HYCON HPP13D User manual

HPP13D
Hydraulic Powerpack
From S/N 8264
Revised 30.08.2013
Prior to Operation
We thank you for choosing a
HYCON powerpack.
Please note that the powerpack is
delivered without hydraulic oil,
and therefore it must be filled up
with hydraulic oil prior to
operation.
To ensure smooth operation and
long-lasting performance of your
new powerpack, we recommend
that you 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
Operating Manual
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 ................................................................................................2
Technical Data...........................................................................................................3
Starting Instructions...................................................................................................4
Service, Maintenance and Hydraulic Settings ................................................................5
Oil Types...................................................................................................................6
Warranty Terms.........................................................................................................7
Spare Parts List..........................................................................................................8

2
Safety Precautions
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. Never add fuel and oil when the engine is running.
4. In case of non-operation or performance of service, always turn off the engine.
5. Never start the engine without side covers.
6. Operation of the powerpack without tool connected and with lever at “ON” may cause
overheating of the system and damage to the powerpack.
7. When lifting the powerpack from a vehicle, we recommend the use of a crane.
8. The pressure relief valve is set at 145 bar from our plant. Never set it higher.
9. Always use filters with by-pass. The use of filters without by-pass may blow the hydraulic
hoses and the filter cover.
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.

3
Technical Data
Hydraulics
The HYCON HPP13D 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 HPP13D is available in one version:
•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. 70° C
Hydraulic oil tank capacity Min. 8 litres/max. 11 litres
Diesel tank capacity 6,5 litres
Hydraulic system compl. 12 litres
Filter system (filter element) 25 Micron with by-pass
Engine Lombardini LD15-440
11.0 HP
Engine oil 1.5 litres
Dimensions (LxWxH) 805x625x695 mm
Weight, without hydraulic oil 114 kg

4
Starting Instructions
2. Turn ignition key one more time and
engine starts. When engine is running, one
green bulb should light constantly.
1. Turn ignition key one step to the right. Two
red bulbs light up.
Electric start of powerpack.
Lever is pushed towards the engine block.
Engine can be turned on and stopped by turning
ignition key.
Electric Start
STOP POWERPACK
TURN IGNITION KEY OFF
Manual Start
STOP POWERPACK
PUSH LEVER TOWARDS ENGINE BLOCK
Manual start of powerpack.
Lever is pushed away from the engine block.
Engine cannot be turned on and stopped by
turning ignition key. Use recoil start.

5
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 valve - the pressure gauge must show 150 bar.
Adjust the pressure relief 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 adjustable flow, the flow is regulated by adjusting the position of
the throttle cable.
If correct pressure/oil flow cannot be achieved by following the above
instructions, the powerpack must be re-adjusted. Then if the pressure/oil
flow is still incorrect, the pump is defect and must be replaced.

6
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 +70° C

7
Warranty Terms
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.