYDRO POWER UNIT 1
Installation and Operation Manual
Intended for specialized personnel or expert users

2 Hydro 1
INTRODUCTION.............................................................................................................................................. 3
UNIT SELECTION AND PARTS LIST...................................................................................................................... 4
SAFETY INFORMATION ............................................................................................................................... 5 – 6
POWER UNIT INSTALLATION ........................................................................................................................ 7 – 8
Planning installation
Location in boat
Secure power unit
Mount control box
HYDRAULIC INSTALLATION......................................................................................................................... 9 – 11
Hose and fitting selection recommendation
Hose shortening
End fittings
Fitting instructions
Port identification
Configuration
Function assignment
Manifold blanking plates
Flushing hoses
Connecting hoses
Case drains
Mounting clamp hose support
Protect hoses from sunlight
Individual function protection
ELECTRICAL INSTALLATION ...................................................................................................................... 12 – 14
Wire selection
Connect deck switches to ECB
Connect ECB to power supply
Connect HPU motor and valves to ECB
Connect HPU to battery
COMMISSIONING.................................................................................................................................... 15 – 16
Fill reservoir
Hydraulic fluid
Closed circuit
Leak check
One-way function flush
System validation
Function pressure check
Oil level and filter
OPERATION..................................................................................................................................................17
Power up / power down
Oil level
Motor thermal protection
Single and multiple function operation
Filter element replacement schedule
Hydraulic oil change schedule
MAINTENANCE....................................................................................................................................... 18 – 19
How to change oil
Leakage inspection
Cleanliness inspection
Oil level inspection
Additional maintenance points
TROUBLESHOOTING.......................................................................................................................................19
DRAWINGS AND SCHEMATICS ................................................................................................................... 20 – 27
Bill of Materials; Exploded View Diagram; 3D Rendering; Electrical Schematic; Suggested Wiring Practice for Motors;
Valve and Switch Wiring Schematic; Control Box Mounting Dimensions; Control Box Interior Diagram
WARRANTY ......................................................................................................................................Back Cover
Table of Contents

Hydro 1 3
Introduction
Sealable penetrations
into ECB provided for
deck switch wiring.
Plumbing to manifolds is
under reservoir top so there
is no exposed plumbing
(not visible).
Harken Hydraulic Power Units (HPU) are the complete power solution. Offered in three sizes (Hydro 1, 2 and 3), the HPU can power
functions including winches, furlers, sail trim cylinders, windlasses and keel cylinders. HPUs can include waterproof, prewired electronic
control boxes (ECB) or act as stand–alone, central or supplemental power units.
Harken HPU features a 4kW 24VDC motor which is sized alongside the pump to power a single function. With additional pumps and
motors, multiple functions can run simultaneously, or the built-in double-flow feature can supply more oil to power-intensive functions.
Motors are fan-cooled, series-wound and energy-efficient at all speeds.
Factory-installed manifolds and pumps are internally plumbed, saving space, installation time and additional hardware. Valve manifolds
are equipped with horizontal ports to provide ease with hose routing. Elevated reservoir fill cap keeps oil from spilling, filters air
exchange and removes moisture from the tank to ensure a healthy hydraulic power unit. Drop-in return line filters with status gauge
make maintenance fast and easy.
The prewired ECB features sealed passage for switch and valve wires. The ECB is prewired internally and contacts are labeled. The user
is required to make electrical connections for supply power, switches and valves.
Prewired and waterproofed
control boxes are molded
from extremely tough
polycarbonate.
Coated aluminum tanks have
hardcoat-anodized 6061-T6
aluminum top plates. Manifolds are
made with clear-anodized aluminum.
Tank-mounted, electrical motor
contactors meet the IP67
waterproof specification.
Fan-cooled, series-wound
motors are energy-efficient
at all speeds.
Manifolds and pumps are
preplumbed, saving space,
installation time, and
additional hardware.
Drop-in return line filters with
status gauges provide a no-mess
alternative to typical spin-on styles.
Electronic
Control Box (ECB)
Hydro 1 (HPU)
Deutsch receptacle and
plug connect motor
power cables to ECB.
External shut-off switches.

