RuggedMade MHP9-20 User manual

WARNING
!
OWNER’S MANUAL &
PARTS LIST
HYDRAULIC POWER PACK
www.ruggedmade.com
Model: MHP9-20 Model: MHP13-20/30

1. INTRODUCTION ....................................................... 1
2. TECHNICAL DATA...................................................... 1
3. HYDRAULIC OILS. ................................................... 1
4. SAFETY PICTOGRAMS USED ON THIS EQUIPMENT.... 2
5. SAFETY..................................................................... 2
6. OPERATION ............................................................. 4
7. FAULT DIAGNOSIS ................................................... 5
8. ROUTINE SERVICING................................................ 6
a) Engine: ............................................................... 6
b) Power Pack:......................................................... 6
9. MAINTENANCE, DISMANTLING AND REASSEMBLY .... 7
a) General............................................................... 7
b) Hydraulic Pipes and Hoses ................................. 7
c) Self Locking Nuts................................................ 7
d) Thread Locking Compound ................................. 7
e) Draining the Hydraulic Oil................................... 7
f) Disassembly and Reassembly ............................. 7
10. FLOW AND PRESSURE RELIEF VALVE ADJUSTMENT…. 8-10
11. PARTS WARRANTY
CONTENTS

1
This manual provides information on the safe operation, servicing and
repair of the following models of RuggedMade gasoline engine
hydraulic power packs:
MHP9-20
MHP13-20/30
The first number denotes the horsepower ofthe engine fitted to the
power pack. The second number denotes the flow in liters per
minute. The 20literpower pack is suitable for operating attachments
that require a flow of20l/min (5.28GPM). The 30liter power pack is
foroperating equipment rated at 30 l/min (7.93 GPM).
MHP9/20
MHP13/20 MHP13/30
Eng. make
Honda
Honda
Honda
Eng. model
GX270
GX390
GX390
Fuel
Gasoline Gasoline Gasoline
Flow, l/min
20 (5.28 GPM) 20 (5.28 GPM) 30 (7.93 GPM)
At approx. Eng.
speed, rpm
3400
3400
3400
Pressure, bar
138 (2,000psi) 138 (2,000psi) 138 (2,000psi)
Weight, kg
76 (168 lbs) 89 (196 lbs) 89 (196 lbs)
Length, mm
760
760
760
Width, mm
570
570
570
Height, mm
620
620
620
Guaranteed
Sound power,
dB(A)
108 Lwa
A wide range of compatible hydraulic oils is available. Ensure the
product purchased is of good quality from a reliable source. Products
from dubious sources must be avoided as they could adversely affect
the reliability and operating efficiency of the hydraulic power pack and
tool. The grade of hydraulic oil used will depend on ambient
temperature as follows:
1. INTRODUCTION
2. TECHNICAL DATA
3. HYDRAULIC OIL

2
Between 0°C and 30°C (32°F to 86°F) usegrade ISO 32hydraulic
oil. Above 30°C (86°F) usegrade ISO 46hydraulic oil.
The capacity ofthe oil tank including priming the pump and pack
hoses is 13.5L (3.5 gal) for MHP9/20, 12L (3.2 gal) for MHP13/20 &
MHP13/30.
Read the manual before operating or servicing this equipment.
Read the safety instructions in the manual supplied with the
equipment that this power pack is driving.
Read these operating and safety instructions before using the
machine and operate the machine in accordance with these
instructions.
Do notrun engine in a confined space.
Do not run engine unless all guards are in position.
Do not carry out any maintenance whilst engine is running.
Disconnect spark plug on gasoline engines before performing
any maintenance.
Do not fill fuel tank while engine is running.
Wipe up spilt fuel. Dispose of fuel-contaminated wipes safely
Do not smoke while refueling.
Do not run engine in areas that have a hazardous or explosive
atmosphere.
4.SAFETY PICTOGRAMS USED ON THIS EQUIPMENT
5. SAFETY
Below 0°C (32°F) usegrade ISO 22hydraulic oil.

