HCM-D23 Hydraulic Power Unit Manual R1
Contents
1. Qiu OSA ae ed GORI 15 Safety Symbols cei intone tos Gael ia ee Ae eae ta waa 16 Protective Equipment Requirements 0 cece cc cece eens 17 Safety aed td 17 19 Chapter 3 Ordering Information 4 3 6 3 46 eee 8 53 21 Ordering Replacement Parts Sek 21 Repair Informatia Pues eee eee Peak ome 21 Warranty Informatio fara a e nce Wee Ea cet cain 22 Retum Goo0ds Address fevclak stews a Ser ee aad 22 E H Wachs Part No 14 MAN 33 Rev 1 0415 1 About the HCM D23 Hydraulic Power Unit 2 Part No 14 MAN 33 Rev 1 0415 E H Wachs Chapter 1 About the HCM D23 Hydraulic Power Unit The Wachs HCM D23 hydraulic power unit provides 15 gpm hydraulic flow at a maximum pressure of 1800 psi 57 l min at 124 bar The unit is powered by a 23 HP diesel engine The HCM D23 is designed to operate Type 1 Type 2 or Type 3 open center tools Before operating the unit read and understand the instruc tions in this manual and in the manufacturer s manual pro vided for the diesel engine FEATURES The HCM D23 hydraulic power unit includes the following standard features Liquid cool2. Equivalent oils Gulf Harmony 32A Mobile D T E 24 Shell Tellus 32 Texaco Rando H D 32 Fill the Fuel Tank Remove the fuel cap and fill the tank with diesel fuel approximately 5 gallons 19 The cap has a fuel level gauge in it E H Wachs Part No 14 MAN 33 Rev 1 0415 About the HCM D23 Hydraulic Power Unit Figure 1 8 Remove the fuel tank cap and fill the tank with diesel fuel approximate capacity 5 gallons 19 lJ Wipe up any spilled fuel and replace the cap tightly Do not operate the power unit without the cap securely in place NOTE The power unit is capable of operating at 1800 psi 124 bar It is extremely important that the hoses used with this unit are rated for 3000 psi 186 bar or higher pressure 1 Connect the pressure supply port male coupler located on the right front side on the oil reservoir item 8 in Connect the return hose from the remote valve or device to the return line coupler female coupler located on the left front side of the unit item 4 in Before starting the unit make sure the adjustable flow control valve item 2 in is set at 0 handle rotated completely clockwise Setting the valve in the on position it would put enough load on the engine to pre vent it from starting Note Never connect or disconnect quick couplers when the flow control valve is on Never connect or disconnect quick couplers when the circuit is under pressure
3. In This Chapter OPERATOR SAFETY Look for this sym bol throughout the manual It indicates a personal injury hazard E H Wachs Part No 14 MAN 33 Rev 1 0415 About the HCM D23 Hydraulic Power Unit Always turn machine off before doing any adjustments or service e 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 if not avoided could result in minor or moderate injury NOTICE This alert indicates a situation that if not avoided will result in damage to the equipment 16 Part No 14 MAN 33 Rev 1 0415 E H Wachs Chapter 2 Safety Operator Safety IMPORTANT This alert indicates a situation that if not avoided may result in damage to the equipment Protective Equipment Requirements WARNING Always wear i
4. Part No 14 MAN 33 Rev 1 0415 E H Wachs OPERATING INSTRUCTIONS Turn the flow control knob to the OFF position all the way counter clockwise 1 Ow igure 1 9 Turn the flow control all the way OFF DIESEL before starting the power unit or connecting hoses Push the throttle lever all the way down Using the keyswitch jog the engine without starting it several times to prime the pump Figure 1 10 the keyswitch briefly with the throt tle at the lowest setting to jog the engine without start ing it NOTE The adjustable flow control valve must always be set to 0 completely clock wise when there is not a pressure hose connected to the pressure port When the flow control is on and the unit is allowed to deadhead it will dump all the flow over the relief valve and cause an extreme amount of heat Wachs Part No 14 MAN 33 Rev 1 0415 About the HCM D23 Hydraulic Power Unit 3 Start the engine see the Kohler engine manual for proper starting of the engine Run the engine at idle speed for a couple of minutes before operating the unit at system pressure 4 Attach the hoses from the tool to the PRESSURE and RETURN fittings on the control panel 5 Adjust the throttle lever to the maximum setting Figure 1 11 Set the throttle to the maximum speed position for operation operate the tool turn the flo
