HPU-750 Portable Hydraulic Power Unit
Contents
1. 1 NPT 1 JIC Male EL NPT JIC 1 Adapter 16 Ga Bullet M Terminal 16 Ga Bullet F Terminal E H Wachs Company Part No 79 405 MAN Rev 0 0108 19 HPU 750 Portable Hydraulic Power Unit NO DESCRIPTION QUANTITY 9AL Battery 15HP Gas Engine 15HP Engine Muffler Muffler Guard Exhaust Deflector Wiring Hamess PTO Adapter Hydraulic Pump Drive Coupling Pump Hose Tank Hose Choke Cable Throttle Cable 14 Tie Down Strap Nipple 3 8 x 6 Terminal Cover Tach Hourmeter Fuse Holder 7 5 AMP Fuse 1 4 20 Wing Nut 1 4 Sg x 1 Key 1 4 20 x 3 4 CRG Bolt 5 16 18 Wing Nut 5 16 18 x 3 4 CRG Bolt 3 8 16 x 1 HHCS 3 8 16 x 1 1 4 HHCS 3 8 Lockwasher ORB x JIC 3 4 M90 Adapter ORB x JIC 1 EL 1 4 Male Terminal 3 8 Yellow Ring Terminal 6 Ga 1 4 Terminal 6 Ga 3 8 Ring Terminal 16 Ga Bullet M Terminal 16 Ga Bullet F Terminal Loop Clamp 14 Ga Black Wire 6 Ga Red Wire 6 Ga Black Wire 18 Ga Whire Wire 14 Ga Yellow Wire 540 09 38 8 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 4 6 10 1 1 1 2 2 3 2 2 Qoa 17 402 00 Gas Engine Assembly 20 Part No 79 405 MAN Rev 0 0108 E H Wachs Company Chapter 5 Parts List and Ordering Information Parts Lists and Drawings E H Wachs Company Part No 79 405 MAN Rev 0 0108 21 HPU 750 Portable Hydraulic Power Unit TANK ASSEMBLY REF NO PART NO DESC2. Operating the HPU cuota a ea eases Chapter 4 Maintenance Hydraulic System 1 ee ale Re UE ENDINE ea fV Neu eme qa Chapter 5 Parts List and Ordering Information Ordering Information Ordering Replacement Parts Repair Warranty Information Return Goods Address Parts Lists and Drawings s ces ves RETE SN de E H Wachs Company Part No 79 405 MAN Rev 0 0108 HPU 750 Portable Hydraulic Power Unit 1 Part No 79 405 MAN Rev 0 0108 E H Wachs Company Chapter 1 About 70 In This Chapter PURPOSE OF THIS MANUAL How TO USE THE MANUAL SYMBOLS AND WARNINGS MANUAL UPDATES AND REVISION TRACKING EQUIPMENT DESCRIPTION Throughout this manual refer to this column for warnings cautions and notices with supplementary information Chapter 1 About the HPU 750 PURPOSE OF THIS MANUAL This manual explains how to operate and maintain the HPU 750 portable hydraulic power unit It includes instruc tions for set up operation and maintenance It also con tains parts lists diagrams and service information to help you order replacement parts and perform user serviceable repairs Before operating the HPU 750 you
3. choke out Turn the keyswitch on the front panel to START When the engine starts release the keyswitch back to the ON position Allow the engine to run for a minute or so to warm up Push the choke back in 1 BW N Part No 79 405 MAN Rev 0 0108 E H Wachs Company HPU 750 Portable Hydraulic Power Unit CAUTION Use short starting cycles with the keyswitch Prolonged cranking more than 15 sec onds can damage the starter motor 12 Chapter 3 Operating Instructions Operating the HPU OPERATING THE HPU The HPU does not have built in flow control To adjust flow you will need to use the controls on the tool you are operating or use a flow control valve Set the throttle so that the system pressure gauge dis plays the pressure you need for the tool you are oper ating 2 Use the controls on the hydraulic tool to adjust the flow rate If necessary adjust the pressure using the throttle on the HPU E H Wachs Company Part No 79 405 MAN Rev 0 0108 13 HPU 750 Portable Hydraulic Power Unit 14 Part No 79 405 MAN Rev 0 0108 E H Wachs Company Chapter 4 Maintenance In This Chapter HYDRAULIC SYSTEM ENGINE Chapter 4 Maintenance HYDRAULIC SYSTEM Check the hydraulic oil level every time you use the HPU Add oil if necessary Keep the oil level at the full mark on the gauge 2 Change the hydraulic oil filter once per year 3 Change the hydrau
4. should read through this manual and become familiar with all instructions You should also read the manual for the gas engine that powers the HPU it describes how to service and maintain the engine How USE THE MANUAL This manual is organized to help you quickly find the infor mation you need Each chapter describes a specific topic on using or maintaining your equipment Each page is designed with two columns This large column on the inside of the page contains instructions and illustra tions Use these instructions to operate and maintain the equipment The narrower column on the outside contains additional information such as warnings special notes and defini tions Refer to it for safety notes and other information E H Wachs Company Part No 79 405 MAN Rev 0 0108 SYMBOLS AND WARNINGS The following symbols are used throughout this manual to indicate special notes and warnings They appear in the out side column of the page next to the section they refer to Make sure you understand what each symbol means and follow all instructions for cautions and warnings This is the safety alert symbol It is used to alert you to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death This is the equipment damage alert symbol It is used to alert you to poten tial equipment damage situations Obey all messages that follow this sym bol to