4 Hydro 1
Power Unit Selection / Parts
*One function delivers double flow output (8 gpm) using 2 motors **This number is reduced by one when a double flow function is in use.
Power
unit
Number of
functions
Max
simultaneous
functions
24v DC
Motor
Maximum
current draw
(amps)
Tank
capacity
Maximum
continuous output
Weight
Fasteners
Without manifolds With attached manifolds
gal l psi@gpm bar@l/m lb kg lb kg
Hydro 1 4 1 1 x 4000 Watt 210 7.9 30 2000 @ 4 140 @ 15 89 40.5 102 46.1 M10
Hydro 2 9* 2** 2 x 4000 Watt 2 x 210 18.5 70 2000 @ 8 140 @ 30 182 82.6 194 88.2 M10
Hydro 3 15* 3** 3 x 4000 Watt 3 x 210 18.5 70 2000 @ 12 140 @ 45 233 105.9 246 111.4 M10
Power Unit Selection
Power unit selection must be based on the flow and pressure requirements for all hydraulic equipment that will operate at the same time.
Most Harken hydraulic equipment (winches, furlers, etc.) requires a flow of 4GPM/15 LPM, with a maximum operating pressure of
2000 PSI/140 BAR.
To select the correct power unit:
1. Consult the manual for each piece of hydraulic equipment that will be driven by the power unit. Note flow and pressure.
2. Determine which pieces of hydraulic equipment or circuits will be used at the same time (i.e. winch and furler).
3. Compare total flow/pressure required for each piece to table below to select power unit.
Harken Hydro Power Units are available in three sizes: Hydro 1, 2 and 3. Each motor/pump combination is rated at 4 GPM/15 LPM with a
maximum operating pressure of 2000 PSI/140 BAR.
Electronic Control
Box (ECB)
Included with Unit
1. Hydraulic Power Unit (HPU)
2. Electronic Control Box (ECB)
3. Electric Wiring Cables with Terminals
1 Cable per motor to connect power unit motor to ECB
1 Cable per valve to connect valve to ECB
Hydraulic Power Unit (HPU)
Hydraulic Power Units
You must Supply
Suitable Hydraulic Hoses (See pg. 9)
Switches
Battery Cable with Suitable Fuses
HPU Mounting Bolts – Four (4) M10
Depth of Threaded Holes in Tank Bottom – 15 mm
ECB Mounting Bolts – Four (4) M6 or 1/4"
Mounting Pad to Secure Power Unit to Boat (See pg. 8)
Hydraulic Oil (See pg. 15)
Flow Control Valves If Required (See pg. 11)
Pressure Reducing Valves If Required (See pg. 11)
Pressure Relief Valves If Required (See pg. 11)
Wiring to Connect Valves to ECB
(1 Cable per Valve)

Safety
Hydro 1 5
Important Safety Information
Read all instructions carefully and follow all safety precautions to avoid personal injury or property damage during system operation.
Harken is not responsible for damage or injury resulting from unsafe product use, lack of maintenance or incorrect product and/or
system operation. Contact Harken with questions regarding safety precautions and operations. If you lack training on hydraulic safety,
consult a hydraulic distribution or service center for a hydraulic safety course. Failure to comply with the following cautions and
warnings could result in equipment damage and personal injury.
Symbols and Safety Statements Used in this Manual
Symbols and safety statements have been placed throughout this text to call attention to special information that may affect the
equipment and/or the equipment operator. Following is an explanation for your reference.
IMPORTANT! Identifies condition or task requiring special attention.
WARNING! This symbol alerts you to potential hazards that may kill or hurt you and others
if you don't follow instructions.
CAUTION! This symbol alerts you to potential hazards that may damage equipment or void
product warranty.
DANGER! This symbol alerts you to hazards that cause death or serious injury.

6 Hydro 1
Safety
Safety Requirements
The instructions provided with this manual are for installation and use only. The Harken Power Unit must only be serviced by
a qualified hydraulic technician. For repair service, contact Harken to find the repair site nearest you.
• Alwaysweareyeprotection.
• Makesureallcomponentsareratedforthemaximumsystempressure.Hoseandttingsgenerallyhavea4:1safetyfactor.
In static applications, these safety factors are normally reduced to 2:1. Special care should be used in selecting the proper
products for these systems. There is a correlation between cost of components and their quality.
• Donotexceedequipmentratings.Overloadingcausesequipmentfailureandpossiblepersonalinjury.
• Neversetthereliefvalvepressurehigherthanthemaximumratedpumppressure.Doingsomayresultinequipmentdamage
and/or personal injury.
• Systemoperatingpressuremustnotexceedthepressureratingofthelowestratedcomponentinthesystem.Ifinquestion,
install pressure gauges in the system to monitor operating pressure. They are your window to what is happening in the system.
• Keephydraulicequipmentawayfromamesandheat.Excessiveheatwillsoftenpackingsandseals,resultinginoilleaks.
Heat also weakens hose materials and packings. For optimum performance, do not expose equipment to temperatures of
65°C [150°F] or higher.
• Usecautionwhensearchingforleaks,cracks,kinksorotherdamage.Seriousinjurycanoccurtohandsorfacefrom
pressure build-up or heated fluids.
• Donothandlepressurizedhoses.Escapingoilunderpressurecanpenetratetheskin,causingseriousinjury.Ifoilis
injected under the skin, seek immediate medical attention.
• Relievesystempressurebeforeservicingorreplacinghoseline.
• Neverremoveahoselinefromapressurizedmotororcylinder.
• Avoidhydraulichosedamage.Avoidsharpbendsandkinkswhenroutinghydraulichoses.Usingabentorkinkedhose
will cause severe back-pressure. Sharp bends and kinks will internally damage the hose leading to premature hose failure.
• Routehoseassembliessothatallbendsaredirectedawayfromtheoperator.
• Donotdropheavyobjectsonhose.Asharpimpactmaycauseinternaldamagetohosewirestrands.
• Applyingpressuretoadamagedhosemaycauseittorupture.
• Donotlifthydraulicequipmentbythehosesorswivelcouplers.Usethecarryinghandleorothermeansofsafetransport.
WARNING! Strictly follow all instructions to avoid an accident, damage to your vessel, personal injury or death.
See www.harken.com for additional safety information.
DANGER! Hydraulic equipment under pressure may cause serious injury or death.

