HYCON HPP09 Instruction manual

Hydrauli
c Powerpack
HPP09
HPP13 POR • HPP13 FLEX
HYCON A S
Juelstrupparken 11
DK-9530 Støvring
Denmark
Tel: [phone]
Fax: [phone]
Mail: [e-mail]
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

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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.

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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

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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

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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.

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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

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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

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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

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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.

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Add Loctite 243 to the four threads, and tighten the screws with a torque of 20 Nm. Mount
the pump with the coupling part into the coupling housing. It is important to fit the
washer between pump and coupling housing perfectly into the frame on the
coupling housing.
Make sure that 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 curve
towards the cooler (see drawing). Place the shaft key in the keyway on the shaft.

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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. 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.

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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). 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 the left fitting on the valve block.

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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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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). 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.

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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.

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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. 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 fittings on the valve block.

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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. 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 of the spool. Mount the seal rings on the two
fittings, and then mount the flat-face couplings.

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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. 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 valve housing.

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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.