VEVOR Hydraulic Power Unit

Introduction

This document provides original instructions for the VEVOR Hydraulic Power Unit. Please read all manual instructions carefully before operating. VEVOR reserves the right to interpret its user manual. The appearance of the product is subject to what you receive. VEVOR will not provide further notice for technology or software updates.

⚠️ Warning: To reduce the risk of injury, users must read the instructions manual carefully.

Correct Disposal

This product is subject to European Directive 2012/19/EC. The symbol ?️ (wheelie bin crossed through) indicates that the product requires separate refuse collection in the European Union. This applies to the product and all accessories marked with this symbol. Products marked as such must not be discarded with normal domestic waste but must be taken to a collection point for recycling electrical and electronic devices.

This product is of protection class III.

DC: Direct current

Instructions

The hydraulic power unit integrates a high-pressure gear pump, DC motor, multi-purpose integrated block, various hydraulic valves, oil tank, and other components. It operates as a typical hydraulic circuit for power up and power down. The second relief valve controls downward pressure, and the pressure-compensated flow valve automatically adjusts the falling speed. This product is widely used in small dump trucks, hydraulic winches, etc.

Care Instructions

• The battery power must be sufficient, with a current of 200A and voltage to match the machine.
• This vehicle hydraulic pump is an S3 working system, not for continuous operation. Recommended operation: 30 seconds to start, 270 seconds to stop. The maximum working time is 180 seconds. Intermittent continuous working time exceeding 360 seconds is too long and may cause motor short circuit or damage.
• When the hydraulic power unit leaves the factory, the system pressure is pre-set. If adjustments are needed, users can adjust the system pressure via a pressure regulator knob according to the actual situation, but it must not exceed the nominal pressure (16 MPa) of the system.
• Check the connection of the motor and electromagnetic valve carefully; virtual connections are strictly forbidden.
• During initial installation and debugging, ensure the oil level inside the oil tank is maintained. After a working cycle, the oil tank should be filled but not overfilled.
• The motor terminal box should be waterproof and moisture-proof. When connecting for the first time, inch the motor to carefully check its direction. From the rear end of the motor, the rotation direction is counterclockwise. Reversing the motor rotation or running without oil is absolutely forbidden.
• The hydraulic oil must be filtered when filling the oil tank, with a filtering accuracy of no less than 25μm.
• The power unit cannot filter impurities inside the hydraulic cylinder. Therefore, the inside of the hydraulic cylinder must be clean to prevent valve failure. The tubing must also be clean.

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Technical Parameters

Parts Illustration

The Hydraulic Power Unit is fully assembled and includes a hand-held remote control and 2 additional SAE#6 connectors. The unit is designed for easy wiring and operation.

Part List

Diagram shows a VEVOR hydraulic power unit with various components labeled numerically. Key components visible include the motor, reservoir, valves, and control box with buttons.

Working Principle and Wiring Method

1. Fill hydraulic oil from reservoir filler (13) until it is 3cm to 5cm below the upper surface of the reservoir.
2. Connect the positive pole of the power supply to the positive pole of the relay, and the negative pole of the power supply to the negative pole of the electronic motor. The power supply wire must be copper wire with a cross-sectional area of 20 to 25 mm².
3. Connect the power supply correctly and then install the oil pipelines. Press the Up button (17) to turn on the motor. The indicator light for electromagnetic coil A (7) should be lit. The two-position four-way valve (9) opens, allowing oil discharge via the reservoir outlet port (14). This generates pressure and causes the reservoir to rise. Release the Up button; the motor will stop, and the oil pump and reservoir will remain stationary.
4. At the end of the hydraulic cylinder's travel, press the Down button (18) for oil return. This turns on the motor and causes the indicator light for electromagnetic coil B (8) to illuminate. Magnetic force is generated to push on the normally closed electromagnetic valve (10), allowing oil to return and the cylinder to go down.