Hydro 1 7
Installation
While unpacking the hydraulic power unit (HPU) and electronic control box (ECB), inspect for irregularities. During transport the power
unit may have been exposed to many unusual conditions. If irregularities appear, document details and contact shipper and Harken
distributor.
Plan Installation
Mounting is required for both the HPU and the ECB. Because this installation is on a boat, the following are some points to consider
when choosing the installation location:
Location in Boat
• Dryandwell-ventilated,typicallyneartheengineroom.
• HPUandECBtobemountedwithinclosemutual
proximity, recommended maximum 5 m wire run.
(See Electrical Installation, pg. 12.)
• ProvidenecessaryclearanceforHPU.
• HPUincloseproximitytobatteryandpowersupplyto
reduce voltage drop. (See Electrical Installation, pg. 12.)
• Provideaccessformaintenanceandservicing.Make
access available to filler tube, filter, filter status
indicator and site gauge.
• CentraltothesystemasillustratedinTypicalSystem
diagram.
• ProvideroutingforhydraulichosesfromHPUto
functions. Hoses attach to manifold horizontally.
• Nearestboat’scenterlineinanuprightpositionto
reduce the heeling extremes.
Typical System
Electronic
Control Box
Hydraulic Power Unit
(HPU)
Attached manifold
Filler tube
Choose an area close to the plumbing center of the system
Filter status indicator
Case Drain Port

8 Hydro 1
Installation
Mount Electronic Control Box
Choose a suitable location for the electronic control box (ECB) as described in the planning section.
The ECB is (L) 11.02" (280 mm) x (W) 7.0" (180 mm) x (H) 5.2" (132 mm) and is externally mounted using four (4) M6 (¼") fasteners.
The ECB is water resistant to IP67; however, its location should be dry and within a 5 m wire run to the HPU. Power supply cables and
deck switches connect to ECB. (See Electrical Installation, pg. 14)
A mounting pad with tie downs will be required for securing the HPU to
the boat. Every installation is unique. Considerations for the mounting
pad and tie downs follow:
• Themountingpad(notsupplied)maybeatray,platform
or bridge that securely attaches to the boat and supports
the HPU. Consider total weight and overall dimensions.
(See Technical Data, pg. 20)
• TheHPUisfastenedusingfour(4)M10–1.5x15mmbolts
which thread into the underside of the HPU tank. Underside
access must be available for fastening.
• Additionaltiedownsupports(notsupplied)arerequired.
These may be similar to battery box tie downs and fabricated
from nylon or polyester webbing. Tie downs should attach
to the mounting pad and be lashed over the HPU tank as
illustrated.
Measure Hose Run
Measure hydraulic hose runs after the HPU has been mounted.
Remember these important points when measuring runs:
• ShortstraightrunsbetweenHPUandfunctionarebest.
• Avoidsharpedgeswhichmaychafethehose.
• Minimizettings/connectionsthroughouttheruntoavoid
possible leak points.
• Minimize90°bends,whichincreasesystemlossesand
decrease performance. If unavoidable use a 90° swept fitting,
do not use a 90° elbow fitting.
CAUTION! The HPU was shipped cleaned and tested. Harken strongly recommends against disassembly or removal
of the tank lid or the HPU components. Introduction of contaminants can cause operational problems and possibly
void warranty.
CAUTION! Do not exceed the manufacturer specified minimum bend radius.
Securing Hydraulic Power Unit
CAUTION! Cleanliness is crucial for any hydraulic system. Contamination is the primary cause of seal failure. Most
hydraulic hoses contain manufacturing debris when purchased. Attaching a dirty hose will contaminate the system.
Always flush hoses thoroughly before use. Failure to do so may void warranty.
Approximate clearance
required for installation
2"
(50 mm)
8"
(200 mm)
4"
(100 mm)
4"
(100 mm)
Avoid using an elbow
Use a swept hose fitting for a 90° bend

Hydro 1 9
Hydraulic Installation
Hose and Fitting Selection Recommendation
Functions must be connected to the HPU manifold using proper
hydraulic hose size and type. Required hose type is SAE 100 R2
or SAE 100 R8. Hose size is determined by flow and run length
between HPU and function.
When ordering, specify that all hoses are flushed, filled with clean
oil and capped at point of purchase. In most conditions, Harken
recommends ISO 46 grade oil*. (See Oil Equivalent Table, pg. 15)
If hoses are shipped, they may not contain oil. Harken can
supply flushed, clean, empty hoses if ordered when purchased.
*Exception noted in Hydraulic Oil section, pg. 15.
gpm lpm in mm
Single Flow Case Drain 1/46.3
Single Pump/Motor Function 415 Supply 3/810
Return 1/212.5
Hose Shortening
Hydraulic hoses typically shorten 2% to 4% of total length when pressurized. When routing and measuring hose lines, ensure extra hose
length is added to compensate for the hose shortening under pressure.
End Fittings
Hydraulic fittings vary widely. HPU manifold A and B ports are -8 SAE female. P and T ports are -10 SAE female. The case drain is
-8 JIC male. Hose end fittings may be selected to fit existing function fittings, or function fitting may be replaced. Refer to individual
function manuals for specific A&B and drain port sizes.
Fitting Instructions
End fittings must be installed using proper tools by qualified persons. Fittings should be stainless steel whenever possible.
Note: Always ensure pressure rating for selected hose is equal to or greater than 2000 psi/140 bar.
Recommended Hose ID for Hose Lengths Under 40'
CAUTION! Cadmium plated fittings rust in saltwater environment. Replacement costs outweigh initial cost advantages.