5. cm x 73 cm e Weight 520 lb 236 kg CAUTION Do not put your hands between the handles and frame of the power unit when collapsing the handles The handle could drop and injure hands or fingers A Pinch Point safety label on the side of the power unit warns of this hazard E H Wachs Part No 14 MAN 33 Rev 1 0415 About the HCM D23 Hydraulic Power Unit e Filtration 10 micron return line canister e Oil Cooler Air to oil e Fuel Capacity 5 gallons 19 liters e Hydraulic Oil Capacity 4 gallons 15 liters e Hydraulic Relief Pressure 1800 psi 124 bar SET UP INSTRUCTIONS The HCM D23 power unit is completely assembled before delivery For safe shipping it is delivered without battery fuel or hydraulic fluid Battery Installation The HCM D23 HPU uses a 12 V 26RC battery 540 cca 0 The battery compartment cover is held in place with 4 screws The following figures show the battery compart ment the battery cables and battery hold down strap 4 Remove the screws and take off the battery compart ment cover Figure 1 4 Remove the battery compartment cover 2 Connect the battery cables to the posts on the battery Part No 14 MAN 33 Rev 1 0415 E H Wachs red cable to positive post black cable to negative post Figure 1 5 Attach the cables to the battery posts 3 Insert the battery into the compartment CAUTION Avoid letting the batt
6. HCM D23 Hydraulic Power Unit User s Manual E H Wachs 600 Knightsbridge Parkway Lincolnshire IL 60069 www ehwachs com Wachs Part 14 MAN 33 Revision 1 April 2015 IMPORTANT Read this manual carefully before starting and operating the power unit Copyright 2015 E H Wachs All rights reserved This manual may not be reproduced in whole or in part without the written consent of E H Wachs Table of Contents Table of Contents Chapter 1 About the HCM D23 Hydraulic Power Unit 0 0 cece eee eeeee 1 ee ar tye eel alee eg LN eng 1 SPCCINCANONSs CRIS REESE ORE 3 Set Up Instructions creires Pag GOR See eee Peg Ka ON Bee ee ae ERT ene 4 Battery Installation 55 5 a 4 Fill the Hydraulic Reservoir ss 24456 eek See eae RAS ewan 6 Pall the Fuel Tank bw SE Se Seow 7 Operating Instr ttions solr ena gure tw oats sa alata bust Aaa tan 9 Op rating TIN alt 11 RG REG Re ES 12 ne ie aoe Ara Ss Ee ee 12 Chapter 2 Safety sas Sool aS oat we Weel Mar so a ae eee RA eae 15 Operator Safety 4 24 Kura c eta ns aed
7. all safety factors when selecting the strength of materials to allow for shock and over pressure conditions which could occur SAFETY LABELS There is a safety label on each side of the unit indicating the location of the engine fan Keep hands away from the engine compartment while the unit is running amp CAUTION S Figure 2 1 Labels on each side of the unit indicate the location of the engine fan WARNING The injection of hydraulic fluid under the skin can cause serious injury and even result in death If an injection injury occurs seek medical treatment immedi ately E H Wachs Part No 14 MAN 33 Rev 1 0415 About the HCM D23 Hydraulic Power Unit A safety label warns that the engine muffler can get very hot Do not touch the muffler during or after operating the power unit ee Figure 2 2 A Hot Surface label is located near the engine muffler A safety label on each side of the unit warns of a pinch point hazard between the enclosure and the collapsible han dles Keep hands clear when lower the handles from the operating extended position Figure 2 3 The Pinch Point label is located on both sides of the unit by the collapsible handles 20 Part No 14 MAN 33 Rev 1 0415 E H Wachs Chapter 3 Ordering Information Chapter 3 Ordering Information In This Chapter To place an order request service or get more detailed information on a
8. aulic oil drain plug under neath the unit eae We Figure 1 14 The hydraulic oil filter is at the top of the engine compartment Replace the filter every time you replace the hydraulic oil E H Wachs Part No 14 MAN 33 Rev 1 0415 About the HCM D23 Hydraulic Power Unit 14 Part No 14 MAN 33 Rev 1 0415 E H Wachs Chapter 2 Safety Chapter 2 Safety E H Wachs takes great pride in designing and manufactur ing 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 hydraulic power unit It contains important safety instructions and recommendations OPERATOR SAFETY Follow these guidelines for safe operation of the equip ment e READ THE OPERATING MANUAL Make sure you understand all setup and operating instructions before you begin e 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 chances for injury e ALWAYS READ PLACARDS AND LABELS sure all placards labels and stickers are clearly legible and in good condition You can purchase replacement labels from E H Wachs Company e KEEP CLEAR OF MOVING PARTS Keep hands arms and fingers clear of all rotating or moving parts