3
Turn fuel petcock off when not in use.
This machine must not be modified in any way without written
permission of the manufacturer. Unauthorized modifications are
likely to invalidate the warranty and also result in the machine not
conforming to safety regulations.
Always comply with site safety regulations.
Inspect the machine for damage or improper function.
To prevent accidental starting of the machine the spark plug lead
must be removed before any maintenance or adjustments are carried
out on the machine.
Do not attempt to fill fuel tank or oil sump while the machine is
running.
When operating machines in confined areas, the exhaust fumes must
be ventilated.
Do not operate in an explosive atmosphere.
Understand and obey the safety labels and instructions attached to
the equipment.
Do not attempt to operate defective equipment. Check that hoses and
fittings are in good condition.
Ensure maintenance procedures are carried out as specified.
Do not attempt to operate this equipment on a greater hydraulic flow
than that specified.
Fine jets of hydraulic oil can penetrate the skin. Check for leaks by
holding a piece of cardboard near to the suspect area. If hydraulic oil
does penetrate the skin or is ingested seek medical help immediately.
Always isolate hydraulic supply before making a disconnection or
connection.
Always comply with local and site safety regulations.

4
Ensure the power pack is positioned safely；
Check the hydraulic oil in the power pack is suitable for the ambient
temperature.
See section on recommended hydraulic oils；
Check hoses and machine for damage；
Check hydraulic level；
Check operation and cleanliness of couplings；
Check that any hydraulic tools to be used are compatible with the flow
and pressure available from the power pack. Do not use hydraulic
tools if they require a lower flow than that provided by the power pack,
the resulting over speed could be extremely
dangerous.；
Check oil level in the engine and that the grade of oil being used is as
recommended for the ambient temperature according to the engine
manufacturers’ handbook；
Check the condition of the couplings both for cleanliness and damage；
Connect the hose couplings to the power pack couplings male to
female；
Start the engine in accordance with the manufacturers’ handbook；
Allow the engine to warm up for 3 to 4 minutes；
Move the flow control handle on the power pack from the ‘off’ position
to the ‘on’ position；
Note that if the hoses and/or the tool are new or have been emptied of
oil prior to use, the level of hydraulic oil in the tank will drop and may
need topping up；
The tool may now beoperated using the controls onthetool. Note
thatthe 270cc and 390cc engines fitted to power packs are fitted
with ‘power on demand’ operated throttle controls. This control
speeds up
6. OPERATION

5
the engine when the tool is being used and allows the engine to slow
down to tick-over when the tool control is released；
Never disconnect couplings with the flow control handle in the on
position as the hoses will remain pressurized and it will be impossible
to reconnect. If this does happen inadvertently the only way of
releasing the pressure is to unscrew a coupling from the hose；
To shut down, first move the flow control lever to the ‘off’ position and
then turn the engine switch to the off (0) position. After the engine
has stopped turn the fuel tap to the off position；
When disconnecting couplings pull back the outside sleeve. Some
couplings may require the sleeve to be rotated into its unlocked
position before it can be slid back.;
ENGINE TURNS OVER BUT WILL NOT START
Check: ignition switch is on
fuel tap is on
there is fuel in tank
engine oil level is correct
the choke is in correct position (closed if engine is cold, open of engine
is hot).
If engine still does not start refer to engine manufacturer’s handbook.
ENGINE IS DIFFICULT TO TURNOVER
Check that the flow control lever is in the ‘off’ position.
If the engine will not turn over refer to the engine manufacturer’s
handbook.
LOSS OF HYDRAULIC OIL
Check for damaged hoses, loose connections faulty couplings.
POOR TOOL PERFORMANCE
Check that the power on demand cylinder is working.
Check for low pressure relief valve setting. This unit is pre-set at the
factory and should require no further attention unless it has been
tampered with. Reset as instructed in section 10.
Check that the suction strainer is not blocked.
Check that the hoses are not blocked.
Check for correct flow with a flow/pressure test unit and adjust engine
speed and throttle setting as required as instructed in section 10.
7. FAULT DIAGNOSIS