10 Hydro 1
Port Indentification
Hydro 1: HPU manifold contains four (4) valve ports, making valve port selection for a given function simple. HPU remote manifold
attaches via hose to port on HPU.
Hydraulic Installation
Configuration
The stock configuration of Hydro 1 is internally plumbed such that valves are pre-assigned to a manifold and motor. This is illustrated
in the Function Assignment Table. Hydro 1 unit uses valves 1-4 with manifold 1 and motor 1.
Function Assignment
The Hydro 1 unit is equipped with either an attached or a remote manifold per design specification. Both manifold styles have four (4)
valve stations corresponding with four (4) ECB switches. Assign each function to its own set of valve ports. Record the function name
in the Function Assignment Table below. Refer to this information when connecting the electric switches. For easy reference, label the
hydraulic hoses in accordance with the valve. For example: label Valve Station 1 hoses for your attached manifold "VS1A and VS1B".
Function
Name
Valve
Station Number
Attached
Manifold Number
Remote
Manifold Number Motor
VS1 A1 — 1
VS2 A1 — 1
VS3 A1 — 1
VS4 A1 — 1
VS1 —R1 1
VS2 —R1 1
VS3 —R1 1
VS4 —R1 1
Function Assignment Table
Attached manifold with 1 valve.
Remote manifold pressure port

Hydro 1 11
Hydraulic Installation
Manifold Blanking Plates
All manifold stations must have either blanking plates or valves. Once all functions have been assigned, attach blanking plates to
stations not in use. Tighten #10-24 bolts to 4.1 ft-lb (5.6 N-m) torque. The unit is shipped with the number of valves ordered. Additional
valves may be added if blanking plates are present.
Flushing Hoses
Flush hoses prior to connecting to HPU, if not done when purchased. Use an external filtration pump (not included) to remove all debris.
Connecting Hoses
Install hoses per predetermined route.
• Ifhoseendttingsdiffer,verifymatingttingspriortorunningthehose.
• RemoveplugsfromtheHPUmanifoldandfunctionportstoconnectAandBhoses.
To prevent filled hoses from draining, connect the lower of the two ends first. This is typically the HPU.
• Attachtheotherhoseendatthehigherconnection.
• Ifcasedrainhosesarerequired,continuewiththesameprocedureusedonAandBhoses.
• PlugallunusedAandBportstopreventcontamination.
Any unused A and B ports with a valve must be plugged with ORB plugs as well.
NOTE: ORB, BSPP and JIC connections do not need PTFE tape or other sealing.
Case Drains
Function motors with drain ports must be routed to a common case drain on the HPU during the installation. T-fittings may be used
to connect multiple drain port hoses to one common hose that leads to the case drain. Line sizing should be based on maximum
flow in order to prevent flow restriction and back pressure.
Example: The Hydro 1 unit is sized to fully power one function at a time. Therefore the common case drain hose that
combines flow from all drain port hoses does not need to be up-sized.
The recommended minimum hose size for function drain ports should be ¼" inner diameter (ID).
Mounting Clamp Hose Support
Support hoses using mounting clamps to prevent chafing and premature failure. Remember to allow for 2% to 4% shortening
when pressurized.
Protect Hydraulic Hose from Sunlight
Sunlight leaches out elastomers causing the cover to weather check or develop cracks deep enough to allow moisture penetration
of reinforcement. Use protective hose covers and/or store under protective cover when not in use.
Individual Function Protection
Some equipment may require lower max flow or lower max pressure than the hydro unit can deliver. Use a flow control valve, pressure
reducing valve and/or pressure relief valve to reduce maximum flow and/or maximum pressure. These valves are not included with the
Hydro 1 unit. They should be purchased as required by the original equipment manufacturer.

Electrical Installation
Harken Hydro Units include 24 volt DC motors standard. 12 volt DC motors are available by special order. If a 12 volt DC motor was
specified with system, refer to 12VDC motor electrical installation supplement for additional information.
Electrical installation is intended to be straight forward. For instance, connections internal to the ECB are prewired. At the time of installation
the user is only required to make the necessary connections between the switches, valves, ECB, HPU and power supply/battery.
To ease installation, the ECB terminals for switches, valves, 24V power and ground are labeled. For quick reference, terminal
and valve port labeling follows a corresponding numbering scheme. For the wires routing from switches on the deck or valves on the
manifold, waterproof integrity is maintained by passage through a sealed gland. Electrical installation is divided into five basic steps:
1. Connect the deck switches to the ECB
2. Connect a ECB to power supply
3. Connect HPU motor to the ECB
4. Connect valves to the ECB
5. Connect the HPU to the battery
NOTICE: Adhere to electrical standards per the National Boatbuilding Regulatory Bureau.
CAUTION! DO NOT connect the cable from the battery to the HPU until all of the other steps are complete.
CAUTION! Be extremely careful when connecting the battery cables. Short circuiting the battery connections can
damage the HPU and/or motor and possibly cause damage to the boat, a fire and/or personal injury.
CAUTION! Never run the HPU pump without oil. This can cause serious damage to the pump and/or motor and will void
the HPU warranty.
Wire Selection
Three types of wire cables are required for installation:
1. Wires to connect switches to the ECB.
2. Wires to connect the power supply to the ECB.
3. Wires to connect the HPU to the battery.
Minimize voltage loss on battery and power supply cables by sizing wire gauge for a length of wire. Refer to the Wire Sizing Table below
for a given length of wire.
At the HPU motor contactor, the positive terminal is an 8 mm stud, and the common ground terminal is a 10 mm stud. Install end
terminals using proper crimping tool.
16 ft (5 m) 33 ft (10 m) 49 ft (15 m)
Switch or Valve to ECB 16 AWG 1.31 mm214 AWG 2.08 mm212 AWG 3.31 mm2
Power Supply to ECB 16 AWG 1.31 mm214 AWG 2.08 mm212 AWG 3.31 mm2
Battery to HPU Motor 00 AWG 67.4 mm20000 AWG 108 mm2— —
Wire Sizing Table
12 Hydro 1

