MultiFlow Hydraulic Powerpack - file.yizimg.comfile.yizimg.com/196154/2007112711140589.pdf · P95 OPERATOR’S MANUAL 4 SYMBOLS & LABELS THE FOLLOWING SYMBOLS & DEFINITIONS ARE FOUND

F/N 521599 Oct 07 © 2007 ICS, Blount Inc.

OPERATOR’S MANUAL

P95 MultiFlow Hydraulic Powerpack


P95 OPERATOR’S MANUAL

3

TABLE OF CONTENTS

SYMBOLS & LABELS 4

SAFETY 5

TECHNICAL SPECIFICATIONS 6

LABELS 7

REQUIREMENTS 8

OPERATION 10

MAINTENANCE 15

CONTROLLER / FAULT CODES 16

TESTING 18

TROUBLESHOOTING 19

© 2007 ICS, Blount Inc. F/N 521599 Oct 07


4

SYMBOLS & LABELS

THE FOLLOWING SYMBOLS & DEFINITIONS ARE FOUND THROUGHOUT THIS MANUAL AND ARE DESIGNED TO MAKE YOU AWARE OF POTENTIAL HAZARDS OR UNSAFE PRACTICES.

A potentially hazardous situation exists which, if not avoided, could result in death or serious injury.

A potentially hazardous situation exists which, if not avoided, may result in minor or moderate injury or property damage.

A potential situation exists which, if not avoided, may result in product or property damage.

THE FOLLOWING SYMBOLS & LABELS MAY BE FOUND IN THIS MANUAL OR ON THE SAW

Read the operator’s manual carefully and understand the contents before you use this equipment.

Always use: • Protective helmet • Ear protection • Protective glasses or full face protection

Wear hand protection

IMPORTANT

WARNING

CAUTION



5

SAFETY

GENERAL SAFETY PRECAUTIONS

• Operator must start in a work area without bystanders. The operator must be familiar with all prohibited work areas such as excessive slopes and dangerous terrain conditions.

• Establish a training program for all operators to ensure safe operation.

• Do not operate the power unit unless thoroughly trained or under the supervision of an instructor.

• Always wear safety equipment such as goggles, ear, head protection, and safety shoes at all times when operating the power unit and a hydraulic tool.

• Do not inspect or clean the power unit while it is running. Accidental engagement of the unit can cause serious injury.

• Alwaysusehosesandfittingsratedat2500psi(172bar)witha4to1safetyfactor.Besureallhoseconnectionsare tight.

• Besureallhosesareconnectedforcorrectflowdirectiontoandfromthetoolbeingused.

• Donotinspecthosesandfittingsforleaksbyusingbarehands.“Pin-hole”leakscanpenetratetheskin.

• NEVEROPERATETHEPOWERUNITINACLOSEDSPACE.Inhalationofengineexhaustcanbefatal.

• Do not operate a damaged, improperly adjusted power unit.

• Never wear loose clothing that can get entangled in the working parts of the power unit.

• Keep all parts of your body away from the working parts of the power unit.

• Keep clear of hot engine exhaust.

• Do not add fuel to the power unit while the power unit is running or is still hot.

• Do not operate the power unit if gasoline odor is present.

• Donotuseflammablesolventsaroundthepowerunitengine.

• Donotoperatethepowerunitwithin3.3ft(1m)ofbuildings,obstructionsorflammableobjects.

• Donotreversetoolrotationdirectionbychangingfluidflowdirection.

• Allow power unit engine to cool before storing in an enclosed space.

• Always keep critical tool markings, such as labels and warning stickers legible.

• To avoid personal injury or equipment damage, all tool repair, maintenance and service must only be performed by authorized and properly trained personnel.