9. ed 23 HP diesel engine tier 4 compliant e Large capacity hydraulic oil cooler e Replaceable 10 micron hydraulic oil filter e flat faced couplers e Fuel level gauge and hour meter Auto shutdown for low engine oil pressure or high tem perature e Solid rubber tires Collapsible handles e Heavy duty single point lift ring E H Wachs Part No 14 MAN 33 Rev 1 0415 About the HCM D23 Hydraulic Power Unit The engine owner s manual is provided with the HCM D23 HPU Refer to the engine manual for all engine maintenance and service procedures The following figure shows the features of the control panel Flow gauge sure dau Flow SSO 6 i Engine hours Pressure gauge Hose connections throttle Hydraulic reservoir cap Figure 1 1 The photo shows the HCM D23 operating features The handles are collapsible to keep them out of the way during operation and for storage A pin secures each handle in its operating or collapsed position Always have the pins inserted to secure the handles 2 Part No 14 MAN 33 Rev 1 0415 E H Wachs AR j Figure 1 2 The photo shows the pin inserted with the handle collapsed Figure 1 3 The photo shows the pin inserted with the handle in the operating position SPECIFICATIONS e Flow 0 15 gpm 1800 psi 0 57 l min 124 bar e Dimensions 39 x 36 5 h x 28 8 w 99 cm x 93
10. erious personal injury Before disconnecting lines be sure to relieve all pressure Before applying pressure to the system be sure all connec tions are tight and that lines and hoses are not damaged Fluid escaping from a very small hole can be almost invisi ble Use a piece of cardboard or wood rather than hands to search for suspected leaks If injured by escaping fluid SEE A DOCTOR AT ONCE Serious infection or reaction can develop if proper medical treatment is not administered immediately See the safety guidelines in the next chapter MAINTENANCE Every time you use the power unit inspect all fasteners hydraulic hoses and fittings Service and maintain the engine according to the mainte nance schedule in the Kohler Engine Owner s Manual Every time you use the power unit check the hydraulic oil level in the reservoir Check the oil level periodically during extended use Proper oil level should be approximately 1 to 1 1 2 from the top of the reservoir Check the condition of the hydraulic fluid looking for con taminants dirt or discoloration Change the fluid as soon as it becomes dirty or discolored The hydraulic system includes a return line filter Replace the filter every time you replace the hydraulic fluid Do not try to get extended life out of a clogged filter 12 Part No 14 MAN 33 Rev 1 0415 E H Wachs Figure 1 13 A label on the side of the HPU indicates the location of the hydr
11. ery posts touch the frame of the power unit 4 Secure the battery with the hold down strap Replace the battery compartment cover E H Wachs Part No 14 MAN 33 Rev 1 0415 About the HCM D23 Hydraulic Power Unit Figure 1 6 A hold down strap is provided to secure the battery in the compartment Fill the Hydraulic Reservoir NOTE It is extremely import Use a premium quality hydraulic oil approximately 4 gal ant that the pump is not lons 15 The reservoir must be filled before power unit started until oil is in the sys is started Oil should have anti wear characteristics excel tem Power units are shipped lent rust protection and contain additives to protect against without oil Operating a pump without oil even for a short time will result in damage NOTE When filling the reser voir initially elevate the front of the power unit slightly so that the air can purge out of the reservoir foaming 6 Part No 14 MAN 33 Rev 1 0415 E H Wachs Hydraulic reservoir cap Figure 1 7 Remove the hydraulic reservoir cap and fill the reservoir with hydraulic oil approximate capacity 4 gallons 15 1 Wipe up any spilled oil and replace the cap tightly Do not operate the power unit without the cap securely in place Recommended oil U S Oil Corporation hydraulic oil with the following characteristics Viscosity Index 101 Grade 32 viscosity of 156 at 100 F viscosity of 43 7 at 210
12. mpact resistant eye pro tection while 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 equipment 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 512 6 Hearing Protectors Safety Procedures All safety requirements listed below are those generally applicable to hydraulically powered machinery but are not intended to be an all inclusive list They are intended as guidelines only and will assist in avoiding risk of injury when followed by qualified experienced personnel These E H Wachs Part No 14 MAN 33 Rev 1 0415 About the HCM D23 Hydraulic Power Unit precautions should be included in the comprehe
