HYDRO-PACK HPP Series Instruction Manual

DD.026 ENG R(1)
MINI POWER PACKS
MANUAL OF OPERATION
DD.026 ENG R(1) POWER PACK MANUAL
Attention! Before starting the hydraulic power pack operation, it is necessary to get
acquainted with all the recommendations included in this manual. The producer
does not bear any responsibility for damages occurred because of improper
operation of hydraulic power pack or constructive changes.

DD.026 ENG R(1)
CONTENTS
I. SECTION A: GENERAL DATA
A1 PRODUCER
A2 INTRODUCTION
A3 CORRESPONDENCE
A4 LABEL
A5 APPLICATIONS
A6 PRODUCTION CONDITIONS AND REQUIREMENTS
A7 TECHNICAL CHARACTERISTIC
A8 NOISE CHARACTERISTIC
A9 WORKING LIQUID
II. SECTION B: SAFETY TECHNICS
B1 RULES FOR TECHNICAL SAFETY
III. SECTION C: DESCRIPTION OF THE HYDRAULIC POWER PACK
C1 MAIN PARTS
C2 ELECTRICAL PARTS
IV. SECTION D: WORKING WITH HYDRAULIC POWER PACK
V. SECTION E: POWER PACK ASSEMBLY
E1 REQUIREMENTS OF THE WORKING AREA
E2 TRANSPORT OF THE HYDRAULIC POWER PACK
E3 POWER PACK PROTECTION
E4 CONNECTING PORTS
E5 CONNECTION TO HYDRAULIC SYSTEM
E6 CONNECTION TO ELECTRICAL SYSTEM
VI. SECTION F: MAINTENANCE OF THE HYDRAULIC POWER PACK
F1 CLEANING OF THE POWER PACK
F2 PRESSURE ADJUSTMENT
F3 PROBLEM SOLVING
VII. SECTION G: WARRANTY

DD.026 ENG R(1)
SECTION A: GENERAL DATA
A1 PRODUCER
HYDRO-PACK Mühendislik Makina Hidrolik San. ve Tic. Ltd. Şti.
Sanayi Mah. İzmit San. Sit. 13. Cad. No: 315 İç kapı no: 54 İzmit, Kocaeli, Türkey
Tel: [phone] Fax: [phone]
E-mail: [e-mail] Web: www.hydropack.com.tr
A2 INTRODUCTION
The present manual of operation is intended for users of hydraulic power packs. It contents the
necessary information for assembly, inital starting into actuation, maintenance, correct and safety work with
the hydraulıc power packs.
During the compiling of this manual the experience of the producing company and its specialists are
taken into consideration. With special responsibility it is recommended that our indications to be followed up
in the part treating the safety precautions at work with the machine.
The operations that request disassembly and assembly of the power packand electric elements have
to be implemented by only qualified and authorized specialists. The repair works and adjustments that are
not included in this manual should not be carried out.
A3 CORRESPONDENCE
At occurrence of technical problem, please refer to technical department of Hydropack.
([email protected].tr) At correspondence or phone call with us regarding the bought power pack, please
give us the following information so that we can help you better:
•Code of power pack which is on label
•Working voltage and current frequency
•Working pressure
•Displacement of the pump
•Date of production
•Detailed description of the claim
•Working hours