6

TECHNICAL SPECIFICATIONS

Engine 18 hp Briggs

CapacityOne5gpm(19l/min)CircuitOne8gpm(30l/min)Circuit

Length 36inches(91.4cm)

Width 23inches(58.4cm)

Height 29.5inches(74.9cm)

Weight(wet) 330lbs(149.6kg)

Fuel Tank Capacity 7gal(26.5ltr)

Esitmated Gas Consumption perHour

1.3gal(4ltr)

HydraulicReservorCapacity

3gal(11ltr)

Releif Valve "crack"Setting

2,100psi(145bar)

Full Relief Setting 2,500psi(172bar)

HTMACategory"C"(20l/min@138bar)"D"(30l/min@138bar)

SoundPowerLevel 104 dBA



7

LABELS

TOOLS STICKERS AND TAGS

ICS® Dash Decal

Single Curcuit

Single Curcuit



8

REQUIREMENTS

HYDRAULIC HOSE REQUIREMENTS

HydraulichosetypesauthorizedforusewiththeP95areasfollows:

• Certifiednon-conductive

• Wire-braided(conductive)

• Fabric-braided(notcertifiedorlabelednon-conductive)

Hoselistedaboveistheonlyhoseauthorizedforusenearelectricalconductors.

Hoseandlistedaboveareconductiveandmustneverbeusednearelectricalconductors.

HOSE SAFETY TAGS

To help ensure your safety, the following DANGER tags are attached to all hoses purchased from ICS.

DONOTREMOVETHESETAGS

If the information on the tag is illegible because of wear or damage, replace the tag immediately. A new tag maybe obtained from your ICS Distributor.

1

23

1

23

1

23

1

23

1

23

1

23

THE TAG SHOWN BELOW IS ATTACHED TO "CERTIFIED NON-CONDUCTIVE" HOSE

THE TAG SHOWN BELOW IS ATTACHED TO "CONDUCTIVE" HOSE

DO

NO

T R

EM

OV

E T

HIS

TAG

D A N G E R

S I D E 2

3. DO NOT EXCEED HOSE WORKING PRESSURE OR ABUSE HOSE. IMPROPER USE OR HANDLING OF HOSE COULD RESULT OR OTHER HOSE FAILURE. KEEP HOSE AS FAR AWAY AS POSSIBLE FROM BODY AND DO NOT PERMIT DIRECT CONTACT DURING HOSE. CONTACT AT THE BURST CAN CAUSE BODILY INJECTION AND SEVERE PERSONAL INJURY.

4. HANDLE AND ROUTE HOSE CAREFULLY TO AVOID KINKING, ABRASION, CUTTING OR CONTACT WITH HIGH TEMPERATURE SURFACES. DO NOT USE IF KINKED. DO NOT USE HOSE TO PULL OR LIFT TOOLS, POWER UNITS, ETC.

5. CHECK ENTIRE HOSE FOR CUTS CRACKS LEAKS ABRASIONS, BULGES, OR DAMAGE TO COUPLINGS IF ANY OF THESE CONDITIONS EXIST, REPLACE THE HOSE IMMEDIATELY. NEVER USE TAPE OR ANY DEVICE TO ATTEMPT TO MEND THE HOSE.

6. AFTER EACH USE, STORE IN A CLEAN DRY AREA.

D A N G E R

S I D E 1

DO

NO

T R

EM

OV

E T

HIS

TA

G

1. FAILURE TO USE HYDRAULIC HOSE LABELED AND CERTIFIED AS NON-CONDUCTIVE WHEN USING HYDRAULIC TOOLS ON OR NEAR ELECTRIC LINES MAY RESULT IN DEATH OR SERIOUS INJURY.

2. FOR PROPER AND SAFE OPERATION, MAKE SURE THAT YOU HAVE BEEN PROPERLY TRAINED IN CORRECT PROCEDURES REQUIRED FOR WORK IN OR AROUND ELECTRICAL LINES.

3. BEFORE USING HYDRAULIC HOSE LABELED AND CERTIFIED AS NON-CONDUCTIVE ON OR NEAR ELECTRICAL LINES, WIPE THE ENTIRE LENGTH OF THE HOSE AND FITTING WITH A CLEAN DRY ABSORBENT CLOTH TO REMOVE DIRT AND MOISTURE AND TEST HOSE FOR MAXIMUM ALLOWABLE CURRENT LEAKAGE IN ACCORDANCE WITH SAFETY DEPARTMENT INSTRUCTIONS.