5. HPU 750 Portable Hydraulic Power Unit User s Manual E H Wachs Company Part No 79 405 MAN Rev 0 0108 January 2008 Revision History Original January 2008 Copyright 2008 E H Wachs Company All rights reserved This manual may not be reproduced in whole or in part without the written consent of E H Wachs Company E H Wachs Company 600 Knightsbridge Parkway Lincolnshire IL 60069 www wachsco com HPU 750 Portable Hydraulic Power Unit Part No 79 405 MAN Rev 0 0108 E H Wachs Company Table of Contents Table of Contents Chapter 1 About the HPU 750 Purpose of This Man al amp wicca SE RR Dr How to Use The Manual Symbols and Warnings Manual Updates and Revision Equipment Description SDBCHICOL OUS o eurer an er Re A CK Oe deett Chapter 29 Safety eed ere aac Bere RUE RI Oper tor Safety s bead te ad va No row s tes Kao Rd b CUR etre oes Safety Symbols dans aa EE Protective Equipment Requirements Safety Deseo ar quss PO ce icd bs MachineSalety sed E Leu REY Aes eam eis Chapter 3 Operating Instructions ooooooooooo oo o Connecting the Hydraulic Hoses Starting he Engine xx x Bi MAN III En
6. RIPTION QUANTITY Tank Assembly Label Manifold Relief Valve Auxilliary Valve Pressure Gauge Grommet Strip Pressure Hose Supply Hose Return Hose Filter Assembly 3 8 16 x 1 3 4 Coupling 1 4 Galvanized LP Coupling 1 4 Hex HD Nipple NPT 1 4 Plug 5 16 18 x 1 3 4 HHCS 5 16 18 Hex Nut 5 16 Split Ring Lockwasher 5 16 Flat Washer 3 8 16 x 7 8 HHCS 3 8 Lockwasher 3 8 16 x 1 1 2 SSS ORB JIC 3 4 MAL Adapter M ORB x F NPT 3 4 Adapter ORB JIC SWVL 3 4 Adapter Bulkhead 3 4 JIC M Adapter W SWVL 1 90 ST EL 1 NPT 1 JIC Male EL 1 NPT Male Female Tee BL 3 8 16 x 1 3 8 Knob 3 8 16 Nylock nut Adpt Orb nptf 90 Elbow Male 1 2 HP Hex Nipple 1 2 HP Disconnect FML Htma Disconnect ML Htma Bushing Red 1 2 x 1 1 1 1 1 1 1 T 1 1 1 1 1 1 1 1 1 1 1 2 2 2 2 3 1 1 1 1 1 1 1 1 1 1 1 1 1 1 22 Part No 79 405 MAN Rev 0 0108 E H Wachs Company Chapter 5 Parts List and Ordering Information Parts Lists and Drawings E H Wachs Company Part No 79 405 MAN Rev 0 0108 23 HPU 750 Portable Hydraulic Power Unit OPTIONAL COOLER THERMOSTATIC CONTROL ENGINE LEGEND BLK BLACK WHT WHITE BLU BLUE RED RED YEL YELLOW Wiring Diagram 24 Part No 79 405 MAN Rev 0 0108 E H Wachs Company E H Wachs Company 600 Knightsbridge Parkway Lincolnshire IL 60069 847 537 8800 www wachsco com
7. avoid damaging the equipment or workpiece on which it is operating Part No 79 405 MAN Rev 0 0108 E H Wachs Company HPU 750 Portable Hydraulic Power Unit WARNING gt A WARNING alert with the safety alert symbol indicates a potentially hazardous situa tion that could result in seri ous injury or death CAUTION gt A CAUTION alert with the safety alert symbol indicates a potentially hazardous situa tion that could result in minor or moderate injury CAUTION A CAUTION alert with the damage alert symbol indi cates a situation that will result in damage to the equipment IMPORTANT An IMPORTANT alert with the damage alert symbol indi cates a situation that may result in damage to the equipment N Chapter 1 About the 110 750 Manual Updates and Revision Tracking NOTE PE NOTE This symbol indicates a user note Notes En provide additional information to supple ANOTE provides suppe mentary information or oper ment the instructions or tips for easier operation ating tips MANUAL UPDATES AND REVISION TRACKING Occasionally we will update manuals with improved opera Current versions of E H tion or maintenance procedures or with corrections if nec Wachs Company man uals essary When a manual is revised we will update the are also available in PDF for mat You can request an electronic copy of this manual by emailing customer service at sales wachsco com