DD.026 ENG R(1)
A4 LABEL
Technical information of power pack (Such as motor power, pump displacement, oil tank size, etc.)
can be seen on label. Label is located on oil tank.
Photo 1. Label of power unit
A5 APPLICATIONS
The hydraulic power pack is intended for integration in hydraulic system of construction building,
transport machines, automobiles, manually operated lifting equipments. They are used for single and double
acting systems as well. (Tippers, car lifts, dock levelers, tail gates, wheel chair lifts, snowplow, forklifts,
industrial automation, etc.
A6 PRODUCTION CONDITIONS AND REQUIREMENTS
The hydraulic power pack is intended to be used in covered premises as well as at open area at
ambient temperature of - 25 to +50°C. Air humidity up to 80 %.
A7 TECHNICAL CHARACTERISTIC
The power packs are designed and accomplished so that they produce a flow rate from 0,4 L/min to
22 L/min depending on the choice of the electric motor (0.5 kW up to 5.5 kW) and hydraulic pump (0,25 cc/rev
up to 9 cc/rev) The pressure that can be reached is from 0 to 220 bar depends on the size of the selected
components.
A8 NOISE CHARACTERISTIC
The hydraulic power pack does not emit noise higher than 85 dB in accordance to EN 60034–9.
A9 WORKING LIQUID
The oil tank must be filled with new, filtered mineral based ISO 6743/4 fluid. Hydraulic oils at mineral
or synthetic base with viscosity rate from 15 to 68 cST at temperature of 40 oC. Hydraulic fluid may change
regarding working climate. Please do not use motor oil, diesel oil or water as fluid in the system. Class of
filtration -9 NAS 1638.
Hydraulic fluid should be changed after 6 months or 1 year depends on usage in application. Suction
filter needs to be cleaned as well.
If there is decrease on fluid level, additional oil should be put in.

DD.026 ENG R(1)
SECTION B: SAFETY TECHNICS
B1 RULES FOR TECHNICAL SAFETY
To work with the power pack it could be allowed only personel who is acknowledged with the rules for
actuation of electrical equipments and equipments working under pressure.
For safety functioning of the hydraulic power pack it is necessary to be kept the following rules:
•It is not allowed an actuation of the power pack with replaced cap of the terminal connecting box of
the motor or using connectors on the coils of the solenoid valves that are not of the same type like
these with which the power pack is accomplished.
•The connection has to be done from a qualified electrician. During the connection it should be
observed the direction of rotation ofthe electric motor ( the arrow at the cover of the el. motor indicates
the correct direction of rotation ).
•Hydraulic connection must be carried out carefully. There are letters on top of the main manifold. P
refers to pump line (pressure) and T refers to tank line (return).
•The selection of the pipelines must be complied with the system pressure and flow rate.
•The tube connectors must be fixed tightly. It should not be allowed any fluid leakage at the outer
surfaces. Proper sealing elements should be used.
•It is not permitted the replacement of the air breather with plug.
•It is not permitted pressure relief valve readjustment to a higher pressure.
•The power pack must be fixed to a basement or to a stable frame.
•It is not allowed the power pack use in explosion –hazardous and combustable environment.
•Lack of oil may cause a damage to hydraulic pump.
•Mono phase and three phase AC motor terminal box covers should be closed.
•Rotation of the AC motor from fan side view is right rotation. Hydraulic pump rotation from shaft view
is clockwise.
•Insulated cables must be used in connection.
•Power pack assembly should not be carried out in watery environment.
•DC motor + & - poles should not contact each other.
•DC motor cable ends must be insulated.
•DC motor should not operate without starter assembled on it.
•There are breathers with red color on oil tanks. Blind plugs should not assemble on these breathers.
•Hose diameters should not be too small.
SECTION C DESCRIPTION OF THE HYDRAULIC POWER PACK
C1 MAIN PARTS
The power pack is consisted on the following main elements:
•Electric motor
•Central manifold (Die casting aluminum alloy)
•Hydraulic gear pump
•Oil tank
•Filter

DD.026 ENG R(1)
Electric motor
Central manifold Hydraulic pump Filter pipe Filter Oil tank
Photo 2. Main components of mini power pack
At switching on the power of the electric motor, it drives the gear pump. The pump sucks the working
liquid from the tank and directs it to the valve block and from there to the implementing components of the
power pack. The pressure in the system is regulated by the pressure relief valve which is built in main block.
Other hydraulic blocks can be assembled to the power pack according to customer’s demand.
C2 ELECTRICAL PARTS
The hydraulic power pack is assembled with:
•Electric motor
•Starter (Used for DC motors only)
•Solenoid valves (Optional)
The electric motor is three phase type or mono-phase for AC. Regarding DC motors, working voltages are
12 or 24 V standard in range.
The solenoid elements are cartridge type. Their coils can operate under voltages of 12, 24, 110 or 220 V.
The connectors are made under DIN 43650.