DO

NO

T R

EM

OV

E T

HIS

TAG

D A N G E R

S I D E 2




D A N G E R

S I D E 1

DO

NO

T R

EM

OV

E T

HIS

TA

G

1. THIS HOSE NOT LABELED OR CERTIFIED AS NON-CONDUCTIVE WHEN USING HYDRAULIC TOOLS ON OR NEAR ELECTRIC LINES MAY RESULT IN DEATH OR SERIOUS INJURY.



DO

NO

T R

EM

OV

E T

HIS

TAG

D A N G E R

S I D E 2





D A N G E R

S I D E 1

DO

NO

T R

EM

OV

E T

HIS

TA

G

1. FAILURE TO USE HYDRAULIC HOSE LABELED AND CERTIFIED AS NON-CONDUCTIVE WHEN USING HYDRAULIC TOOLS ON OR NEAR ELECTRIC LINES MAY RESULT IN DEATH OR SERIOUS INJURY.


3. BEFORE USING HYDRAULIC HOSE LABELED AND CERTIFIED AS NON-CONDUCTIVE ON OR NEAR ELECTRICAL LINES, WIPE THE ENTIRE LENGTH OF THE HOSE AND FITTING WITH A CLEAN DRY ABSORBENT CLOTH TO REMOVE DIRT AND MOISTURE AND TEST HOSE FOR MAXIMUM ALLOWABLE CURRENT LEAKAGE IN ACCORDANCE WITH SAFETY DEPARTMENT INSTRUCTIONS.

DO

NO

T R

EM

OV

E T

HIS

TAG

D A N G E R

S I D E 2




D A N G E R

S I D E 1

DO

NO

T R

EM

OV

E T

HIS

TA

G

1. THIS HOSE NOT LABELED OR CERTIFIED AS NON-CONDUCTIVE WHEN USING HYDRAULIC TOOLS ON OR NEAR ELECTRIC LINES MAY RESULT IN DEATH OR SERIOUS INJURY.





9

REQUIREMENTS

HTMA REQUIREMENTS

TOOL CATEGORYHydrualic System Requirements

TYPE I TYPE II TYPE III TYPE RRFlow Rate 4-6gpm

(15-23l/min)7-9gpm

(26-34l/min)11-13gpm(42-49l/min)

9-10.5gpm(34-40l/min)

Tool Operating Pressure(atthepowersupplyoutlet)

2000 psi (138bar)

2000 psi(138bar)

2000 psi(138bar)

2000 psi(138bar)

System Relief Valve Setting(atthepowersupplyoutlet)

2100-2250psi(145-155bar)

2100-2250ps(145-155bar)i

2100-2250psi(145-155bar)

2200-2300psi(152-159bar)

Maximum Back Pressure(atthetoolendofthereturnhose)

250 psi(17bar)

250 psi(17bar)

250 psi(17bar)

250 psi(17bar)

Measured at max. fluid viscosity of:(atmin.operatingtemperature)

400SSU*(82CST)**

400SSU*(82CST)**

400SSU*(82CST)**

400SSU*(82CST)**

TemperatureSufficient heat rejection capacity to limit max.fluidtemperatureto:(atmax.expectedambienttemp.)

140˚F(60˚C)

140˚F(60˚C)

140˚F(60˚C)

140˚F(60˚C)

Minimum Cooling Capacity(atatemperaturedifferenceofbetweenambientandfluidtemps)

3hp(2.24kW)40˚F(22˚C)

5hp(3.73kW)40˚F(22˚C)

7hp(4.47kW)40˚F(22˚C)

6hp(5.22kW)40˚F(22˚C)

NOTE: DO NOT operate the tool at oil temperature above 140˚ F (60˚ C). Operation at higher temperatures can cuase operator discomfort at the tool.

Filter 25 microns 25 microns 25 microns 25 microns

Minimum Full-Flow FiltrationSizedforFlowatLeast:(forcoldtemp.start-upandmax.dirtholdingcapacity)

30 gpm (114l/min)

30 gpm (114l/min)

30 gpm(114l/min)

30 gpm(114l/min)

Hydraulic Fluid(Petroleumbased;premiumgrade,anti-wear,nonconductive)

100-400SSU*(20-82CST)**

100-400SSU*(20-82CST)**

100-400SSU*(20-82CST)**

100-400SSU*(20-82CST)**

NOTE: When choosing hydraulic fluid, the expected oil temperature extremes that will be experienced win service determine the most suitable temperature viscosity characteristics. Hydraulic fluids with a viscosity index over 140 will meet the requirements over a wide range of operating temperatures.

