PortaCo G-09, G-11, G-13 Operation, Maintenance, And Repair Manual

Hydraulic Power Unit

Pioneer Series

G-09, G-11, G-13

1805 2ndAVENUE NORTH * MOORHEAD, MN, USA 56560-2310

E-MAIL ADDRESS; [e-mail] * INTERNET ADDRESS: www.portaco.com

OPERATION,

MAINTENANCE,

AND REPAIR MANUAL

PHONE [phone] * FAX [phone]

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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

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1.0 INTRODUCTION

1.1 General Information

CAUTION: DO NOT USE CLOSED­CENTER TOOLS WITH THIS
POWER UNIT

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).

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)

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 self­contained with the required reservoir,
filtration and level indicators.

(Fig. 1.2A)

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LIFT HERE

1.3 Options

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.

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 ifoperated according
to the instructions provided in this

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,

5

EQUIPMENT OR LOSS OF
MISSION EFFECTIVENESS.

See engine manual for recommended oil
and checking procedures.

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.

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)

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.

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

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The following fluids work well over a

Type

Hydraulic fluid

Chevron

“Clarity” AW 15032

Exxon

“Univis” J 32

Mobil

D.T.E. 13

M

Gulf

“Harmony” AW

-

HVI-150-32

Shell

“Tellus T” 32

Texaco

“Rando” HDZ 32

Union

“Unax” AW

-WR-32Amsoil

AWH 15032

Sunvis

Low Pour H/032

-

product code 19300

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.

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.

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.

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

- 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.

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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.

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.

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 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 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.

The rated working pressure of the
hydraulic hose must be at least 175 bar
(2500 PSI.)

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HYDRAULIC HOSE RECOMMENDATIONS

Table 2.6A

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

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

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

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

Return

5/8
3/4

5/8
3/4

3/4
1

16
19

16
19

19

25.4

(WIRE BRAID)

SAE 100R2-10
SAE 100R1-12

SAE 100R2-10
SAE 100R3-12

SAE 100R2-12
SAE 100R1-16

SAE SPEC

HOSE (FIBER

BRAID)

SAE 100R8-10
SAE 100R7-12

SAE 100R8-10
SAE 100R7-12

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.