YZA10-20/2D Hydraulic Power Unit

Installation and
Maintenance Manual

JIANGXI HUAWU BRAKE CO., LTD.

Version No.： 1.0 Date： Dec. 1 s t , 2012

 Contents
1. Limited Warranty…………………………………………………..（ 3）

2. General ……………………………………………………………（ 3）

3. Installation and adjustment………………………………………..（ 5）

§3.1 Preparations before installation………………………………（ 5）

§3.2 Installation……………………………………………………..（ 7）

§3.3 Adjustment …………………………………………………...（ 8）

4. Operation and Maintenance……………………………………….（ 9）

§4.1Operation ………………………………………………………（ 9）

§4.2Maintenance…………………………………………………….（ 9）

§4.2.1 Replace oil and clear the system…………………………..（ 9）

§4.2.2 Replace pipeline filter element ………………………………（ 10）

§4.2.3 Replace accumulator…………………………………………（ 10）

§4.3 Daily check …………………………………………………..（ 11）

5. Parts list…………………………………………………………..（ 12）

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1. Limited Warranty

Our company warrants that the product will be free from defects in design, produce, materials
and workmanship for one year from the date on which the product is delivered to the purchaser.
Within the warranty period, our company’s responsibility is to replace or restore the product that
has been confirmed which is defective after test in our company, but the original purchasers must
keep the product is intact and carry it to our company or to our company’s authorized service
stations. Except as stated in this limited warranty our company does not make and
disclaims all express or implied warranties, including (but not limited to) its fitness for a
particular purpose, its design, condition or workmanship.

Our company will not be liable for any special, indirect, incidental damages, including
without limitation: transportation costs, loss of profits, property damage, lost production,
loss of life or body injury. Our company’s maximum liability under any circumstances will be
the purchase price of the product paid by the original purchaser.

If the product is damaged due to installing and maintaining not complying with the manual,
misuse or incorrect operation and accident, our warranty will not be valid.

Only maintain or operate the product after read and understand thoroughly the manual and
warning on the product warning marks (if have). However, such warning information can’t
ensure to forecast all possible mishaps or accidents, so the user is obligated to try to find out
dangerous state under the product work normally, and to maintain or care correctly.

2. General
This hydraulic power unit is applied on boat and used for driving the oil cylinder of hydraulic
normally-open brake on main shaft of propeller. System is set with pressure-holding function,
having certain leakage compensating capacity. System is equipped with hand pump, which can
be used when powered off and emergency occurred.
Outline and mounting dimensions of this series hydraulic power unit are same; some additional
devices can be added. Structure of hydraulic power unit see figure 1 (with protective cover).

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 Technical parameters see table 1： Table 1
data Charge
Motor Relay Pressure of
pressure Flow pressure of
power pressure overflow Remark
type (MPa) (L/min) accumulator
(KW) (MPa) valve (MPa)
(MPa)
YZA10-20/2D 10 20 5.5 9.5/7.5 10 7±0.2

Fig.1
1. motor 2.hand pump 3.pump 4.oil tank 5.hydraulic switch (optional) 6.air filter 7.overflow valve 8.oil return

filter 9.heater(optional) 10.temperature sensor(optional) 11.oil-draining valve 12.accumulator 15.temperature

switch (optional) 16.pressure gauge 17.pressure relay 18.junction box 19.manual ball valve
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Hydraulic schematic diagram see figure 2, wiring diagram see figure 3, working principle as
follows:
a． When the motor is switched on and the solenoid directional valve is switch off, the system
supply pressure oil to accumulator until pressure relay set a pressure, and then the switch of
pressure relay control the motor to stop running;
b． When the motor and solenoid reversal valve coil YV1 are switched on and YV3 is switched
off, the system supply oil to the oil cylinder one by oil way one. After the oil cylinder finished
action, pressure goes on rising until pressure relay set a pressure and send signal to make the
motor switch off, solenoid valve coil YV1 is switched on and YV3 is switched off, oil cylinder is
kept at oil-taking pressure-holding state at this time, and leaking oil in system can be
compensated by accumulator. At this moment, system is in oil circuit 1 pressure-holding
position.
c． When the motor and solenoid directional valve coil YV2 are switched on and YV3 isn’t
switched on, the system supply oil to the oil cylinder in oil circuit 2. After the oil cylinder
finished action, pressure goes on rising until pressure relay set a pressure and send signal to
make the motor switch off, when solenoid valve coil YV2 is switched on and YV3 is switched
off, oil cylinder is kept at oil-taking pressure-holding state at this time, and leaking oil in system
can be compensated by accumulator. At this moment, system is in oil circuit 2 pressure-holding
position.
d． When motor and solenoid directional valve de-energized at the same time, YV3 will be
energized, system unload, and brake is in release condition.
e． When coil of solenoid valve YV3 burnt out and brake cylinder required discharging pressure,
completely open throttle valve (6.2) will be okay.
f． In order to avoid brake cylinder supplying oil too quick and impact being too big when
brake braked, adjusting throttle valve (6.1) can be used to control flow rate.

