HYCON HPP09E User manual

HPP09E
Hydraulic Powerpack
From serial
number 13885
Revised
22.11.2018
Prior to Operation
We thank you for choosing a
HYCON powerpack.
Please note that the power-
pack is delivered without hy-
draulic oil, and therefore it
must be filled up with hydrau-
lic oil prior to operation.
To ensure smooth operation
and long-lasting performance
of your new powerpack, we
recommend you to study this
operating manual carefully and
pay special attention to the
Safety and Service
Precautions
We hope you will be satisfied
with your new HYCON power-
pack.
Best regards
HYCON A/S
HYCON A/S
Juelstrupparken 11
DK-9530 Støvring
Denmark
Tel: [phone]
Fax: [phone]
Mail [email protected]
www.hycon.dk

1
Contents
Page
Safety precautions................................................................................................ 2
Filling up hydraulic oil ........................................................................................... 3
Technical data...................................................................................................... 4
Electrical Circuit Diagram ...................................................................................... 5
Starting instructions ............................................................................................. 6
Service, maintenance and hydraulic settings .......................................................... 7
Oil types .............................................................................................................. 8
EC-Declaration of Conformity ................................................................................ 9
Warranty conditions ............................................................................................10
Spare parts list....................................................................................................11

2
Safety Precautions
DANGER: The power pack must only be connected to an electrical power
source with the correct fuse and fault current protection.
If this is not observed, there is a risk of major personal injury or, in
extreme consequence, death due to electric shock.
1. 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.
2. Always connect hoses before starting.
3. Always keep the electric box, cables and sockets clean.
4. Always connect the powerpack to a power source with the correct electrical
protection.
5. Always turn off the motor and disconnect the power supply when the powerpack
is not used and before performing any service.
6. Never start the motor 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 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.
IMPORTANT: Read and follow this operating manual carefully to avoid
personal injury and damage to the power pack.

3
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.

4
Technical Data
Hydraulics
The HYCON HPP09E 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 super-
heating.
Oil flow 20 l.p.m at 2950 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. 6 litres/max. 8 litres
Hydraulic system compl. Max. 9 litres
Filter system (filter element) 25 Micron with by-pass
Motor Electric motor
5.5 kW, 3x400 V, 50 Hz
Motor and electric box
approved for IP55
Motor rotation Clockwise
(seen from the back)
Fuse minimum 16 Amp
Guaranteed sound power level LWA 97 dB
Sound pressure level 1 m LPA 85 dB
Dimensions (LxWxH) 710x550x645 mm
Weight, without hydraulic oil 84 kg

5
Electrical Circuit Diagrams

6
Starting Instructions
Please observe the starting instructions on the electro box.
Start: Check hydraulic oil level at sight glass
Connect hoses and tool
Press the green button
If the motor’s direction of rotation is wrong, invert the phases in the
socket by means of a screw driver
Move the lever to “ON”
Stop: Move the lever to “OFF“
Press the “STOP” button
The powerpack is not equipped with an
automatic phase inverter. If the motor’s
direction of rotation is wrong, the phases
must be inverted in the socket by means of
a screw driver. Also see above under
“Start”.
Motor’s Direction of Rotation: Clockwise (seen from the back)

7
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 *)
1 x replacement
Check hoses
(tighten up if needed)
Air filter
1 x replacement
Fuel filter
1 x replacement
*) Use only filters with by-pass
Hydraulic Settings
Check the working pressure by means of test equipment. The test equipment must
comprise 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 flow valve - the pressure gauge must show 150 bar.
Adjust the pressure relief valve by loosening the lock nut and turning the adjust-
ment 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 l. p.m.
If correct pressure/oil flow cannot be achieved by following the
above instructions, the powerpack must be re-adjusted. If the
pressure/oil flow is then still incorrect, the pump is defect and
must be replaced.

8
Oil Types
The HYCON power packs use standard hydraulic oil, i.e. all types of mineral oil and
biodegradable oil, which comply with the following values:
Ambient temperature range
Below 10°C
50°F
10 … 30°C
50 … 68°F
Above 30°C
68°F
Recommended oil viscosity grade
VG 32
VG 46
VG 68
Recommended oil cleanliness
ISO 4406 /19/16 / NAS 1638 10
Permitted viscosity
cSt
10 –600
Viscosity index
Minimum
100
Oil temperature area
°C /°F
-20 to 70 / -4 to 158

9
EC-Declaration of Conformity
We hereby declare that
HPP09E hydraulic powerpack –from serial No. 13885
(with 5.5 kW electric motor)
is manufactured in conformity with the EC Directives:
2006/42/EC
2000/14/EC
2006/95/EC
Notified Body 1585:
AkustikNet A/S
Frederikssundsvej 179 B
DK-2700 Brønshøj
Denmark
Guaranteed sound power level: 97 dB
HYCON A/S
Juelstrupparken 11
DK-9530 Støvring
Denmark
Martin Møller
Managing Director
24.08.2018
HYCON A/S
Juelstrupparken 11
DK-9530 Støvring
Denmark
Tel: [phone]
Fax: [phone]
Mail [email protected]
www.hycon.dk

10
Warranty Conditions
We grant 12 months warranty from the first date of operation –however, not more
than 18 months from the date of delivery.
The warranty applies to faults that can be related to construction and production
errors.
Faults caused by incorrect operation, incorrect handling, lack of maintenance or the
like will not be accepted as warranty.
The warranty covers the parts necessary for repair and the suggested average time
needed for repair.
For further warranty details, please contact your local dealer.