6
If engine speed needs to be set higher than 3600 rpm to achieve the
required flow this indicates that the pump and/or diverter valve may
be worn.
Tool fault – check tool handbook.
FOAMING OR MILK COLOURED HYDRAULIC OIL
Air or water in the oil. Check filler cap is tight.
If associated with poor breaker performance the breaker accumulator
may have degassed.
TOOL RUNNING HOT
Check that the power pack has good access to cooling air.
Check that the oil cooler matrix is not blocked with debris.
Excess back pressure, check hoses for blockage.
Check cooling fan is not damaged.
Tool fault – check tool handbook.
ENGINE STOPS SUDDENLY
Check fuel level in tank.
Check oil level.
8.1 Engine:
Refer to engine manufacturer’s handbook.
8.2 Power pack:
Before Starting:
Check engine oil level.
Check hydraulic oil level.
At End of Shift:
Clean the machine using water and/or steam. Ensure water does not
enter breather on hydraulic oil tank. Check that the air cooler matrix
is clear of debris.
Check for oil leaks.
Every 1,000 Hours or 6 Months:
Change hydraulic oil.
Change suction strainer.
Change filter.
Check flow and pressure output.
8. ROUTINE SERVICING

7
9.1 General
Parts are machined to a very high degree of accurary and finish. On
certain items the degree of accuracy of fit necessitates selecting parts
to make up a matched assembly and may only be available as
matched sets.
To ensure continued reliability , servicng should only be carried out by
a skilled fitter who is experienced in working on hydraulics
components.
The following general precautions must be observed when servicing
hydraulic equipment:
•Absolute cleanliness is essential. Most hydraulic failures are caused
by the ingress of dirt.
•Before dismantling a component, clean external surfaces and drain
all fluide.
•When holding components in a vice, fit soft metal pads over the vice
jaws to prevent damage and distortion to precision surfaces and
bores.
•All parts should be laid out on a clean resilient surface.Special
attention should be paid to the identification of parts and their
dismantling sequence.
•All dismantled metal parts should be washed in a cleaning solvent
and coated with hydraulic fluid.
•The safety management of the company where the work is being
carried out must approve all solvent cleaners in use. The COSHH
regulations must be read and understood.
•It is recommended that all disturbed seals be renewed. If a seal is
reused it should be closely examined for cust, flaws or wear. A seal
that is suspect should never be reused.
•All internal metal parts and seals should be lightly coated with clean
hydraulic oil ora lithium based no.2 grade grease before assembly.
This assists in assembly and lessens the risk ofseal damage. Use only
seals provided in component service kits, which are obtainable from
RuggedMade engineering co.,ltd or their agents, as these will be ofa
different composition and hardness toseals normally commercially
available.
9.2 Hydraulic Pipes and Hoses
When remvoing and replacing rigid pipes and flexibe hoses the
following points should be obserived:
9.
MAINTENANCE, DISASSEMBLY AND REASSEMBLY

8
•Use adjustable or open-ended spanners on end connections and
fittings. Do not use pipe wrenches as these damage fittings and
protective plating.
•Ensure the particular connection and its surrounding area is clean.
9.3 Self Locking Nuts.
These must not be reused.
9.4 Thread Locking Compound
Use the grade of compound recommended. Clean and degrease the
joint or threads before application.
9.5 Drainning the Hydraulic Oil
The old oil may be drained from the tank by disconnecting the suction
hose. Do not reuse old hydraulic oil. Disposal of hydraulic oil should be
carried out according to appropriate COSHH regualtions. Do not pour
it down the drain.
9.6 Disassembly and Reassembly
Dismantling and reassembly are straightforward by reference to the
parts diagrams and parts lists.
Method 1:
RuggedMade power packs are allpre-set for correct flow and
pressure prior to dispatch.
Proceed as follows:
1. Remove the protective upper cover in the front of the power pack.
2. Using a pair of hoses, connect the test meter so that the flow
passes from the power pack, through the test meter and back to the
power pack.
3. Start the engine and open the diverter valve.
4. Adjust the pressure-loading valve to give a pressure reading of
about 55 bars to 60 bars. Allow oil to warm up on this setting for about
5 minutes.
5. Screw in the pressure-loading valve to give a pressure reading of
90 bars to 100 bars. The flow rate should read 20 or 30 litres per
10. FLOW AND PRESSURE RELIEF VALVE ADJUSTMENT