8. connections are secure 10 Part No 79 405 MAN Rev 0 0108 E H Wachs Company Chapter 3 Operating Instructions In This Chapter CONNECTING THE HYDRAULIC HOSES STARTING THE ENGINE OPERATING THE HPU Chapter 3 Operating Instructions CONNECTING THE HYDRAULIC HOSES You can use either the standard hydraulic circuit ports on the side of the HPU or the auxiliary circuit ports on the front not both Connect the hydraulic hoses to one of the circuits on the HPU Standard circuit ports Auxiliary circuit ports pressure return tank return tank pressure Figure 3 1 Connect the hydraulic hoses to only one circuit on the HPU 2 Ifyou are using the standard circuit side connectors push the port selector knob in This option is labeled TM 7 on the front panel E H Wachs Company Part No 79 405 MAN Rev 0 0108 If you are using the auxiliary circuit front connec tors pull the port selector knob out 3 Port selector knob Push in when using standard side ports Pull out when using auxiliary front ports Figure 3 2 Set the port selector knob for the circuit you are using Connect the other ends of the hoses to the ERV 750 or other tool you are using STARTING THE ENGINE Check that there is enough fuel in the gas tank for the job you are performing Open the fuel valve on the engine fuel line Pull the throttle halfway out If the engine is cold pull the
9. controls Specifications Hydraulic supply 8 gpm at 2000 psi Engine performance 15 horsepower 1500 Ib ft at 2000 psi 4 hour fuel endurance Hydraulic reservoir 10 gallons 37 8 1 Filtration 10 micron canister filter Finish Powder coated white Weight 265 Ib E H Wachs Company Part No 79 405 MAN Rev 0 0108 5 HPU 750 Portable Hydraulic Power Unit 6 Part No 79 405 MAN Rev 0 0108 E H Wachs Company Chapter 2 Safety In This Chapter OPERATOR SAFETY SAFETY LABELS MACHINE SAFETY Look for this sym AN bol throughout the manual It indicates a personal injury hazard Chapter 2 Safety The E H Wachs Company takes great pride in designing and manufacturing safe high quality products We make user safety a top priority in the design of all our products Read this chapter carefully before operating the HPU 750 It contains important safety instructions and recommenda tions Also refer to safety information in the manual for the gas engine OPERATOR SAFETY Follow these guidelines for safe operation of the equip ment READ THE OPERATING MANUAL Make sure you understand all setup and operating instructions before you begin INSPECT MACHINE AND ACCESSORIES Before starting the machine look for loose bolts or nuts leaking lubricant rusted components and any other physical conditions that may affect operation Properly maintaining the machine can greatly decrease the chance
10. d handling When you send the equip ment please include the following information e Your name company name e Your address e Your phone number E H Wachs Company Part No 79 405 MAN Rev 0 0108 description of the problem or the work to be done Before we perform any repair we will estimate the work and inform you of the cost and the time to complete it Warranty Information Enclosed with the manual is a warranty card Please fill out the registration card and return to E H Wachs Company Retain the owner s registration record and warranty card for your information Return Goods Address Return equipment for repair to the following address E H Wachs Company 600 Knightsbridge Parkway Lincolnshire Illinois 60069 USA PARTS LiSTS AND DRAWINGS The following pages illustrate components of the HPU 750 Refer to the figures to identify parts for ordering Table 1 HPU 750 Assemblies Qty Part No Description 1 17 135 00 Weldment HPU 750 Frame 1 17 302 01 Tank for HPU 750 1 17 401 00 Cooler 1 17 402 00 15 HP Gas Hydraulic Supply Part No 79 405 MAN Rev 0 0108 E H Wachs Company HPU 750 Portable Hydraulic Power Unit 18 Chapter 5 Parts List and Ordering Information Parts Lists and Drawings 17 135 00 Frame Weldment 051 AUXILLIARY COOLER ASSEMBLY indicates part not shown in exploded view Oil Cooler Thermostat Switch Cooler Hose
11. hile operating or working near this equipment For additional information on eye and face protection refer to Federal OSHA regulations 29 Code of Federal Regula tions Section 1910 133 Eye and Face Protection and American National Standards Institute ANSI Z87 1 Occu pational and Educational Eye and Face Protection Z87 1 is available from the American National Standards Institute Inc 1430 Broadway New York NY 10018 CAUTION Personal hearing protection is recom mended when operating or working near this tool Hearing protectors are required in high noise areas 85 dBA or greater The operation of other tools and equipment in the area reflective surfaces process noises and resonant struc tures can increase the noise level in the area For additional information on hearing protection refer to Federal OSHA regulations 29 Code of Federal Regulations Section 1910 95 Occupational Noise Exposure and ANSI S12 6 Hearing Protectors SAFETY LABELS There is no safety labeling on the HPU 750 E H Wachs Company Part No 79 405 MAN Rev 0 0108 HPU 750 Portable Hydraulic Power Unit MACHINE SAFETY To avoid damaging the equipment follow these usage guidelines Make sure the hydraulic fluid is clean and that there is no air in the hydraulic system Make sure that the engine has oil and is running prop erly Follow the engine maintenance schedule in the engine manual Make sure that all hydraulic