DD.026 ENG R(1)
SECTION D WORKING WITH HYDRAULIC POWER PACK
The power pack work is determined by the machine at which it is integrated. At work with the power
pack it is not allowed the presence of leakage of working fluid on the outside surfaces. The power pack is
switched when the motor is supplied with the necessary voltage. The control is effected by proper
combination of switching on the motor and the solenoid valves.
SECTION E: POWER PACK ASSEMBLY
E1 REQUIREMENT OF THE WORKING AREA
The power pack must be mounted using M10 holes if there is no mounting bracket. The working area
around the power pack must be free and an access to the oil filler, to the valves and the unloading throttle
has to be ensured. The power packs must not be placed in closed areas that may prevent its cooling. The
power pack should not contact with any parts that may vibrate and transmit noise.
E2 TRANSPORT OF THE HYDRAULIC POWER PACK
The power pack can be transported with any kind of covered transport. At its transporting it should be
observed the recommendations on the carton. If there is oil inside the tank during transportation, air breather
should be replaced with blind plug or oil should be pour out before transport.
E3 POWER PACK PROTECTION
The hydraulic power pack is taken out of the carton. The polyethylene packing is removed of it. The
safety plugs are replaced of the supply ports.
E4 CONNECTING PORTS
There are two letters on main manifold which refer to pump (pressure) and tank lines. P refers to
pump line and T refers to tank line. Both ports are G 3/8’’ as standard. Max. tightening torque of fittings is 65
Nm.
Tank port Pressure port
Photo 3. Connection ports on central manifold

DD.026 ENG R(1)
E5 CONNECTION TO HYDRAULIC SYSTEM
The pipelines from the power pack are connected to the implementing components of the machine.
Hydraulic circuit and technical information ca be found on technical drawing. After the final installation of the
power pack, the clean working liquid is poured into the tank to the indicated level.
E6 CONNECTION TO ELECTRICAL SYSTEM
The cap of the motor terminal connecting box is removed. The nuts of the terminals are unscrewed.
The cable shoes are connected to the terminals. Then the nuts are screwed and reliably tighten. The motor
is nullified. The cap is placed at the terminal connecting box. The coils of the solenoid valves are connected
in the analogical manner. Motor rotation must be checked carefully.
The connecting of the power pack to the electrical system should be done by a certified electrician as
the rules for safety work with electrical equipments should be observed. Please refer to producer for electrical
schema. For keeping electric motor, you must use current relay (100 mA), thermic relay and main circuit
cutoff switch. After electrical connection have been made, please check the motor rotation by executing short
pulses of right rotation (from fan side) 1 second each (max.).
Grounding 3rd phase 2nd phase 1st phase
Photo 4. Connection on 380 V AC three phase motors
Phase Neutral
Photo 5. Connection on 220 V AC mono phase motors*
* If mono phase motor operates in anti-clockwise rotation, please kindly check instructions located on terminal
box cover to make it right rotation.

DD.026 ENG R(1)
(-) from battery (+) from battery For switch/remote etc.
Photo 6. Connection on DC motor
For detailed information, please refer to “DD.043 R(0) Remote control connection on power units”
document.
SECTION F MAINTENANCE OF THE HYDRAULIC POWER PACK
F1 CLEANING OF THE POWER PACK
The cleaning of the power pack is made by textile cloth without using any cleaning substances or
solvents. The cloth should not left any filaments on the treated surfaces. Once yearly it is necessary the oil
to be changed in the tank to be cleaned. The oil changing is done in the following way:
•The pressure is unloaded in the system.
•The power pack is switched off from the electric installation.
•The pipelines are disassembed. The screws by which the power pack is fixed to the basement
are unscrewed.
•The power pack is placed vertically on the tank and the fixing screws are unscrewed and also
the tank brackets are replaced.
•The electric motor is placed outside together with the central manifold and the pump. The old
oil is poured out and the internal surface of the tank is cleaned. The suction filter is cleaned
also.
After cleaning, the electric motor with the central manifold are placed on the tank. The fixing screws
and the brackets are screwed. The assembled power pack is installed on its working position. The working
liquid is poured up to the indicated level on the stick. The air breather must be closed firmly. The pipelines
are assembled and the power pack is connected to electrical system in accordance to the way of application.
Dirty oil sharply decreases the life time of power pack.
F2 PRESSURE ADJUSTMENT
The pressure adjustment in the hydraulic power pack is made by meansof pressure relief valve which
is built in on main manifold. The pressure adjustment is effected in the following order:
A pressure gauge is installed at port “P”. The nut of the adjusting screw is unlocked. The adjusting
screw is unscrewed up to its end.