9
minute. If the flow rate is incorrect go to next paragraph. If flow rate
is correct go to paragraph 6.
6. If the Power-On-Demand (POD) cylinder is working correctly, the
speed of the engine will need to be adjusted by repositioning the POD
in its bracket. Slacken off the clamp screw in the POD bracket and
adjust the position of the POD so that the engine speed is increased or
decreased as required to give 20 litres per minute flow. Retighten the
clamp screw. If the pressure reading has changed carry out check 4
above and continue to readjust as required.
7. Check the relief valve setting by screwing in the pressure-loading
valve until thepressure reading is 138 bar (2,000 psi). At this
reading the flow should bestarting to fall off as the pressure relief
valve is beginning to open. Ifthis isnot happening the relief valve
will need adjusting. Slacken off the lock nut and unscrew the
adjusting screw until the flow just starts to drop off. Retighten the
lock nut. If onscrewing the pressure-loading valve init is not
possible to achieve a pressure of 138 barsitmay be that the relief
valve hasopened prematurely. In this case, with thepressure-
loading valve screwed right in, slacken off the lock nut on the relief
valve, screw intheadjusting screw until the pressure reading is 145
bars and retighten the lock nut. Slacken off the pressure-loading
valve to give areading of 138 bars and check the flow rate. Carry out
further adjustments asrequired.
8. Whilst carrying out these checks ensure the oil temperature does
not exceed 60 ℃.
9. Carry out a functional test by operating a tool, preferably a breaker,
and checking for satisfactory operation.
Method 2:
1. Remove the protective upper cover in the front of the power pack.
2. Connect a pressure gauge (range more than 50MPa) to the oil
outlet of the switching valve.
3. Turn off the switching valve (the switching handle at OFF
position).Start the engine and warm up about 5 minutes.
4. Using the engine tachometer test the engine speed.
5. Adjust the bolt in the overflow valve of the switching valve to the
outermost (make the system pressure minimum).
6. Turn on the switching valve (the switching handle at OFF position),
watch the pressure gauge registration and engine speed.
7. Adjust the bolt of the cartridge valve inward slowly, make the
pressure gauge registration around 70-80 bar. Watch the POD work,
the engine speed should be 3400rpm.
8. If the engine speed is not 3400rpm, adjusting the POD position to
make the engine speed at 3400rpm ±50

10
9. Adjusting the bolt of the cartridge overflow valve to make the
system pressure between130-138 bar.
10. Fasten the adjusting bolt and nut.
11. Turn off the switching valve, shut down the engine. Restore the
Machine.
12. Whilst carrying out these checks ensure the oil temperature does
not exceed 60 ℃.
13. Carry out a functional test by operating a tool, preferably a
breaker, and checking for satisfactory operation.
All products supplied by RuggedMade are warranted to be free of
defects due to faulty materials orworkmanship for a period of 30
daysfrom the date oforiginal purchase.
Filter elements, gauges,and fluids are specifically excluded from
this warranty.
RuggedMade shall attheir discretion repair orreplace parts
determined to be defective free ofcharge tothe customer.Shipping
costs are not covered under warranty. Parts believed to be
defective must be returned to RuggedMade's Warranty Center at
customer's expense for inspection.
For proprietary items such as engines, the original manufacturer's
warranty and conditions shall apply.
11.
PARTS WARRANTY
Failure due to carelessness, improper operation, abuse, inadequate
servicing, incorrect engine speeds, bad fuel, normal wear and tear
or non-compliance with operating instructions is not covered under
warranty.
To theextent permitted bylaw, the liability ofRuggedMade under
this section is confined only to providng a remedy for defective goods
and does notextend to any consequential loss,loss of time or
revenue, cost to rent equipment, injury ordamage suffered.
NO claim shall be considered if other than genuine parts supplied by
RuggedMade have been used.
Warranty is only valid for original purchaser in the country where
item was delivered.
This warranty shall not apply if the serial number or other identifying
numbers or marks have been removed or are otherwise illegible.

PARTS LIST
HYDRAULIC POWER PACK
MHP9-20

FUEL TANK ASSY.

FUEL TANK ASSY.
ITEM
NO. DESCRIPTION PART NO. QTY REMARKS
1 HEXAGON SOCKET HEAD CAP SCREWS GB70.1-M4x15 4
2 HYDRAULIC AIR FILTER EF1-25 1
4HEXAGON SOCKET BUTTON HEAD
SCREWS GB70.2-M5x20 12
5 FUEL TANK COVER ASSY.. PHP9/20.04.02 1
6 TANK GASKET PHP9/20.04-01 1
7 COUNTERSUNK HEAD RIVETED NUTS GB17880.2-M5 10
8 LIQUID TEMPERATURE GAUGE YWZ1-80T 1
9 FUEL TANK PHP9/20.04.01 1
10 HOT RESISTANCE PLATE PHP9/20.04-02 1
11 SUCTION FILTER WU-63X100-J 1
12 HEXAGON HEAD BOLTS GB5783-M8x30 2
13 BIG WASHER GB5287-8 白锌 8
14 STANDARD SPRING WAHSER GB93-8 4
15 HEXAGON NUT (I TYPE ) GB6170-M8 2
16 PIPE EXTERNAL THREAD RUBBER
GASKET SEAL SOCKET HEAD PLUG 4BN-04WD 1
17 HEXAGON SOCKET HEAD CAP SCREWS GB70.1-M8x25 2