Hydro 1 13
Electrical Installation
Connect Deck Switches to the ECB
Install the deck switches in a convenient location. By design, two (2) deck switches are used per function. Generally, one switch would
actuate the function motor in a forward direction and the other in the reverse. Example: for a furler, the (A) switch would furl and the
(B) would unfurl.
Connect ECB to Power Supply
Follow these steps to connect power to ECB:
1. Prior to making any connection, verify internal 5A circuit breaker is
in OFF position and system isolation switch on ECB cover is in OFF
position.
2. Pass power supply wires through gland into the ECB case.
3. Connect power supply positive lead to the circuit breaker 0CB
terminal 2.
4. Connect power supply common lead to any GND(–) terminal.
Valve Switch Wire 1 Wire 2
1A +24 -1 SW1A
B +24 -1 SW1B
2A +24 -2 SW2A
B +24 -2 SW2B
3A +24 -3 SW3A
B +24 -3 SW3B
4A +24 -4 SW4A
B +24 -4 SW4B
Note: Polarity is not an issue with 2-wire deck switches
Switch Wiring Table
Note: Deck switches must be N/O (normally open).
Follow these steps to connect deck switches to ECB:
1. Select moisture barrier gland insert.
2. Pass switch wires through gland into the ECB case.
3. Connect deck switch wires per Switch Wiring Table below.
Switch wires connect to terminal strip labeled +24 - X and SWXX.
(See photo).
Note: For wire gauge information, refer to pg. 12.

14 Hydro 1
Electrical Installation
Connect HPU to Battery
Follow these steps to connect HPU to Battery:
1. A 250-300A circuit breaker or fuse (not supplied) must be installed between HPU motor and battery. Prior to making connection,
remove fuse element or verify circuit break is in OFF position.
2. Connect positive lead from fuse to open 8 mm terminal stud contactor on solenoid switch.
3. Connect from fuse to battery.
4. Connect negative lead from 10 mm stud on motor case to common terminal or (-) battery terminal.
CAUTION! DO NOT close the circuit with the fuse or circuit breaker until the Commissioning phase.
Valve Black White Blue
1SW1A SW1B Ground
2SW2A SW2B Ground
3SW3A SW3B Ground
4SW4A SW4B Ground
Valve Wiring Table
Connect HPU Motor and Valves to ECB
Each valve operates using a three-wire cable bundle with an M12
connector.
Note: Valve wires supplied are 5M. These can be extended with a
16-gauge wire if needed. (Refer to Wire Sizing Table, pg. 12.)
Follow these steps to connect HPU motors and valves to ECB:
1. Join mating ends of Deutsch Connector to connect the ECB
to the HPU motor.
2. Pass valve wires through gland into the ECB case.
3. Connect valve wires per Valve Wiring Table at right. Valve wire
sets connect to terminal strip labeled SWXA, SWXB and GND(–).
(See photo, pg. 13).
4. Connect valve cable to M12 connector on valve.
Note: Align key and keyway on connector.
White (N/C) Port A or B
Black (N/C) Port B or A
Blue (–)
Green/Yellow (Not Used)
Brown (Not Used)
1
2
4
3
5

Hydro 1 15
Commissioning
Manufacturer Brand Name Manufacturer Brand Name
Amoco®Rykon 46 Gulf®46AW
Ashland Valvoline®Evergol 46 Mobil®DTE 20 Series 25
Atlantic Richfield®Duro AW-S-215 Mobil®DTE 10 Series 19
BP®Energol HLP Pennzoil®Magnus A 315
Chevron®USA AW Hydraulic Oil 46 Phillips Petroleum®Corp. Tellus 46
Citgo®Petroleum Corp. A/W Pacemaker XD-46 Shell®Tellus T46
Citgo®Petroleum Corp. A/W 46 Shell®SUNTAC WR 150 WR
Conoco®(Continental) Super Hydraulic Oil 21 Texaco®Rando HD 46
Esso®Nuto H46 Union®Hydraulic Oil Unax AW 215
Exxon®Nuto H46
Registered trademarks: Amoco®- Amoco Oil Company: Ashland Valvoline®- Ashland, Inc.; Atlantic Richfield®- Atlantic Richfield Co.; BP®- BP p.l.c; Chevron®USA - Chevron Intellectual
Property LLC; Citgo®Petroleum Corp. - Citgo Petroleum Corp.; Conoco®(Continental) - ConocoPhillips; Esso®and Exxon®- ExxonMobil; Gulf®- GULF Oil International; Mobil®- ExxonMobil;
Pennzoil®- SOPUS Products; Phillips Petroleum®Corp. - Phillips 66; Shell®- SOPUS Products; Texaco®- Chevron Intellectual Property LLC: Union®- Phillips 66.
Filling Reservoir
Pump hydraulic oil through an adequate filter into reservoir. Fill until oil
level indicator is 2/3- 3/4full. Inspect for leaks. Reservoir capacity is
30 liters (7.9 gal.). Approximately 25 liters (6.6 gal) will be needed for
the reservoir. If installation is completed with empty hoses, extra oil
will be needed to meet the 2/3- 3/4tank fill indicator requirement.
Hydraulic Oil
Harken recommends mineral-based, ISO 46 grade oil. Refer to Oil
Equivalent Table below. If HPU is primarily used in an extreme cold
weather environment, ISO 32 is suitable.
Characteristics of good quality, mineral-based hydraulic oil are:
• Goodanti-wearperformance
• Resistancetooxidationdepredation
• Protectionagainstrustandcorrosion
• Resistancetofoaming
• Abilitytoseparatewaterrapidly
• Suitableforwidelyvaryingtemperatureconditions
• Goodlowtemperatureowproperties
• Retainsviscosity/temperaturecharacteristicswhileinservice
• Universallyavailable
Note: If the hydraulic installation was completed with empty hoses,
be sure to have extra oil on hand to top off the tank as the hoses
are filled.
Filler Tube
Oil Level
Indicator
CAUTION! Never run the HPU pump without oil. This will void warranty.
When commissioning hydraulic equipment, it is extremely important to carefully follow each procedure to avoid premature system damage
and/or failure. Secure connections, ensure cleanliness, confirm proper fluid levels and perform all recommended tests. The following are
instructions to ensure proper commissioning of your Hydro 1.
Oil Equivalent Table

