HYCON HPP09 Operation Manual

We thank you for choosing 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 long-lasting performance of your new powerpack, we recommend you to 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 HYCON A/S Vester Hassingvej 33 DK-9320 Hjallerup Denmark Tel: +45 9647 5200 Fax: +45 9647 5201 Mail [email protected] www.hycon.dk

Technical data.................................................................................................. 3 Starting instructions ......................................................................................... 4 Service, maintenance and hydraulic settings ...................................................... 4 Oil types .......................................................................................................... 5 EC-Declaration of Conformity ............................................................................ 6 Warranty conditions ......................................................................................... 7 Spare parts list................................................................................................. 8

of max. 104 dB, but by daily long-lasting operation there is a risk of hearing de- fects. 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 150 bar from our plant. Never set it higher. 9. Always use filters with by-pass. The use of filters without by-pass may involve a danger of explosion.

the EHTMA category 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 high pressure. Furthermore, the very efficient air cooling protects the powerpack against super- heating. Oil flow 20 l.p.m at 3300 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. 4½ litres/max. 7 litres Hydraulic system compl. Max. 8 litres Filter system (filter cartridge) 25 Micron with by-pass Engine Honda GX270QXB7 9 HP 4-stroke petrol with oil alert system Petrol - normal or unleaded Engine oil 1.1 litres Measured sound power level LWA 101 dB Sound pressure level 1 m LPA 90 dB Dimensions (LxWxH) 680x575x593 mm Weight, without hydraulic oil 68 kg

Start: •••• Check engine oil level • Check hydraulic oil level at sight glass • Connect hoses and tool • Switch fuel tap to “ON” • Activate choke • Turn ignition switch to “1” • Pull recoil starter • Move the lever to “ON” Stop: •••• Move the lever to “OFF“ • Turn off the ignition switch • Turn the fuel tap to “OFF” 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 the flow. 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 flow valve - the pressure gauge must show between 145 and 150 bar.

ment 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 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 (higher flow) or to the right (lower flow). Secure the POD cylinder in the bracket again after adjustment. 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 If correct pressure/oil flow cannot be achieved by following 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.

From Serial No. We hereby declare that the HPP09 hydraulic powerpack 1188-1278 (with 6.6 kW petrol engine) is manufactured in conformity with the EC Directives 98/37/EC and 2000/14/EC. Notified Body 404: SMP Svensk Maskinprövning AB Fyrisborgsgatan 3 S-754 50 Uppsala Sweden Measured sound power level: 101 dB Guaranteed sound power level: 104 dB HYCON A/S Vester Hassingvej 33 DK-9320 Hjallerup Denmark Henrik Steen General Manager 15.04.2003 HYCON A/S Vester Hassingvej 33 DK-9320 Hjallerup Denmark Tel: +45 9647 5200 Fax: +45 9647 5201 Mail [email protected] www.hycon.dk

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.