*SSU=SayboltSecondsUniversal**CST=Centistokesl

NOTE: These are general hydraulic sysem requirements. See tool Specification page (page 6) for tool specific requirements.

C20l/min@138bar

BHTMACATEGORY

D30l/min@138bar

BHTMACATEGORY



10

OPERATION

OPERATION

Do not operate the power until you have read the operating manual.

1. CrankcaseOilLevel:Alwayschecktheoillevelbeforestartingtheengine.MakesuretheoillevelisattheFULLMARKonthedipstick.Donotoverfill.Usedetergentoilclassified“ForServiceSE,SF,SG”asspecifiedintheengine operating and maintenance manual. See engine manual for oil viscosity grade.

2. EngineFuelLevel:Checkthefuellevel.Iflow,fillwithun-leadedgasolinewithaminimumof85octane.

3. HydraulicFluid:Checkthedipstickinthehydraulicfluidreservoirfortheproperfiuidlevel.Usefluidsmeetingthefollowingspecifications.

U.S.A. Metric

50˚F-450SSUMaximum 10˚C-95CSTMaximum

100˚F-130-200SSU 38˚C-27-42CST

140˚F-85SSUMinimum) 60˚C-16.5CSTMinimum

PourPoint -10˚F(-23˚C)Min.(coldstartup)

Viscosity Index (ASTMD-2220)140Min.

Demulsibility (ASTMD-1401)30MinutesMax.

FlashPoint (ASTMD-92)340˚F(171˚C)Min.

Rust Inhibition (ASTMD-665A&B)Pass

Oxidation (ASTMD-943)1,000Hrs.Min.

PumpWearTest (ASTMD-2882)60mgMax.

Thefollowingfluidsworkwelloverawidetemperaturerange, allow moisture to settle out and resist biological growththatmayoccurincooloperatinghydrauliccircuits.ThesefluidsarerecommendedbyICS.Otherfluidsthatmeetorexceedthespecificationsofthesefluidsmayalsobeused.

Chevron AW-MV-32

Exxon "Univis"J-26

Mobile D.T.E. 13

Gulf "Harmony"AW-HVI-150-32

Shell "Tellus"T-32

Texaco "Rando"HD-HZ

Union "Unax"AW-WR-32

Terresolve EnviroLogic132

3. Therecommendedhoselengthis25ft(8m)witha1/2inch(12.7mm)insidediameter.Thehosesmusthaveaworking pressure rating of at least 2500 psi/175 bar. Each hose end must have male thread ends compatible with H.T.M.A.(HYDRAULICTOOLMANUFACTURERSASSOCIATION)quickdisconnectfittings(NPTtypethreads).



11

OPERATION

OPERATION

Facingthepanelcontrolvalve,thebottommalequickdisconnectfittingisthePRESSUREFLUIDOUTfitting.ThetopfemalequickdisconnectfittingistheRETURNFLUIDINfitting.

QUICK DISCONNECT COUPLERS

H.T.M.A.approvedquickdisconnectcouplingsareinstalledtohydraulichosessothatthedirectionofoilflowisalwaysfromthemaletothefemalequickdisconnectasshowninfigure2.Quickdisconnectcouplingsandhosefittingsareselectedsothatadditionalfittingssuchasreduceroradapterfittingsarenotrequired.

Ifadapterfittingsareused,theymustbeapprovedsteelhydraulicfittingsmeetingaminimumoperatingpressureratingof2500psi(172bar).Donotusegalvanizedpipefittingsorblackpipefittings.

Usethreadtapeorpipejointcompoundwheninstallingquickdisconnectcouplingstohoseortoolfittings.Follow

the instructions furnished with the selected thread sealant.

DONOTOVERTIGHTENTHEFITTINGS.

Thesupplied12VoltDCbatteryisanon-spillable,maintenance-freebatteryandisfullycharged.

Makesurethebatterycablesaretightandchargingcircuitfunctionsareoperatingproperly.

