HYDRO-PACK HPP Series User manual

DD.057 ENG R(0)
MINI POWER PACKS
DD.057 ENG R(0) WHEELCHAIR LIFT UNIT 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.

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CONTENTS
I. SECTION A: GENERAL DATA
A1 PRODUCER
A2 INTRODUCTION
A3 PRODUCT CLAIMS
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 POWER PACK 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 E: DESCRIPTION OF THE HYDRAULIC POWER PACK
E1 MAIN PARTS
E2 ELECTRICAL PARTS
VII. SECTION F: MAINTENANCE OF THE HYDRAULIC POWER PACK
F1 CLEANING OF THE POWER PACK
F2 PRESSURE ADJUSTMENT
F3 PROBLEM SOLVING
VIII. SECTION G: WARRANTY

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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, Turkey
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 dock leveler 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 PRODUCT CLAIMS
At occurrence of technical problem, please contact technical department of Hydropack.
([email protected].tr) Please send us an e-mail or call with us regarding your claim. Please also provide
us the following information so that we can help you better:
•Code of power pack which is on label (Label is located on oil tank.)
•Working voltage and frequency
•Working pressure
•Displacement of the pump
•Date of production
•Detailed description of the claim
•Working time of the power unit

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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 intendedfor integration in hydraulic system ofwheelchair lift units in order
to provide hydraulic energy to platform lifting/lowering. The unit can also be used for any single acting
applications.
There is a normally closed 2/2 carridge valve for unloading purpose. Hand pump is integrated for
lifting when there is problem with electricity. To adjust return speed, a pressure compensated flow control
valve was built in. Check valve and pressure relief valve are also integrated with the manifold.
A6 WORKING 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 aredesignedand accomplished so that they provide flow from 0,8 L/min to 4.3 L/min
depending on selected hydraulic pump (0.25 cc/rev up to 1.25 cc/rev) Working pressure is from 40 to 220
bar depends on the size of the selected hydraulic pump and electric motor. 0.5 kW and 0.8 kW 12-24 V DC
motors can be used with the system.
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. (After
initial 100 operation hours, afterwards once every 3000 hours is recommended.) Suction filter needs to be
cleaned as well.If there is decrease on fluid level, additional oil should be put in.

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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 of the electric motor. Electric motor rotation from shaft view must be
anti-clockwise.
•Hydraulic connection must be carried out carefully. There is one outlet port on the manifold that needs
to be connected to the actuator in the system.
•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 damage to hydraulic pump.
•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
•Hydraulic gear pump
•Oil tank
•Filter
•Hand pump and unloading valve
•Pressure relief valve
•Pressure compensated flow control valve
•Normally closed 2/2 cartridge valve

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Oil tank Central manifold Hand pump Electric motor
Photo 2. Main components of wheelchair lift unit 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 central manifold and from there to the actuators of the system. Outlet
port must be connected to the actuator. When electric motor is off and normally closed 2/2 valve coil is
energised, oil will return to reservoir.
C2 ELECTRICAL PARTS
The hydraulic power pack is assembled with:
•Electric motor
•2/2 cartridge solenoid valve
The electric motor can be 0.5 kW or 0.8 kW, 12-24 V DC.
The solenoid elements are cartridge type. Their coils can operate under voltages of 12, 24 or 220 V. The
connectors are made under DIN 43650.

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SECTION D: WORKING WITH HYDRAULIC POWER PACK
The power pack work is determined by themachine at which it is integrated. During operation of 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. 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 is one outlet port (P) on central manifold that needs to be connected to the actuator. Port thread
is G 1/4’’ as standard. Max. tightening torque of the fitting is 50 Nm.
Outlet port (P)
Photo 3. Connection port (pressure port) on central manifold

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E5 CONNECTION TO HYDRAULIC SYSTEM
The pipelines from the power pack are connected to actuators in the system. Hydraulic circuit and
technical information can 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. Please clean all hydraulic parts concerned
before mounting. Please check the oil level in the tank after initial operation.
E6 CONNECTION TO ELECTRICAL SYSTEM
Hydropack power packs are supplied with starter relay which is assembled on DC motor. Cables from
battery must be connected to terminals on DC motor. 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. Low voltage can cause damage to motor. DC motor should not run for long period of time.
For switch/remote (+) from battery (-) from battery
Photo 3. Connection on DC motor
For detailed information, please refer to “DD.043 R(0) Remote control connection on power units”
document or contact us.
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 thetreated surfaces. Once yearly it is necessary changing
oil and flushing tank. Oil change 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.

DD.057 ENG R(0)
•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 bracket are screwed. The assembled power pack is installed on its working position. The working
liquid is poured up to the indicated level. 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 means of 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.
•The hydraulic power is switched on and the adjusting screw 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 6. 2/2 normally closed cartridge valve
2/2 normally closed cartridge valve

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Photo 7. Hand pump, pressure relief valve and unloading valve
Factory setting of the power packs canusually meet the requirements of most field applications. Users
must be cautious when resetting the settings on the manifold. Loose lock nut of pressure relief valve.
Adjusting screw is turned clockwise to increase pressure setting or anti-clockwise to decrease pressure
setting.
Attention! Please do not pass max. working pressure indicated on technical drawing.
Pressure relief valve
Hand pump
Unloading valve

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F3 PROBLEM SOLVING
PROBLEM
REASONS
METHOD OF ELIMINATION
Motor doesn't run
•Wrong motor wiring
•Starter relay problem
•Check and correct wiring
•Check starter relay
Starter relay clicks but motor
doesn’t turn
•Loose wire from relay to
motor
•Wrong cable size from batter
to motor
•Starter relay housing is
cracked
•Check wiring
•Change to proper size of
cable
•Replace starter relay
Cylinder doesn’t hold
•Check valve problem
•Disassemble check valve,
clean with brake cleaner and
air gun then assemble again
Cylinder doesn’t retract
•2/2 cartridge coil is not
energised.
•Damaged cartridge valve
•Check and correct the wiring
•Replace the cartridge valve
Not sufficient pressure
•Lack of oil inside the tank
•Damaged pressure relief
valve
•Damaged hydraulic pump
•Filter is blocked
•Air in system
•The oil is filled up
•Readjustment of the relief
valve
•Replacement
•Replacement
•Elimination of the air
Overheating
•Electrical ground problem
•Defective battery
•Pressure relief valve setting
problem
•Contaminant stuck on relief
valve
•DC motor problem
•Check electrical connection
•Check batter performance
•Clean the relief valve with
brake cleaner and air gun to
remove contaminant and
assemble again
•Replace DC motor
All power packs are tested 100% before delivery to customer. Please kindly contact us for all questions.

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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 implementedin 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