PortaCo G-09 Betriebsanleitung

Hydraulic Power Unit

Pioneer Series

G-09, G-11, G-13

OPERATION,

MAINTENANCE,

AND REPAIR MANUAL

1805 2nd AVENUE NORTH * MOORHEAD, MN, USA 56560-2310

PHONE (218) 236-0223 * FAX (218) 233-5281

E-MAIL ADDRESS; info@portaco.com * INTERNET ADDRESS: www.portaco.com

TABLE OF CONTENTS

1.0 Introduction

1.1 General Information

1.2 Features

1.3 Options

1.4 Safety Summary

1.5 General Safety Precautions

1.6 Warning and Caution Statements

1.7 Training Requirements

2.0 Installation Instructions

2.1 Unpacking Instructions

2.2 Engine Preparation

2.3 Hydraulic Power Unit Preparation

2.4 Testing

2.5 Adjustments

2.6 Hose Requirements

2.7 Tool Connecting Procedures

2.8 Work Area Safety Precautions

3.0 Operating Instructions

3.1 Description of Power Unit

3.2 Controls and Graphics

3.3 Before Start Up

3.4 Positioning the Power Unit

3.5 Startup

3.6 Shutdown

3.7 Cold Weather Operation

3.8 Storage Preparation

4.0 Maintenance Instructions

4.1 Routine Servicing and Inspection

Schedule

4.2 Assembly View and Parts List

4.3 Hydraulic Fluids and engine

maintenance

4.4 Trouble Shooting

4.5 Technical Specifications

1.0 INTRODUCTION

1.1 General Information

This manual presents installation,

operation, and maintenance information

for the Pioneer G-09, G-11, G-13 series

PortaCo Hydraulic Power Units. Model

G-09S06-52-W, G-11S07-52-W,

G-13S08-52-W.

PortaCo, Inc. reserves the right to make

changes at anytime without notice and

without incurring any obligation.

The Pioneer Power Unit is designed to

provide hydraulic flow and pressure for

operation of H.T.M.A. type I, II,

hydraulic tools.

The G-09506-52-W provides 5.9 gpm

(22.4 Liters) at 1800 psi (125 BAR) to

operate type I hydraulic tools. The

G-11507-52-W provides 7gpm

(26 Liters) at 2000 psi (148 BAR) to

operate type I hydraulic tools. The

G-13508-52-W provides 8 gpm (30.3

Liters) at 2000 psi (148 BAR) to operate

type II hydraulic tools.

For the G-11, and G-13 PortaCo power

units produce a maximum pressure of

148 BAR (2150 PSI). The G-09 power

unit produces a maximum pressure of

135 BAR (1950 PSI).

The power units are all equipped with

air-to-oil coolers with suction fan

mounted to the power shaft on the

engine.

The fuel and hydraulic systems are self-

contained with the required reservoir,

filtration and level indicators.

CAUTION: DO NOT USE CLOSED-

CENTER TOOLS WITH THIS

POWER UNIT

1.2 Features

The main features of the PortaCo

Pioneer G-09, G-11, and G-13 pioneer

series are as follows:

Standard unit is a wheeled style frame:

Length 67.3 cm (26.5 in.)

Width 50.8 cm (20 in.)

Height 69.8 cm (27.5 in.)

Weight 64.9 kg (143 lbs.)

Upper ambient operating

Temperature 43 C (110° F)

Lower ambient operating

Temperature -28°C (-20 F)

The Pioneer series comes with either a

Briggs & Stratton or a Honda Engine.

See the engine manual supplied with the

power unit for recommended fuel and

fuel restrictions.

The standard wheeled Pioneer series

power unit is equipped with collapsible

handle, which locks in place with a

latch, (see fig. 1.2A) and a lifting point

for a crane hook. (Fig. 1.2B)

(Fig. 1.2A)

1.3 Options

Consult PortaCo. For special options that

may be available

1.4 Safety Summary

Tool operators and maintenance

personnel must always comply with the

safety precautions given in this manual

and on the stickers and tags attached to

the tool and hoses.