Donotchargethebatterywithastandardauto-motive battery charger. This type of charger produces a charging amperage higher than 2 amps. Charging the battery at higher than 2 amps will damage the battery

N O T I C E

If the engine runs out of gas or dies during operation and the ignition switch is left in the ONorRUNposition,thiscoulddrainthebattery.MakesuretheignitionswitchisreturnedtotheOFF position.

N O T I C E



12

OPERATION

CONTROL PANEL



13

OPERATION

CONTROLS

This unit is equipped with an advanced proportional engine control system. It provides a means of controlling engine speedbyadjustingthefuelcontrolleverwithanactuator.ThePowerUnitprovidesonecircuit,withanoilflowof5gpm(19l/min)upto2000psI(140bar)or8gpm(30l/min)upto2000psi(140bar)withafactory-programmedelectronic governed engine throttle.

Onehydraulictoolcanbeconnectedtothetoolcircuit.Thecircuitisactivatedbyturningtheflowcontrolswitchtoeitherthe5gpm(19l/min)or8gpm(30l/min)setting.

THROTTLECONTROL

Thethrottlecontrolpermitstheoperatortoselectoneof2operatingmodesaftertheenginehaswarmedup.Whenstartingtheengine,makesuretheflowselectorswitchisintheOFFposition.ThethrottlecontrolswitchcanbesetineithertheAUTO-IDLE-ONorAUTO-IDLE-OFFpositions.

AUTO-ON

Whenthethrottlecontrolswitchisinthe“AUTO-ON”position,theoilflowisregulatedautomaticallywhenthetriggeronthetoolactivated.Whenthetoolisnotbeingusedtheenginewillreturntoidleautomatically,aftera10seconddelay. Thissettingwillproduce5gpm(19l/min)or8gpm(30l/min)dependingonwhichpositiontheoperatorhasselectedwiththeflowselectorswitch.

AUTO-OFF

Whenthethrottlecontrolswitchisinthe“AUTO-OFF”position,theenginespeedisheldtomaintain5gpm/19l/minor8gpm/30l/mindependingonwhichpositiontheoperatorhasselectedwiththeflowselectorswitch.WhenatoolisnotbeingusedtheenginewillnotreturntoidleuntileithertheflowselectorswitchisturnedtotheOFFpositionorthethrottlecontrolswitchisturnedtoAUTO-ON.Note:ItmaybenecessarytoresettheController.

Attimesitmaybenecessarytoresetthecontroller.Thiscouldhappenifafaultoccursinthecontroller.Forex-ample, excessive engine speed. If a fault does occur the power unit will return to an idle and the operator will have no control of the unit. To reset the controller, simply turn off the power unit and restart it.

THROTTLECONTROLSWITCH

IGNITIONSWITCH FLOWSELECTORSWITCH



14

OPERATION

START UP

Before starting the engine make sure the flow selector switch is in the OFF position.

NOTE:Thepowerunitwillnotstartiftheflowcontrolswitchisnotinthe“OFF”position.

• PullchokeknoboutandmovetheThrottleControlSwitchtotheauto-idle-offortheauto-idle-onposition,whichevermodeofoperationtheoperatorprefers.EnsuretheflowselectorswitchisintheOFFposition.

• Turn the Ignition Switch to the START position. After the engine starts, release the switch.

• Gradually push in the choke knob as the engine begins to idle smoothly.

• Allow the engine to warm up.

• Connecthosesandthetool

FOR 5 gpm (19 l/min) OPERATION

• For5gpm(19l/min)operation,selectmodeofoperationwiththeThrottleControlswitch,eitherauto-idle-onortheauto-idle-offposition.Movetheflowselectorswitchtothe5gpmposition.

• Whenfinishedoperatingthetool,movetheflowselectorswitchtotheOFFposition.

FOR 8 gpm (30 l/min) OPERATION

• For8gpm(30l/min)operation,selectmodeofoperationwiththeThrottleControlSwitch,eitherauto-idle-onortheauto-idle-offposition.Movetheflowselectorswitchtothe8gpm(30l/min)position.

• Whenfinishedoperatingthetool,movetheflowselectorswitchtotheOFFposition.

