HYCON HPP09 User manual

HPP09
Hydraulic Powerpack
From serial
number 1188-1278
Revised
December 2003
Prior to Operation
We thank you for choosin 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 lon -lastin performance
of your new powerpack, we
recommend you to study this
operatin 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 re ards
HYCON A/S
HYCON A/S
Vester Hassingvej 33
DK-9320 Hjallerup
Denmark
Tel: [phone]
Fax: [phone]
Mail [email protected]k
www.hycon.dk

1
Contents
Page
Safety precautions............................................................................................ 2
Technical data.................................................................................................. 3
Startin instructions ......................................................................................... 4
Service, maintenance and hydraulic settin s ...................................................... 4
Oil types .......................................................................................................... 5
EC-Declaration of Conformity ............................................................................ 6
Warranty conditions ......................................................................................... 7
Spare parts list................................................................................................. 8

2
Safety Precautions
1. Always use protective earplu s. The powerpack complies with the EU noise limits
of max. 104 dB, but by daily lon -lastin operation there is a risk of hearin de-
fects.
2. Always connect hoses before startin .
3. Never add fuel and oil when the en ine is runnin .
4. In case of non-operation or performance of service, always turn off the en ine.
5. Never start the en ine without side covers.
6. Operation of the powerpack without tool connected and with lever at “ON” may
cause overheatin of the system and dama e to the powerpack.
7. When liftin the powerpack from a vehicle, we recommend the use of a crane.
8. The pressure relief valve is set at 150 bar from our plant. Never set it hi her.
9. Always use filters with by-pass. The use of filters without by-pass may involve a
dan er of explosion.

3
Technical Data
Hydraulics
The HYCON HPP09 open centre hydraulic powerpack is desi ned in accordance with
the EHTMA cate ory 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 hi h pressure.
Furthermore, the very efficient air coolin protects the powerpack a ainst super-
heatin .
Oil flow 20 l.p.m at 3300 r.p.m.
Working pressure no inal 120 bar
Pressure relief valve Set at 150 bar
Pu p Gear pump
Oil te perature Max. 70° C
Hydraulic oil tank capacity Min. 4½ litres/max. 7 litres
Hydraulic syste co pl. Max. 8 litres
Filter syste (filter cartridge) 25 Micron with by-pass
Engine Honda GX270QXB7
9 HP 4-stroke petrol
with oil alert system
Petrol - normal or unleaded
En ine oil 1.1 litres
Measured sound power level L
WA
101 dB
Sound pressure level 1 L
PA
90 dB
Di ensions (LxWxH) 680x575x593 mm
Weight, without hydraulic oil 68 k

4
Starting Instructions
Please observe the startin instructions on the front of the powerpack.
Start: •
••
• Check en ine oil level
•Check hydraulic oil level at si ht lass
•Connect hoses and tool
•Switch fuel tap to “ON”
•Activate choke
•Turn i nition switch to “1”
•Pull recoil starter
•Move the lever to “ON”
Stop: •
••
• Move the lever to “OFF“
•Turn off the i nition switch
•Turn the fuel tap to “OFF”
Service, Maintenance and Hydraulic Settings
Service/Maintenance
Daily Weekly Yearly
En ine oil Check 1 x replacement
Hydraulic oil Check 1 x replacement
Hydraulic oil filter *) 1 x replacement
Check hoses (ti hten up if needed)
Air filter 1 x replacement
Fuel filter 1 x replacement
*) Use only filters with by-pass
Hydraulic Settings
Check the workin pressure by means of test equipment. The test equipment must
comprise a pressure au e, a flow meter and a valve for adjustment of the flow.
The pressure relief valve is placed on the ri ht 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 au e must show between 145 and 150
bar.

5
Adjust the pressure relief valve by loosenin the lock nut and turnin the adjust-
ment screw in or out. “In” increases the pressure, and “out” decreases the
pressure.
Reti hten the lock nut after adjustment.
2. When the pressure relief valve has been adjusted correctly, the workin pressure
must be set at 100 bar by means of the flow valve. At 100 bar, the oil flow should
be 20 l. p.m.
If the oil flow is not correct, loosen the POD cylinder in the bracket and push it to
the left (hi her flow) or to the ri ht (lower flow).
Secure the POD cylinder in the bracket a ain after adjustment.
Oil Types
The HYCON powerpack uses standard hydraulic oil, i.e. all types of mineral oil and
biode radable oil, which comply with the followin values:
Recommended viscosity 20-40 cSt
Permitted viscosity 15-1000 cSt
Viscosity index Min. 100
Temperature area -20° to +70° C
If correct pressure/oil flow cannot be achieved by followin
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.

6
EC-Declaration of Confor ity
From Serial No.
We hereby declare that the HPP09 hydraulic powerpack 1188-1278
(with 6.6 kW petrol en ine)
is manufactured in conformity with the EC Directives 98/37/EC and 2000/14/EC.
Notified Body 404:
SMP Svensk Maskinprövnin AB
Fyrisbor s atan 3
S-754 50 Uppsala
Sweden
Measured sound power level: 101 dB
Guaranteed sound power level: 104 dB
HYCON A/S
Vester Hassin vej 33
DK-9320 Hjallerup
Denmark
Henrik Steen
General Mana er
15.04.2003
HYCON A/S
Vester Hassingvej 33
DK-9320 Hjallerup
Denmark
Tel: [phone]
Fax: [phone]
Mail [email protected]k
www.hycon.dk

7
Warranty Conditions
We rant 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 handlin , lack of maintenance or the
like will not be accepted as warranty.
The warranty covers the parts necessary for repair and the su ested avera e time
needed for repair.
For further warranty details, please contact your local dealer.