These safety precautions are given for

your safety. Review them carefully

before operating the power unit and

before performing maintenance or

repairs.

Supervising personnel should develop

additional precautions relating to the

specific work area and local safety

regulations.

1.5 General Safety Precautions

The PortaCo Inc. Pioneer G-09, G-11,

and G-13 Series Hydraulic Power Units

are designed to provide safe and

dependable service if operated according

to the instructions provided in this

manual. Read and understand this

manual and any stickers attached to the

power unit before operating. Failure to

do so could result in personal injury or

equipment damage.

Check the rules and regulations at your

location. The rules may include

employer’s work safety program.

Regulations may identify hazards such

as working around utility supply lines or

hazardous slopes.

Read and understand any manuals for

additional or optional equipment, which

maybe shipped with the Pioneer power

unit.

1.6 Warning and Caution Precautions

Warning and Caution statements have

been strategically placed throughout the

text, prior to operating or maintenance

procedures, practices, or conditions,

considered essential to protection of

personnel or equipment and property.

WARNING: HIGHLIGHTS AN

ESSENTIAL OPERATING OR

MAINTENANCE PROCEDURE,

PRACTICE, CONDITION

STATEMENT, ETC. WHICH IF

NOT STRICTLY OBSERVED,

COULD RESULT IN INJURY TO,

OR DEATH OF, PERSONNEL OR

LONG TERM HEALTH HAZARDS.

CAUTION:HIGHLIGHTS AN

ESSENTIAL OPERATING OR

MAINTENANCE PROCEDURE,

PRACTICE, CONDITION

STATEMENT, ETC. WHICH IF

NOT STRICTLY OBSERVED,

COULD RESULT IN DAMAGE TO,

OR DESTRUCTION OF,

LIFT HERE

EQUIPMENT OR LOSS OF

MISSION EFFECTIVENESS.

1.7 Training Requirements

Operator training should consist of

information found in this manual for the

hydraulic power unit. In addition the

operator must receive instructions both

through demonstrations and verbally

with the tools or applications in which

the power unit is going to be used. The

new operator must start in an area

without bystanders and use all controls

until able to fully operate the power unit

under the conditions for the work area.

2.0 INSTALLATION

INSTRUCTIONS

2.1 Unpacking Instructions

Upon receiving your Pioneer hydraulic

power unit, promptly remove it from the

shipping container. Always keep top

side of container up. Inspect unit for

damage which may have incurred during

shipping and report it to carrier for

claim.

2.2 Engine Preparation

CAUTION: READ AND

UNDERSTAND ENGINE MANUAL

WHICH IS PROVIDED IN

ADDITION TO THE PORTACO

MANUAL BEFORE STARTING

THE POWER UNIT.

CAUTION:ALWAYS CHECK

ENGINE OIL BEFORE STARTING

POWER UNIT.

Make sure engine oil is at the “FULL”

mark on the dipstick.

See engine manual for recommended oil

and checking procedures.

NOTE: clean up oil and fuel spills

immediately. Do not over fill fluids.

2.3 Hydraulic Power Unit Preparation

CAUTION: DO NOT OPERATE

POWER UNIT WITH BELOW

RECOMMENDED HYDRAULIC

OIL LEVEL. PUMP DAMAMAGE

MAY ACURE.

Check hydraulic fluid level by looking at

sight pipe located on top of the oil

reservoir. Proper oil level is indicated

when the center section of the sight pipe

is dark. To add hydraulic fluid remove

filter cap on top of reservoir, replace

when finished. Reservoir capacity is

18.9 LTR (5.0 gal) do not overfill fluids,

clean up oil spills immediately. Only

hydraulic fluids meeting the

specifications located below are

recommended for use with PortaCo

hydraulic power units.

(Fig. 2.3A)

Viscosity (Fluid Thickness)

METRIC U.S.A.