13. nsive safety program for the particular machinery equipment plant or process and overseen by personnel capable of analyzing any hazards associated with operating and maintaining the equipment WARNING 4 Return all movable parts of the machinery being oper Many types of AN ated to their normal startup condition if possible machinery have before starting unit parts that may start moving as soon as the 2 Be sure all personnel product etc are clear of hydraulic circuit is filled and machinery before starting hydraulic unit pressurized This could result i in injury to personnel or dam 3 Check to make sure any hydraulic connections which age to machinery may have been removed replaced or disconnected during shut down have been reconnected securely before starting hydraulic unit 4 Before starting the unit perform all equipment checks described at the beginning of the operating instruc tions 5 1 there are tools or machinery being operated by the HPU that may move when hydraulic flow or pressure are turned off or turned on block or lock these parts in position before shutting down the hydraulic unit Make sure all per from all pressurized accumulators actuators and lines sonnel are clear before removing tearing down or performing mainte from the machin nance on any remotely located actuators hoses fil ery being operated before ters valves piping etc shutting down the HPU WARNING 6 Shut down the hyd
14. ny E H Wachs products call us at one of ORDERING REPT ACEMENT P the following numbers pa REPAIR INFORMATION U S 800 323 8185 WARRANTY INFORMATION International 847 537 8800 RETURN COODSANGRESS You can also visit our Web site at www ehwachs com ORDERING REPLACEMENT PARTS When ordering parts refer to the drawings and parts lists in Chapter 8 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 and handling When you send the equip ment please include the following information e Your name company name e Your address Your phone number e A description of the problem or the work to be done E H Wachs Part No 14 MAN 33 Rev 1 0415 21 About the HCM D23 Hydraulic Power Unit 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 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 600 Knightsbridge Parkway Lincolnshire Illinois 60069 USA 22 Part No 14 MAN 33 Rev 1 0415 E H Wachs
15. raulic unit and relieve pressure 7 Any personnel observing or working on or adjacent to hydraulically powered equipment must never place themselves in a location or position that could produce an injury in the event of e a hydraulic line failure either with the unit running or shut down e pump or motor failure or e pin hole leaks in hoses or fittings movement of machine components during normal oper ation or resulting from a component malfunction or fail ure 18 Part No 14 MAN 33 Rev 1 0415 E H Wachs Chapter 2 Safety Safety Labels Do not inspect hoses and fittings for leaks using your bare hands A pin hole leak can inject hydraulic fluid through the skin with the potential for serious injury 9 Avoid locating equipment in any environment for which it was not designed and which may create a dangerous operating condition such as an explosive atmosphere e g gas dust high heat e g molten metal furnace chemicals extreme moisture etc 40 Avoid bodily contact with hydraulic fluids Some hydraulic fluids may irritate or injure the eyes and skin Check with your fluid suppliers to obtain this information 41 Use only E H Wachs parts and materials when servic ing the equipment Substitute parts or materials could produce a hazardous operating condition 42 When piping your equipment use only materials of adequate size and strength to suit the flows and pres sures of the system Consider
16. w control knob clock wise to start hydraulic flow Adjust the knob for the desired operating speed 10 Part No 14 MAN 33 Rev 1 0415 E H Wachs DIESEL T EA 1 Figure I 12 Turn the flow control in the ON direction to operate the tool Control panel shown without hoses attached 7 stop the tool turn the flow control knob back to OFF 8 To turn off the power unit set the throttle lever to the minimum speed position and then turn off the key switch Operating Notes Make sure that the hydraulic circuit is properly plumbed and appropriate for the available amount of oil from the unit A circuit with long hoses or a high capacity tool could lower the reservoir level considerably The power unit must be plumbed to an open center valve If the hydraulic circuit is improperly plumbed pressure will build immediately and dump over the relief valve setting causing excessive heat Allow the power unit to run for at least 10 minutes at a time to make sure the battery is charged Starting and stopping the unit frequently and operating for only short periods of time will not keep the battery fully charged E H Wachs Part No 14 MAN 33 Rev 1 0415 About the HCM D23 Hydraulic Power Unit NOTE A hydraulic hose fail ure could be very hazardous frequent inspection is import ant Cautions Escaping hydraulic fluid under pressure can have sufficient force to penetrate skin causing s
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