12. lic oil Mobil DTE Light or equivalent every two years 4 Check the oil temperature as the pump is operating If the temperature exceeds 180 F the oil will break down and continued operation will damage the pump Replace the oil if it exceeds 180 F and check to make sure that the cooler is working ENGINE Refer to the manufacturer s manual supplied with the engine for maintenance schedules and instructions Check the engine oil level every time you use the HPU 750 and add oil if necessary E H Wachs Company Part No 79 405 MAN Rev 0 0108 HPU 750 Portable Hydraulic Power Unit 16 Part No 79 405 MAN Rev 0 0108 E H Wachs Company Chapter 5 Parts List and Ordering Information In This Chapter ORDERING INFORMATION PARTS LISTS AND DRAWINGS Chapter 5 Parts List and Ordering Information ORDERING INFORMATION To place an order request service or get more detailed information on any E H Wachs Company products call us at one of the following numbers US 800 323 8185 International 847 537 8800 You can also visit our Web site at www wachsco com Ordering Replacement Parts When ordering parts refer to the parts lists in this chapter Please provide the part description and part number for all parts you are ordering Repair Information Please call us for an authorization number before returning any equipment for repair or factory service We will advise you of shipping an
13. revision history on the title page You may have factory service or upgrades performed on the equipment If this service changes any technical data or operation and maintenance procedures we will include a revised manual when we return the equipment to you EQUIPMENT DESCRIPTION The Powerpack HPU is designed to supply hydraulic power to the Wachs ERV 750 valve operator other Wachs utility tools except the Trav L Cutter or any HTMA Class II hydraulic tool It supplies 8 gallons per minute gpm flow at a pressure of 2000 psi Figure 1 1 shows the components of the Powerpack Figure 1 2 illustrates the front panel controls Figure 1 3 shows the engine controls E H Wachs Company Part No 79 405 MAN Rev 0 0108 3 Engine Side hydraulic ports Hydraulic pressure return reservoir cap ngine gas tank Hydraulic fluid filter Figure 1 1 The photo shows the major components of the Powerpack HPU Front hydraulic ports Port selector knob return tank pressure pull for front ports D Engine hours Hydraulic Engine Hydraulic oil gauge pressure gauge keyswitch level temp gauge Figure 1 2 The photo shows the HPU front panel Part No 79 405 MAN Rev 0 0108 E H Wachs Company HPU 750 Portable Hydraulic Power Unit Chapter 1 About the HPU 750 Equipment Description Throttle Choke TUN Electrical port to ERV 750 Figure 1 3 The photo shows the front panel engine
14. s for injury ALWAYS READ PLACARDS AND LABELS Make sure all placards labels and stickers are clearly legible and in good condition You can purchase replacement labels from E H Wachs Company E H Wachs Company Part No 79 405 MAN Rev 0 0108 KEEP CLEAR OF MOVING PARTS Keep hands arms and fingers clear of all rotating or moving parts Always turn machine off before doing any adjustments or service SECURE LOOSE CLOTHING AND JEWELRY Secure or remove loose fitting clothing and jewelry and securely bind long hair to prevent them from getting caught in moving parts of the machine e KEEP WORK AREA CLEAR Keep all clutter and nonessential materials out of the work area Only people directly involved with the work being performed should have access to the area Safety Symbols A This icon is displayed with any safety alert that indicates a personal injury hazard Z WARNING This safety alert indicates a potentially hazardous situation that if not avoided could result in death or serious injury Z CAUTION This safety alert with the personal injury hazard symbol indicates a potentially hazardous situation that 1f not avoided could result in minor or moderate injury Part No 79 405 MAN Rev 0 0108 E H Wachs Company HPU 750 Portable Hydraulic Power Unit Chapter 2 Safety Safety Labels Protective Equipment Requirements WARNING Always wear impact resistant eye pro tection w
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