DD.026 ENG R(1)
The hydraulic power is switched on andthe adjustingscrew is activated(clockwise to increase, anti-clockwise
to decrease) until it reaches the desired pressure. Then the nut is locked.
For detailed information, please refer to “DD.030 ENG R(0) Adjusting relief valve pressure on power pack”
document.
Photo 7. Pressure relief valve
Attention! Please do not pass max. working pressure indicated on technical drawing.
F3 PROBLEM SOLVING
PROBLEM
REASONS
METHOD OF ELIMINATION
Not sufficient pressure
•Lack of oil inside the tank
•Damaged pressure relief
valve
•Damaged solenoid
operated valve
•Damaged Hydraulic pump
•Filter pipe type is incorrect
•Filter is blocked
•Air on suction line
•Contamination
•The oil is filled up
•Readjustment of the relief
valve
•Replacement
•Replacement
•Replacement
•Replacement
•Elimination of the air
No pressure
•Gear pump does’t operate
properly
•Electric motor rotation is
wrong
•Electric wiring is wrong
•Repair or replacement
•Make sure correct rotation
•Check wiring
Non-performance of the
function
•Damaged solenoid valve
•Damaged check valve
•Damaged pressure relief
valve
•Damaged hydraulic pump
•Replacement
All power packs are tested 100% before delivery to customer. Please kindly contact us for all questions.

DD.026 ENG R(1)
Please feel free to fill information below and send to us for custom designed mini power units.
Application
Number of cylinders
Type of cylinders
☐ (Single acting)
☐ (Double acting)
☐ (Telescopic)
Number of stages if
cylinder is telescopic
Assembly of cylinders
☐ (Vertical)
☐ (Horizontal)
☐ (Angled)
Please specify angle if
cylinder operates angled
Operating of cylinders
☐ . (Cylinders operate at the same time.)
☐ (Cylinders operate independently.)
Max. load in the system
Cylinder bore diameter
(If cylinder is telescopic,
please specify bore
diameter and stroke of
each stage.)
Cylinder stroke
Cylinder opening time
[seconds]
Required motor voltage
Power pack assembly
☐ (Vertical)
☐ (Horizontal)

DD.026 ENG R(1)
SECTION G WARRANTY
The producer guarantees the conformance of the product to the standard and technical
documentation and its work capability at actuation complied with the present manual.
Please do not take out product label on oil tank during warranty period.
The guarantee period is 12 months from the date of starting in operation, but not more than 18
months from the purchase date.
The producer undertakes to eliminate the defects occurred because of its fault.
The guarantee conditions are not be carried out if the user has made a repair without permission and
has not kept the clauses mentioned in the present manual.
The guarantee engagements of the producer will be implemented in its factory or in authorized service
by it.
PRODUCT CODE
HPP …
SERIAL NO
DATE OF PRODUCTION
Warranty is only valid on document which has date, stamp and signature information.
RELEASE DATE:
STAMP AND SIGNATURE
___________________________________
HYDRO-PACK Mühendislik Makina Hidrolik San. ve Tic. Ltd. Şti.
Sanayi Mah. İzmit San. Sit. 13. Cad. No: 315 İç kapı no: 54 İzmit, Kocaeli, Türkey
Tel: [phone] Fax: [phone]
E-mail: [e-mail] Web: www.hydropack.com.tr