CAUTION! If installation was completed with empty hoses, check the oil level indicator after each function, and add oil as
necessary.
16 Hydro 1
Commissioning
Closing Circuit
Verify the system installation after completing hydraulic and electrical installation and filling the reservoir. To begin closing the electrical circuit:
1. Flip internal ECB circuit breaker to ON position.
2. Install fuse element between HPU motor and battery cable or flip circuit breaker to ON position.
3. Flip system isolation switch on ECB cover to ON position.
Leak Check
To perform leak check, run one function at a time in a single direction for 5 – 10 seconds. If installation was completed with empty
hoses, increase the run time to 10 – 30 seconds. Perform the following:
1. Confirm hose run is correct by verifying operation of intended function.
2. Inspect each fitting for leakage.
CAUTION! If leak is present, decrease system pressure to 0 psi before tightening fittings.
3. Tighten fitting as necessary.
4. Repeat procedure for all functions.
One-Way Function Flush
Flush the function motor through the system filter by running each function in a single
direction. Run in same direction as previous step. This process helps ensure system
cleanliness by depositing any contaminates into the system filter. Refer to Run Time
Table. Total length is sum of A and B hose. Repeat procedure for all functions.
Hose size Run time per 10' (3 m) of Hose
in mm sec
3/810 5
1/212.5 7.5
5/816 10
3/419 15
1 25 25
System Validation
Verify proper function performance and correct switch wiring by running one function at a time first in one direction and then in the other.
Single direction functions, i.e. single speed winch, are operated by one deck switch. If function does not operate per specific user manual,
switch wiring may be incorrect, or A and B hoses may be reversed. If this is the case, refer to the Hydraulic and Electrical Installation sec-
tions and verify each step.
Two direction functions, i.e. furlers, two- and three-speed winches are operated by two deck switches. Each switch operates one direction.
Verify each switch operates the intended function direction. If not, either reverse switch wiring at terminal strip inside the ECB, or reverse A
and B hoses. For more specific operational instructions refer to specific function user manual.
Function Pressure Check
Refertoeachfunction’susermanualformaximumow,maximumpressureandfunctionworkingloadbeforeoperationunderstatedcondition.
CAUTION! To avoid equipment damage, DO NOT exceed function’s maximum pressure or maximum flow.
DO NOT exceed the safe working load of any function.
Carefully load system and verify function operates per specific user manual. During function operation, inspect hoses for chafing or
binding. With pressure at zero, inspect fittings for leaks. Ensure proper safety precautions are practiced to avoid personal injury due
to pressurized oil.
CAUTION! If leak is present, decrease system pressure to 0 psi before tightening fittings.
Oil Level and Filter
Maintain an oil level of 2/3- 3/4full as viewed through tank fill indicator.
Most foreign particles flush into the return filters after first few hours of operation. If system was exposed at any time to possible
contamination, replace filter element.
If you have any questions, contact your Harken Tech Service Representative.
Run Time Table

Hydro 1 17
Operation
Power Up / Power Down
Harken Hydro Power Units have system isolation switches on
the electronic control box.
During short-term, inactive periods the system isolation switch
should be in OFF position. This deactivates deck switches.
For long-term storage, in addition to placing isolation switch in
OFF position, remove the fuse or circuit breaker between HPU
motor and battery.
Oil Level
Maintain an oil level of 2/3- 3/4full as viewed through Oil Level
Indicator. Always inspect oil level before use. If necessary to
maintain proper level, add more filtered oil to tank.
Motor Thermal Protection
Harken standard Hydro Power Units feature a 4kW 24VDC series
wound motor. (12VDC motor available by special order) Motors
are specified to provide years of service under standard operating
conditions.
Due to high current draw, these motors will generate excessive
amounts of heat after extended periods of operation at load.
To avoid motor damage, the motor is equipped with an
internal thermal monitor and switch.
The motor is sized to run a minimum of five (5) minutes without
tripping the thermal switch. If overheating occurs and the thermal
switch is tripped, an indicator light on ECB will illuminate. After this
occurrence, the motor requires a variable cooling period based
ambient conditions.
CAUTION! In case of emergency, thermal switch override is located inside the ECB. Flip toggle switch to engage override.
Once thermal switch override is engaged, motor will operate until it stalls. If thermal switch override is engaged, HPU
warranty may be voided.
CAUTION! Motor operation beyond temperature limits will cause damage to motor and possibly other components.
Single- and Multiple-Function Operation
The Hydro 1 is designed to operate a single function at a time. All functions are powered by one motor. If multiple functions are
operated simultaneously, oil flow will be divided among the functions and performance across all operating functions will decrease.
Electronic Control
Box (ECB)
Oil Level
Indicator
Internal Thermal Switch
Override