10 C 95 Centistokes 50 F 450 SSU Max

38 C 27-42 C.S. 100 F 130-200 SSU

60 C 16.5 C.S, Min. 140 F 85 SSU Min.

Pour Point -10 F/23 C Minimum (for cold startup)

Viscosity Index (ASTM D 2220) 140 Minimum

Demulsibility (ASTM D-1401) 30 Minutes Maximum

Flash Point (ASTM D-92) 340 F/171 C Minimum

Rust Inhibition (ASTM D-665 A & B) Pass

Oxidation (ASTM D943) 1000 Hours Minimum

Pump Wear Test (ASTM D2882) 60 mg Maximum

The following fluids work well over a

wide temperature range at startup, allow

moisture to settle out, and resist

biological growth likely in cool

operating hydraulic circuits. These

fluids are recommended by PortaCo, Inc.

Other fluids that meet or exceed the

specifications of these fluids may also be

used.

Type

Hydraulic fluid

Chevron

“Clarity” AW 15032

Exxon

“Univis” J 32

Mobil

D.T.E. 13

Gulf

“Harmony” AW

HVI

150

Shell

“Tellus T” 32

Texaco

“Rando” HDZ 32

Union

“Unax” AW

Amsoil

AWH 15032

Sunvis

Low Pour H/032

product code 19300

Fill the fuel reservoir to a level just

below the bottom of the filter tube.

Always use clean gasoline as

recommended in the engine manual. Do

not overfill fluids, clean up oil and fuel

spills immediately.

2.4 Testing

All power units are tested at the factory

and their flows and pressures are

recorded on the test report, which is

shipped with the power unit. Testing of

the power unit is not required unless it is

damaged during shipping.

Always perform “before startup

procedures” found in section 3.3 before

testing. PortaCo Hydraulic Tester, Part

Number T-00016-XX-0 is recommended

for all tests.

a. Set the hydraulic circuit to “OFF.”

b. Connect hydraulic hoses to the

power unit. Connect the PortaCo

Hydraulic Tester to the opposite end

of the hoses. Make sure flow

direction is correct.

c. Start the engine and allow the

hydraulic fluid to warm to about

100° F/38 C°.

d. Open the tester restrictor valve (fully

open.) This represents minimum

load.

e. Set the flow control to “ON” and set

engine throttle for maximum speed.

f. Check the flow rate and pressure on

the tester gauges. The back pressure

reading should be under 17.3 bar

(250 PSI). The flow readings should

match those listed in section 1.1

General Information of this manual.

g. With engine throttle set at maximum

speed slowly close the restrictor

valve on the tester while observing

the flow pressure gauges.

h. As the hydraulic system relief valve

begins to crack (open) and bypass

fluid through the valve, the flow rate

will begin to drop. At this time, the

pressure in the system should be

between 145-155 BAR (2100-2250

PSI).

i. If the pressure is not as specified, the

hydraulic circuit relief valve must be

adjusted or replaced. (See section

4.2 for procedure.)

- If the flow rate drops below the

specified range, the pump or

control valve may be worn.

- If the flow remains constant, but

pressure does not increase, the

relief valve may be defective.

2.5 Adjustments

The engine RPM’s and the hydraulic

system flow and pressure relief are set at

the factory and must not be readjusted.

DO NOT change governor setting or

tamper with governor components,

which may increase the governed engine

speed.

WARNING: OPERATING THE

POWER UNIT AT EXCESSIVE

SPEEDS INCREASE THE DANGER

OF PERSONAL INJURY.

2.6 Hose Requirements

The Pioneer series are easily moved

close to the job site. It is not often

necessary or advisable to use long hoses.

All hoses must have an oil resistant inner

surface and an abrasion resistant outer

surface. Each hose must have male pipe

ends for most application. Longer hoses

can be used when necessary, but can

affect the operation of the tool due to

resistance in the hose.

If small diameter or long hoses are used,

or if restrictive fittings are connected to

the supply and return ports, the pressure

required, to push the fluid through the

system and back to the tank will be

higher. This will reduce tool power.

The pressure and return hose are

connected to the control block. A

½-inch male pipe hose end can be

connected, to H.T.M.A. flat-nosed

quick-disconnect couplings (available

through PortaCo, Inc).