Common Failures and Troubleshooting

1. Unit does not rise (advance) or rises unstably.

• a. If the oil level is too low in the oil tank, add oil to the specified level.
• b. The hydraulic power unit should use anti-wear hydraulic oil with a kinematic viscosity of 22-46mm²/s (50°C). ISO VG46 is recommended for temperatures below 50°C, and ISO VG68 for temperatures above 50°C. Added oil should be filtered to an accuracy of 30μm. Oil volume should be 80% of the oil tank's effective capacity. Oil temperature is typically between -10°C to 80°C. Low-temperature hydraulic oil (e.g., ISO VG32) should be used in extremely cold areas. These measures prolong the service life and improve the stability and reliability of the hydraulic power unit and its components.
• c. Blocked oil filter screen: Wash or replace the filter screen.
• d. Unsealed or leaking oil suction pipe: Check for leaks or unsealed places and repair or replace the pipe.
• e. Unclosed electromagnetic valve or hand valve: Wash the electromagnetic valve and hand valve, or replace the oil.

2. Unit does not drop or drops unstably.

• a. Blocked electromagnetic valve or hand valve filter screen: Clean the filter screen and electromagnetic valve.
• b. Blocked throttle valve: Adjust the throttle valve.

3. Unit does not pressurize.

• a. Unsealed check valve: Wash the check valve or replace the oil seal and oil.
• b. Unsealed electromagnetic valve or hand valve: Clean the electromagnetic valve and hand valve, or replace the oil seal and oil.

Simple Commissioning Diagram

Diagram shows a close-up of hydraulic valve adjustments. One section indicates adjusting a throttle valve: clockwise to slow down, counterclockwise to speed up. Another section indicates adjusting pressure: clockwise to increase pressure, counterclockwise to decrease pressure. Dimensions and connection types (e.g., M10X20) are indicated.

Schematic Diagram

Diagram illustrates the overall layout of the hydraulic power unit components, including the motor, reservoir, valves, and remote control. It shows fluid flow paths and component connections. Dimensions are provided, such as Ø114 for the reservoir diameter and 176, 210, 178 for various lengths.

Durable Compact Structure

Will not leak or be easily damaged.

Component Labels: Electric Motor, Electromagnetic Coil B, Normally Closed Solenoid Valve, Overflow Valve, 8 Quart Reservoir, Oil outlet, Reservoir Filler, 15 Ft Cable Wire, Remote Control, The Negative Pole of the Electronic Motor, The Positive pole of the Electronic Motor, Electromagnetic Coil A.

DC Motor Electric Wiring Diagram

Diagrams illustrate the electrical connections for the DC motor. It shows the motor, start relay, K operation switch, connection bar, and battery. Two types, Type A and Type B, are shown, differentiating how wires are connected. A legend indicates which wires are user-connected and which are pre-connected at the factory.

Parts Illustration - Type 1

Exploded view diagram of Type 1 hydraulic power unit components, with numbered parts.

Parts Illustration - Type 2

Exploded view diagram of Type 2 hydraulic power unit components, with numbered parts.

Parts Illustration - Type 3

Exploded view diagram of Type 3 hydraulic power unit components, with numbered parts.

Parts Illustration - Type 4

Exploded view diagram of Type 4 hydraulic power unit components, with numbered parts.

Parts Illustration - Type 5

Exploded view diagram of Type 5 hydraulic power unit components, with numbered parts.

Parts Illustration - Type 6

Exploded view diagram of Type 6 hydraulic power unit components, with numbered parts.

Maintenance

1. Actuators and pipelines should be kept clean to prevent the introduction of foreign material into the system.
2. The reservoir should be adequately filled with oil. Proper refilling is needed after certain working circles. It may damage the oil pump and the enclosure if the oil pump sucks air.
3. The hydraulic oil should be replaced upon working for 100 hours since the initial filling. Subsequently, the hydraulic oil should be replaced once per year or at about 1500 working hours.
4. The viscosity of the hydraulic oil should be 22-46mm²/s.
5. High-viscosity hydraulic oil should be used in high-temperature working environments, while low-viscosity hydraulic oil should be used in low-temperature environments.