18 Hydro 1
Maintenance
CAUTION! If necessary, top off oil reservoir using proper fluid type. Do not mix oil types. Refer to Oil Equivalent Table,
pg. 15. Only use filter elements capable of meeting or exceeding the oil cleanliness level requirements.
IMPORTANT! Oil filter status indicator functions only when unit is powered and when motor and pump are running. In operating
conditions with high levels of airborne particles, inspect breather at frequent intervals.
IMPORTANT! Conduct recommended oil change schedule in accordance with fluid type, aging and oil contamination level. Oil
condition depends on moisture content and additive level. In operating conditions with high levels of airborne particles and/or
elevated thermal loads, reduce intervals between oil changes accordingly.
Hydraulic Oil Change Schedule
• Afterrst500operatinghours
• Every1000operatinghoursorbiannuallyregardlessofaccumulatedoperatinghours
• Oilchangeintervallengthscanbeadjusted(longerorshorter)ifresultsoflaboratoryuidsamplingandoilanalysisrevealoilis
cleaner or more contaminated than expected at 1000 operating hours.
How to Change Oil
Oil change intervals are recommended based on various factors such as the type of fluid, the degree of aging and the contamination of
the oil. Water content and the levels of additives are also significant factors in determining the condition of the oil. Important guidelines
to remember are:
• Followproperprocedureswhenchangingoil.Impropercleaningproceduresmaycontaminatehydraulicsystem.
• Performoilchangesinawarmoperatingenvironment.
• Drainoldoilbeforeaddingnew.Reservoirmaybeemptiedviaoneoftwomethods:
1. Place basin near HPU beneath drain plug. Remove plug and let oil drain into basin until reservoir is empty.
2. Use siphon/oil pump method to pull oil up through hose in filler tube. Use a basin to collect oil.
• Onceoilisdrained,uselint-freeragstocleanreservoir.Removedebrispriortorelling.
• Filteroilpriortollingreservoir.Neverllareservoirthroughallerbreatherwithoutlteringitpriortoorduringthellingprocess.
• Takecaretonotintroducecontaminatesfromthelterhousingwhenremovinglter.
Note: Always dispose of oil properly. Contact your local waste authority, and follow guidelines for recycling and/or disposal.
CAUTION! Filter oil prior to filling the reservoir. Cleanliness of oil directly from barrel is not sufficient for system operation.
Contact local hydraulic service company for filter carts or pre-filtered oil.
Problems occurring during oil change result from:
• Useofunsuitablehydraulicoil
• Useofoilwhichwascontaminatedduetofaultystorage
• Failuretocleanreservoir
• Inadequatecleanlinesswhenlling,i.e.dirtydrumsorcontainers
• Fillingtoimproperlevels
Harken Hydraulic Power Units will provide years trouble free operation with proper, routine
maintenance. Adherence to a maintenance schedule will lengthen component life, reduce downtime,
and minimize repair costs. Typical maintenance includes regular oil changes, replacing filter elements,
oil sampling and component inspection. Under normal operating conditions, the following maintenance
schedules are suggested:
Filter Element Replacement Schedule
• Withineight(8)operatinghoursaftertheinitialcommissioning
• Every500operatinghoursorwhenOilFilterStatusIndicatorsignalsadirtylter
• Duringanycompleteoilchange
Filter supplied with the unit is a drop-in element (HYFEH10). Ensure O-rings are fitted into ends of filter
prior to installation. Contact Harken for replacement elements. If using other manufacturer, cross-
reference the filter and use element rated for 10 micron or better. Oil Filter Status Indicator