The left port of the control block is the

pressure (oil out) fitting. A male

H.T.M.A. quick-disconnect coupling

(without lock ring) must be connected to

this port.

Two hoses are required to complete the

circuit, each hose should have a male

coupler on one end and a female coupler

on the opposite. See diagram on page 8

for hose routing.

*Important – Oil should always flow

from the male coupler through the

female coupler.

The right port is the return port. A

female H.T.M.A. quick-disconnect

coupling should be connected to this

port.

NOTE: The pressure increase in

uncoupled hoses left in the sun may

make them difficult to connect. When

possible after use, connect the free ends

of the operating hoses together.

HOSE TYPES

Hydraulic hose types authorized for use

by PortaCo, Inc. are as follows:

1. Labeled and certified non-conductive

2. Wire braided (conductive)

3. Fabric braided (not certified or labeled non-

conductive)

Hose 1: Listed above is the only hose authorized

for use near electrical conductors.

Hoses 2 and 3: Listed above are conductive and

must never be used near electrical conductors.

HOSE PRESSURE RATING

The rated working pressure of the

hydraulic hose must be at least 175 bar

(2500 PSI.)

HYDRAULIC HOSE RECOMMENDATIONS

Table 2.6A

FLOW PER CIRCUIT LENGTH EACH HOSE USE INSIDE DIAMETER SAE SPEC HOSE

(WIRE BRAID) SAE SPEC

HOSE (FIBER

BRAID)

GPM LPM FEET METERS INCH MM

5 to 8 19 to 30 To 50 To 15 Both 1/2 13 SAE 100R1-8 100R7-8

5 to 8 19 to 30 51-100 15 to 30 Both 5/8 16 SAE 100R2-10 SAE 100R8-10

5 to 8 19 to 30 100-300 30 to 90 Pressure

Return 5/8

3/4 16

19 SAE 100R2-10

SAE 100R1-12 SAE 100R8-10

SAE 100R7-12

9 to 12 34 to 45 To 50 To 15 Both 5/8 16 SAE 100R2-10 SAE 100R8-10

9 to 12 34 to 45 51-100 15 to 30 Pressure

Return 5/8

3/4 16

19 SAE 100R2-10

SAE 100R3-12 SAE 100R8-10

SAE 100R7-12

9 to 12 34 to 45 100-200 30 to 60 Pressure

Return 3/4

119

25.4 SAE 100R2-12

SAE 100R1-16 SAE 100R8-12

SAE 100R7-16

FOR SINGLE CIRCUIT FLOWS UP TO

10 GPM plumb hose and tool as illustrated

in fig. 1. Numbers are represented below as

paragraph numbers.

1. H.T.M.A. 3/8-inch Male Quick Acting

Coupler with ½-inch NPT thread.

2. H.T.M.A. 3/8-inch Female Quick

Acting Coupler with ½-inch NPT

thread.

At the tool this may be H.T.M.A.

3/8-inch Female Quick Acting

Coupler with 3/8-inch NPT

thread.

3. H.T.M.A. 3/8-INCH Female

Quick Acting Coupler with ½-inch

NPT thread.

4. H.T.M.A. 3/8-inch Male Quick

Acting Coupler with ½-inch NPT

thread.

At the tool this may be 3/8-inch

Male Quick Acting Coupler with

3/8-inch NPT thread.

A. Refer to Table 2.6A for hose

recommendations

B. Use adapters with threads that

match tool port.

2.7 Tool Connecting Procedures.

Inspect hose for cuts, crushing, leaks, or

abrasion which maybe a safety hazard or

reduce fluid flows.

WARNING: DO NOT

ATTEMPT TO LOCATE

HYDRAULIC LEAKS BY FEELING

AROUND HOSES AND FITTING

WITH HANDS. “PIN-HOLE” LEAKS

CAN PENETRATE THE SKIN.

Stop the engine before connecting the

tool and, or hoses to the off power unit,

and when switching hoses or tools. Turn

the hydraulic on/off valve to the off

position before starting the engine.