3. Installation and adjustment

Hydraulic power unit should be correctly adjusted, otherwise which will effect normal operation,
therefore, when make adjustment, please do referring to methods and steps in this manual. If
need help, please contact our after-sale service department.
3.1 Preparations before installation
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a. Check the mark of the hydraulic power unit; see if the data comply with the standards;
b. Check if the painting on the surface has damage, if so, please repair;
c. Check if the valve block and cover are damaged, if so, please change immediately;
d. If need with pipeline parts during ordering, please account the number and see if the
specification is up to the standards.
If above all check are ok, then you can install.

Fig. 2

Fig. 3
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3.2 Installation
When lifting hydraulic power unit, please refer to fig 4, prevent from damaging the inner
part!
Mounting dimensions of hydraulic power unit see figure 4, installation please refer to the
following steps:

Fig.4
a. Horizontally lift the hydraulic unit to the mounting position,
electric control box and hand pump face towards the direction
where can be operated conveniently;
b. Find correct mounting position, correctly install the anchor
bolt and fix it.
c. Connect electric circuit. (Note: all wiring joints must pass
through the cable gland and enter into terminal box).
d. Connect hydraulic pipeline
Two same oil outlet (refer to fig.1 and fig.5) on hydraulic valve
block, the connect-into steel pipe is R15 x 1.5VZ Parker steel
pipe (or high-precision 10＃cold drawing seamless steel pipe, its
outer diameter isφ15)
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e. Open the cover of air filter (refer to figure 1), use such filter that filtrate accuracy less 20μm,
and pour fresh hydraulic oil into oil tank (brand No. of hydraulic oil is L-HM32 (for the possible
working environment with temperature lower than -10℃, L-HV32 hydraulic oil can be used).
Oil height is 2/3 visible height of level gauge (about 63 liter)
Note: if the pipeline is too long, some hydraulic fluid in pipeline should bypass flow during
first operation so that oil level of oil tank will drop, so oil should be added after running-in,
but don’t fill the oil tank fully (considering that oil will spill out when hydraulic oil return)!
f. Upward turn the handle of two three-way reversal ball valves (Pos.1 in fig.1) to the end (such
state already exist before being delivered), at first move slightly to confirm that the turn direction
of the motor (already marked the rotated direction on the tail of the motor). Looking from the
motor tail, the fan’s clockwise direction is correct.
g. After confirm that the turn direction of motor is correct, begin to switch on and adjust the data,
the install working is finished.
3.3 Adjustment
The hydraulic unit has been well-adjusted before delivery. When found any abnormality and
after maintaining, please make adjustment according to the following steps:
a. Pressure adjustment of overflow valve: Close power supply of hydraulic power unit, tighten
the adjusting screw of pressure relay (Pos.16 in figure 1) 2-3 coils, increase the pressure of
system motor; loosen overflow valve (in figure 1), adjust the pressure (see P0 position on
pressure gauge) of overflow valve to let the pressure comply with the value specified in table 1.
When turn the regulating rod of the overflow valve, at first should shut off the power supply of
the hydraulic power unit, after adjust one time, switch on and observe the system pressure. If it
isn’t in accordance with requirements, shut off and adjust again until it accord with the value in
table 1. Return the adjusting screw of pressure relay, and then tighten the screw nut on the
regulating rod of the overflow;
b. Switchover pressure adjustment of pressure relay: The motor is electrified, observe system
pressure (refer to the P0 on pressure gauge, which are well adjusted before delivery), switch of
pressure relay acts to control the motor to stop running. If switchover pressure of relay isn’t right,
power supply should be shut off to turn the adjust screws on pressure relay, make it accords with
the specified value in table 1.
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c. After finished adjustment, switch of pressure gauge should be turn to neutral position, namely
dial plate point at 0 (operating condition).