COLD WEATHER START UP

1. Usetheproceduresdescribedunder“STARTUP”andthenfollowtheprocedurebelow.

2. Hydraulicfluidsarethickerincoldweather.Therefore,itisrecommendedthattheengineberunatlowidlelongenoughtobringthefluidtemperatureuptoaminimumof50˚F(10˚C).

3. Ifthetoolsandtoolhosesarecold,itisrecommendedtoallowhydraulicfluidtocirculatethroughthetoolhosesuntil warm before using the tool.

SHUTDOWN

1. EnsuretheflowselectorswitchintheOFFposition(centerposition).

2. Unlessalreadyatidlethepowerunitshouldreturntoidle.Thismaytakeafewsecondsfortheunittoreactduetoabuilt-inprogramdelay.

3. Allow the engine to idle for approximately one minute and move the Ignition Switch to the OFF position.



15

MAINTENANCE

ROUTINE MAINTENANCE

ENGINE MAINTENANCE

Follow the maintenance schedule and general maintenance instructions in the engine maintenance and operation manual furnished with the power unit

HYDRAULIC SYSTEM MAINTENANCE

• Checkhydraulicfluidleveldaily.Addfluidperspecificationsinthismanual.

• Removecondensedmoisturefromthehydraulicfluidbypumpingthehydraulicfluidintoa5gal/20lcontainerthroughthepressurehose.Makesuretheengineisatidlewhenperformingthisprocedure.Whenthehydraulicreservoir is empty turn the engine off immediately.

• Allowthefluidtositlongenoughforthewatertosettletothebottomofthecontainer.Slowlypourthefluidbackintothe hydraulic tank, avoiding the water at the bottom of the container.

• Eachday,checkhydrauliclinesandfittingsforleaks,kinks,etc.Donotuseyourhandtoperformthischeck.

• Changethehydraulicfilterelementevery200hoursofoperation.Changemoreoftenifcold,moistordustyconditions exist.

• Checkoilcoolerfordebris.Removedebriswithairpressure.

STORAGE

• Cleantheunitthoroughlybeforestorage.Donotusewaterpressure.

• Alwaysstoretheunitinacleananddryfacility.

• Iftheunitwillbestoredforaprolongedperiod(over30days),addafueladditivetothefueltanktopreventthefuelfrom gumming. Run engine for a short period to circulate the additive.

• Replacecrankcaseoilwithnewoil.

• Removesparkplugsandpourapproximately1ounce(30ml)ofengineoilintoeachcylinder.Replacesparkplugsand crank the engine slowly to distribute the oil.

• Checkhydraulicreservoirforwater.Ifwaterisfound,changetheoilandcirculateitthroughthetoolhoseandtool.

• Disconnecttoolhoses.



16

CONTROLLER / FAULT CODES

PROGRAMMABLE CONTROLLER

The ICS programmable controller is an electronic engine governor that provides a means of controlling and limiting engine speed by adjusting the fuel control lever with a proportional actuator.

The controller is factory programmable and has no manual adjustments.

CALIBRATION

Calibration and programming can only be done by the factory.

TROUBLESHOOTING GUIDELINES

PleasefollowthechecklistbelowtotroubleshootyourICScontroller.

1. Checkbatteryvoltageforstabilityandcorrectvalue.TheLEDwillturnonforonesecondwhenthecontrollerisfirstpowered up.

2. Check the actuator linkage for binding and backlash.

CHECKING PERFORMANCE CONTROL (ELECTRICAL GOVERNOR-STATIC CHECK)

To determine whether a governor problem is being caused by the actuator or the control module, perform the following static check exactly in order shown.

Apairofjumperwiresandaknowngood12-voltbatteryisrequired.

1. Disconnect red and green wires from the control module to actuator.

2. Attach jumper wires from battery to RED and GREEN wires to actuator.

A.Attach12volt+(positive)toREDwire.

B.Attach12volt–(negative)toGREENwire.

3. Actuator should move throttle lever to wide open position.

A.Ifactuatordoesnotmoveitisdefective.(Replace).

B.Ifactuatormovesthrottletowide-openposition,themoduleisdefective.(Replace).