Make sure all hoses are connected for

correct flow direction to and from the

tool being used. When routing hose in

the work area, position them where

personnel will not be at risk of tripping

over them or where vehicles can run

over the hoses. Do not lay hose over

sharp projects.

WARNING: PRESSURIZED FLUID

ESCAPING FROM A DAMAGED

HOSE CAN PENETRATE THE

SKIN AND BE INJECTED IN THE

BODY CAUSING INJURY OR

DEATH.

CAUTION:DO NOT PULL ON HOSES

TO DRAG POWER UNIT.

2.8 Work Area Safety Precautions

- Never operate the power unit in a

closed space. Inhalation of

engine exhaust can be fatal.

- Keep clear of hot exhaust.

- Do not use PortaCo hydraulic

power units in potentially explosive

atmospheres such as near

wastewater drains or landfill sites.

- Do not operate if flammable gases

or vapors are present.

- Keep the power unit at least 1meter

(3.3 ft) away from buildings, obstructions,

and flammable objects. Do not aim engine

exhaust at materials that could catch fire.

- Allow the engine to cool before

storing the power unit in an

enclosed space.

- PortaCo hydraulic power units must

not be located below overhead

gantries, power lines, or walkways

where there might be a risk of

falling objects.

- Provide ambient light intensity of

200 Lux for working indoors or

outdoors particularly if working at

night.

- Always wear appropriate safety

equipment such as goggles, ear

protection, and foot protections.

- Operate only tools which fit into

the specifications prescribed in

section 1.1 of this manual.

- Do not stand on power unit.

3.0 OPERATING INSTRUCTIONS

3.1 Description of Power Unit

The PortaCo Pioneer series

Hydraulic Power Unit has been designed

for the purpose of supplying hydraulic

fluid under pressure to power hydraulic

hand tools. The standard engine is a

Honda 9 hp, 11 hp, or 13 hp. depending

on the model of power unit purchased.

See section 1.2 features of this manual

for specifications. See the technical

manuals supplied by the engine

manufacture included with this power

unit for detailed technical specifications.

PortaCo Hydraulic Power Units have

been designed for use indoors and

outdoors. PortaCo power units should

not be operated under wet conditions, or

at ambient operating temperatures,

outside the recommended temperature

range of -28° C to 43° C. (-20° F to

110° F).

CAUTION: DO NOT USE CLOSED-

CENTER TOOLS WITH THIS

POWER UNIT.

During operation, the engine may bog,

run at lower rpm, when under load. As

the tool being used is loaded, meets with

increase resistance, the pressure required

to operate the tool increases. The

increased pressure adds load to the pump

which loads the engine, there by

reducing the RPMS. As a result, the

flow will drop as pressure increases.

The hydraulic system has a pressure

limiter set at 148 BAR (2150 PSI) which

diverts the flow back to the tank until the

pressure drops below 148 BAR (2150

PSI.)

Tools with higher flow and, or pressure

requirements will not operate at their full

potential if used with the PortaCo

Hydraulic Power Unit. Tools with lower

flow and or pressure requirements may

be damaged if used with this power unit.

The engine throttle and the hydraulic

system relief value are preset at the

factory and must not be altered for any

reason without consulting PortaCo Inc.

Any alterations approved by PortaCo

Inc., can only be preformed by personnel

qualified to maintain hydraulic systems.

Tools which are commonly used with

PortaCo’s Pioneer series Hydraulic

power unit are as follows:

Impact Wrenches

Impact Drills

Picks

Handheld grinders

Breakers

Tampers

Hand Held Saws

Hand Held Pruners

Do not use the Pioneer series power unit

with close-center tools, tools which do

not allow the oil to return to the power

unit when not activated. Do not use in

jacking operations. Do not use to

activate cylinders without an inline

open-center control system. Do not

operate without a return oil hose.

If there are any doubts weather your tool

can be used with the Pioneer series unit

please contact the service department at

PortaCo Inc. (218-236-0223) for advice.

PortaCo Inc. accepts NO responsibility

for machines that are used for any

purpose other than the intended purpose

as specified in the operating instructions

or approved directly by PortaCo Inc.

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