VALVE ASSY.
ITEM
NO. DESCRIPTION PART NO. QTY REMARKS
21 SWITCH KNOB PHP9/20.05-04 1
22 SWITCH AXLE PHP9/20.05-05 1
23 SPRING CYLINDRICAL PIN GB879.2-4x20 3
24 O-RING SEAL RING C0 0008A 1
25 PIPE EXTERNAL THREAD RUBBER GASKET
SEALING PLUG 4BN-02WD 4
26 INSTRUMENTATION OVERFLOW VALVE RPEC LAN 138bar 01
K9K1 1
27 COMBINED SEALING WASHER SCR236 2
28 PIPE THREAD 60°SEAL JOINT 1B-06-08 2
29 QUICK CONNECTORS MALE HEAD FH10-2-1 GF08 1
30 QUICK CONNECTOR FEMALE HEAD FH10-1-1 GF08 1
31 HEXAGON SOCKET HEAD CAP SCREWS GB70.1-M5x10 1
32 FILTER INSTALLATION TUBE PHP9/20.05-06 1
33 SCREW-PLUG LINE FILTERS P163542 1
34 VALVE SEALING RUBBER SHEET PHP9/20.05-02 1
35 COMBINED SEALING WASHER SCR29 2
36 HEXAGON SOCKET SET SCREWS WITH FLAT
POINT GB77-M6x30 2
37 STANDARD SPRING WAHSER GB93-6 2
38 I TYPE HEXAGON NUT GB6170-M6 2
39 HEXAGON SOCKET SET SCREWS WITH FLAT
POINT GB77-M8x35 3
40 STANDARD SPRING WAHSER GB93-8 3
41 I TYPE HEXAGON NUT GB6170-M8 3
42 SPRING COMPRESSION COLUMN PHP9/20.05.01-06 1
43 SPRING PHP9/20.05.01-03 1
44 STEEL BALL PHP9/20.05.01-02W 1
45 SMALL VALVE BODY PHP9/20.05.01-01 1
46 NON-RETURN VALVE ASSY. PHP9/20.05.01 1
47 VALVE PHP9/20.05-01 1

OIL PUMP ASSY.
ITEM
NO. DESCRIPTION PART NO. QTY REMARKS
51 SQUARE SET SCREWS WITH LONG DOG
POINT GB85-M6x16 1
52 INPUT COUPLING HEAD PHP9/20.03.01-01 1
53 STAR OF FLEXIBLE COUPLING RUBBER
PIECES PHP9/20.03.01-02W 1
54 INPUT COUPLING HEAD PHP9/20.03.01-3 1
55 SQUARE SET SCREWS WITH LONG DOG
POINT GB85-M5x25 1
56 SHAFT COUPLING ASSY. PHP9/20.03.01 1
57 OIL PUMP INSTALLATION OF FLANGE PHP9/20.03-01 1
58 SHIELD TABLET PHP9/20.03-02 2
59 HEXAGON SOCKET BUTTON HEAD SCREWS GB70.2-M4x10 2
60 OUTER SCRAPER SEAL PHP9/20.03-04 1
61 INNER SCRAPER SEAL PHP9/20.03-03 1
62 WASHER GB97.1-8 4
63 STANDARD SPRING WAHSER GB93-8 4
64 HEXAGON SOCKET HEAD CAP SCREWS GB70.1-M8x16 4
65 OIL PUMP FLAT KEY WP01A1-B-06-R--PJ-
W1
66 GEAR PUMP WPA09A1-B-060-R 1
67 WASHER GB97.1-10 2
68 STANDARD SPRING WAHSER GB93-10 2
69 HEXAGON SOCKET HEAD CAP SCREWS GB70.1-M10x45 2