Hydro 1 19
Maintenance
Leakage Inspection
After commissioning visually inspect system for leaks. Perform visual leak inspection at regular intervals. It is good practice to visually
inspect for leaks prior to every use.
Cleanliness Inspection
Maintain a dirt-free system. This is very important in applications in environment with a high degree of airborne contaminants.
Leak detection is easier and quicker on clean system.
Oil Level Inspection
Check oil level every 2 to 4 hours during the first day of use. Check oil level twice a day during first week and once a week thereafter.
CAUTION! If necessary, top off oil reservoir using proper fluid type. Do not mix oil types.
Refer to Oil Equivalent Table, pg. 15.
Additional Maintenance Points
• AlwayspowerdownHPUpriortoperformingmaintenance.
• PlacealabelortagonHPUindicatingtypeofuidthatisinstalled.
• Replaceanyhosesthatappeartobewornorchafed.
Troubleshooting
Problem Possible Cause How to Verify
None of the functions are working
No electrical power
Check power to ECB
Check motor switches on ECB
Check wiring from ECB to motor
Check main circuit breaker to ECB
Check lights on micro circuit breaker. If red, reset circuit breaker.
Motor is not operating
Check thermal switch trip light on ECB
Verify proper voltage at motor
Verify operation of motor relay
Motor is stalling Pressure relief valve not working
Not enough current going to motor
Pump is not operating correctly Check oil level in reservoir
Repair pump
Single function is not working
Function is turned off Check function breaker in ECB
Switch is not working Check wiring from deck switch to ECB
Valve is not working
Check wiring from ECB to directional valve
Check lights on micro circuit breakers. If red, reset circuit breaker.
Check operation of directional valve solenoids
Perform manual override with hex wrench
Functions are running slow
System leak present Check hose and fitting connections
Reduced motor speed Verify adequate battery voltage to motor
Relief valve is opening Hydraulic line is plugged
Pump flow is reduced Check oil level in reservoir
Filters are plugged Check filter status gauge. Replace filter element if needed.
Function load reduced
System leak present Check hose and fitting connections
Insufficient motor torque Verify batteries are fully charged
Relief valve is opening Check relief valve opening pressure
Pump is not operating correctly Check oil level in reservoir
Check system pressure under load
CAUTION! If leak is present, decrease system pressure to 0 psi before tightening fittings.

20 Hydro 1
Bill of Materials H-51332
22.350
567.69
7 8
6
2
3
14
19
5.650
143.51
16 17
19.331
491.00
13.425
341.00
14.694
373.24
5 4
10 11 13
15
9
1
NO.
QTY.
DRAWING NO.
PART NO.
MATERIAL
DESCRIPTION
1 1
H-50915
-
VARIOUS
HYDRO PUMP/MOTOR ASSY
2 1
H-51469
CAST ALUMINUM
FINISHED AB 30 ALUMINUM HYDRO TANK
3 1
H-51333
-
6061-T6 AL
TANK TOP
4 2
H-52567
HFS259
10-32 X 1.25 SS SL RH
5 1
H-51191
SOLENOID SWITCH 12-24V
6 1
H-52564
HYDRO- 3/4in NPT MALE-MALE AL PIPE NIPPLE X 6in
7 1
H-52566
HYDRO- EATON MALE NPT FILL MBR110
8 1
H-52565
HYDRO- 3/4 NPT FEMALE-FEMALE ALUMINUM COUPLER
9 1
H-52732
-
VARIOUS
HYDRO- 1 MFLD AND FILTER ASSY
10 7
H-52522
HFS568
18-8 SS
FST-5/16-18X1.00 18-8 SHCS
11 7
H-52521
HFS 232
SS
5/16 SS LOCK WASHER
12 1
H-52606
-
VARIOUS
HYDRO - -6 HOSE - PUMP TO DIST. MANIFOLD
13 8 H-38261A
HFS336 A4 (316) SS
M8 X 1.25 X 16 SHCS
14 1
H-52568
- -
HYDRO- 5in SIGHT LEVEL GAUGE
15 1
H-52623
-
VARIOUS
HYDRO - CASE DRAIN ASSY
16 1
H-52735
- -
HYDRO - 30L TANK GASKET
17 1
H-53305 HYZPSG8
316 SS
HYD FIT PLUG SS G1/2A BSPP
18 1
H-53543
- -
WIRING KIT
19 4
H-46834
HYDROEXVALVE
VARIOUS
HYDRO EXTRA VALVE KIT - 24VDC
22.350
567.69
7 8
6
2
3
14
19
5.650
143.51
16 17
19.331
491.00
13.425
341.00
14.694
373.24
5 4 10 11 13
15
9
1
NO.
QTY.
DRAWING NO.
PART NO.
MATERIAL
DESCRIPTION
1 1 H-50915
-
VARIOUS
HYDRO PUMP/MOTOR ASSY
2 1 H-51469
CAST ALUMINUM
FINISHED AB 30 ALUMINUM HYDRO TANK
3 1 H-51333
-
6061-T6 AL
TANK TOP
4 2 H-52567
HFS259
10-32 X 1.25 SS SL RH
5 1 H-51191
SOLENOID SWITCH 12-24V
6 1 H-52564
HYDRO- 3/4in NPT MALE-MALE AL PIPE NIPPLE X 6in
7 1 H-52566
HYDRO- EATON MALE NPT FILL MBR110
8 1 H-52565
HYDRO- 3/4 NPT FEMALE-FEMALE ALUMINUM COUPLER
9 1 H-52732
-
VARIOUS
HYDRO- 1 MFLD AND FILTER ASSY
10 7 H-52522
HFS568
18-8 SS
FST-5/16-18X1.00 18-8 SHCS
11 7 H-52521
HFS 232
SS
5/16 SS LOCK WASHER
12 1 H-52606
-
VARIOUS
HYDRO - -6 HOSE - PUMP TO DIST. MANIFOLD
13 8
H-38261A
HFS336 A4 (316) SS
M8 X 1.25 X 16 SHCS
14 1 H-52568
- -
HYDRO- 5in SIGHT LEVEL GAUGE
15 1 H-52623
-
VARIOUS
HYDRO - CASE DRAIN ASSY
16 1 H-52735
- -
HYDRO - 30L TANK GASKET
17 1 H-53305 HYZPSG8
316 SS
HYD FIT PLUG SS G1/2A BSPP
18 1 H-53543
- -
WIRING KIT
19 4 H-46834
HYDROEXVALVE
VARIOUS
HYDRO EXTRA VALVE KIT - 24VDC