4. Operation and maintenance

4.1 Operation
Hydraulic unit should be operated several times as to expulse the air in the route and
hydro-cylinder before the hydraulic unit put into use formally, and add oil to tank. After
everything is ok, the hydraulic unit can be put into use.
If need braking when in switch-off state, the hand pump can be operated as follows:
If oil circuit 1 (connect main hoist brake) need to input oil by hand, open the right hand lever of
three-way optional ball valve (Pos.19 in fig.1) to a horizontal position, up and down operate the
rocker arm of hand pump (Pos.2 in fig.1) to supply oil to the pipeline of oil circuit 1. Operate
hand pump by using a galvanized steel pipe (outer diameter is 20mm, length is about 500mm),
such galvanized steel pipe is at the bottom right corner of protective cover of oil tank). After the
oil cylinder in oil circuit 1 operate correctly, don’t operate hand pump any more to avoid too high
pressure damaging pipe parts!
When oil cylinder restored, so long as let the hand directional valve restore to its normal working
condition (pull it upward), namely the oil-return way is connected thorough. After hand pump
finished its operation, the rocker arm should be pressed to the bottom to avoid pump plunger
being corroded and exposed in air.
Note: when hand pump is opened to a proper position, please don’t continually press oil
with hand pump, to avoid the too high pressure damaging pipeline system!
If oil circuit 2 (connect boom pitching mechanism) need to input oil by hand, open the left hand
lever of three-way optional ball valve to a horizontal position. Operating methods is the same as
above.
4.2 Maintenance
4.2.1 Replace hydraulic oil and clean system
Hydraulic oil must be changed after first used for 6 months, cleaning system (oil suction filter,
oil tank, etc.). After first cleaning, it suggests that hydraulic unit must be cleaned every one year
and replace hydraulic oil one time every year (no matter whether the hydraulic oil is dirty or not),
this work can be done according to the following steps:
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a． Unscrew oil-draining valve (Pos.11 in fig.1) to exhaust out the hydraulic oil in oil tank.
Unscrew the bolts on cover plate of oil tank, entirely lift up the motor, valve blocks and cover
plate by hoisting rope entering through the lifting ring of motor and eye bolt on cover plate;
Note: don’t lift with other parts except eye bolt!
b． Clean the oil tank cave, pump and oil pipe. Dismantle the oil suction filter from pump,
cleaning it with clean oil. If the contaminant is too much to clean, should change the new oil
suction filter;
c． Correctly install cover plate of oil tank (including valves), well-connect pipeline, take down
the cover of air filter (Pos.6 in figure 1), pour oil (oil brand see 3.2e) into hydraulic unit through
filter screen, height of hydraulic oil should observe the regulations in 3.2e, properly tighten the
cover of air filter;
d． Start-up to test run，observe whether pressure and work are normal or not，otherwise adjust
according to the methods in section 3.3.
4.2.2 Replace pipeline filter element
If found the indicator of oil return filter (Pos.8 in fig.1) indicates yellow (it’s normal when
indicated green, filter is severely blocked when indicated red, it’s in transition phase when
indicated yellow), which means that the oil return filter begin to be blocked, it’s necessary to
clear the system and replace with new hydraulic oil (do as 4.2.1). And the filter element also
must be washed or replaced, methods as follows: unscrew the top filter cover that can fix filter,
wash or replace filter, finally install the filter cover back.
4.2.3 Replace accumulator
If found the pressure-holding performance falling off (motor start up frequently) when hydraulic
power unit works, at this moment we should check whether the pipeline is leaked or the
accumulator is damaged. If accumulator were damaged, please change it and the replacing
methods as follows:
a． Loosen overflow valve (in fig. 1) to adjust the locknut on adjusting rod, anti-clockwise turn
the adjusting rod with inner hexagonal spanner S=4 to the end, drain out the possible residual
high-pressure oil in accumulator.
b．Lock the square port on the foundation of accumulator with spanner and anticlockwise rotate
the spanner (see from up to down), remove accumulator to check whether the air bag or other
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parts are damaged, if damaged, please repair or replace them.
c． After re-install the new or well-repaired accumulator which is fully filled with nitrogen
(inflation pressure see the technical parameters specified in table 1), adjust the pressure of
overflow valve to a proper value (refer to 3.3), finally tighten the locknut.
Note: when wash or maintain, the accumulator should be removed according to the
methods in this section!
4.3 Daily check
Following items must be checked every 100~150 hours:
a． The indication of the hydraulic oil;
b．Check if each connecting point at pipe parts become loose;
c． Check if oil leaked or not;
d．Check if abnormal noise has happened on motor, pump and valves when operated;
e． Check if smudgy-indicator of pipe filters points at red, if so, it necessary to change filter
element and clear system.
If found any abnormal, please stop operating hydraulic power unit, and only after the problems
has been solved can the hydraulic power unit be put into use.

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5. Parts list

Part No. Part Name Specification & Type (Qty) Remark

1 Solenoid directional valve SV10-20-0-N-230AG(3) DC:24V

2 Pressure relay HED3OA3X/200K

3 Pressure-measuring joint EMA3/M10×1ED(1)
4 Accumulator NXQ-2.5/10(1)
5 Three-way optional ball valve KH3/2-15L(2)
6 Oil return filter RFA-40×20L-Y(1)
7 Level gauge YWZ-80T(1)

8 Hand pump SB-1-20W(1)

9 Air filter EF3-40(1)
10 One way valve RHV15LMEDA3C(1)
11 Pump PV2R1-14-FRAA-40(1)
12 Motor M2QA132S4A(1) 50Hz
13 Oil suction filter WU-100×100-J(1)

14 Oil tank 63L(1)

15 Pressure gauge & switch 213.53-063/25Mpa-R-M14X1.5-F STAUFF

Note: only use the spare parts provided or recognized by our company, the performance of
products can be ensured.

JIANGXI HUAWU BRAKE CO., LTD.

Market information
Tel： 0795-6201884 6203474
Fax： 0795-6201896
E-mail： zpmc.hua-wu.com
Technical support
Tel： 0795-6242071 0795-6242070
After-sale service
Tel： 0795-6201939
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