FAULT CODES

TheICScontrolleriscapableofidentifyingcertainfaultconditionsandalertingtheusertothem.AflashingLEDindicatesthefaultconditions.Thecurrentfaultcodelistisshownonthefollowingpage.Pleasenotethefollowing:

1. Whenpowerisfirstappliedtothecontroller,theLEDwillflashjustonceforonesecondtoindicatethattheLEDisworking.

2. Iftherearemultiplefaults,theLEDwillflashthemallinsequence.CounttheflashcodestodeterminethefaultconditionsorconnecttheCalibrationTooltoobservethefaultconditions.(Usethe“DisplayFaults”optionundertheMonitorMenu).

3. Iftherearenofaults,theLEDwillflashonceatresetandfromthenonindicatethedetectionofenginespeed.AcontinuousONLEDindicatesthatavalidenginespeedisbeingsensed.

4. The controller will attempt to shut down for some faults and will not permit starting after reset with faults 1, 5 and 8.



17

CONTROLLER / FAULT CODES

FLASH CODE

FAULT ENGINE SHUTDOWN

CORRECTIVE ACTION

1 Unitnotcalibrated YES HaveengineservicedbyanAuthorizedICSDealer.

2 Engine speed excessive

YES HaveengineservicedbyanAuthorizedICSDealer.

3 Engine speed unusually low


4 Engine shutdown due to engine protection input


5 Factory settings lost YES HaveengineservicedbyanAuthorizedICSDealer.

6 Externalpotout-of-range

NO HaveengineservicedbyanAuthorizedICSDealer.

7 Accelerator position/idle switch conflict


8 Controller unit failed YES HaveengineservicedbyanAuthorizedICSDealer.

9 Limitingexcessiveactuator current


10 Engine speed input signal missing

NO Check speed sensor wiring.Check starter motor.

11 Auto crank unable to start engine

NO Check fuel.

12 Auxillary output is shorted

NO Check the lamp or relay hooked to the output. If fault is still present, have engine serviced by and ICS Authorized Deale.r

13 Auxillary output #2 is shorted

NO Check the lamp or relay hooked to the output. If fault is still present, have engine serviced by and ICS Authorized Dealer.

14 Actuator disconnected or open circuit

NO Check actuator wiring and actuatro resistance.Resistance should be less than 10 ohms.



18

TESTING

TESTING

GENERAL

Tests and adjustments should be performed periodically to ensure the power unit is operating at maximum efficiency.ICSCircuitTesterisrecommended.Thistestercanbeusedtoisolateproblemsinboththeengineandhydraulic system prior to any power unit disassembly.

TESTING THE HYDRAULIC CIRCUIT

Thefollowingtestscanbeperformedtoensurethatthehydraulicpumpissupplyingthecorrectflowandpressureand that the system relief valve is operating properly.

Duringthesetests,makesuretheengineiswarmandoperatingsmoothly.Iftestresultsarenotasspecified,referto the troubleshooting table in this section for possible causes.

TESTING THE 5 GPM HTMA TYPE 1 CIRCUIT OR THE 8 GPM TYPE 11 CIRCUIT

Totestthecircuit,proceedasfollows:

1. SettheflowselectorswitchtotheOFF(center)position.

2. SetthethrottlecontrolswitchtoAUTO-OFFposition.

3. ConnecttheICSCircuitTesteracrosstwohoseends(wherethetoolwouldnormallybeconnected).

4. Fullyopenthetesterrestrictorvalve(counterclockwise).

5. Start the engine and allow it to run until warm.

6. Switchtheflowselectorswitchto5or8gpmdependingonwhichflowyouaretesting.

7. Withtheengineattheprogramedspeed,thetestflowgaugeshouldread4-6gpm(15-23l/min)or7-9gpm(26.5-34l/min).

8. Slowlyturntherestrictorvalveclockwisewhilewatchingthepressuregauge.Theflowrateshouldstayat4-6gpm(15-23l/min)or7-9gpm(26.5-34l/min)asthepressuregaugereaches2100-2200psi(148-155bar).

9. At2100-2200psi(148-155bar),thereliefvalveshouldbegintoopen.Thepressureatwhichthereliefvalvejustbeginstoopeniscommonlyreferredtoasthe“crackingpressure”.Atthe“crackingpressure,”theflowrateshouldstarttodropbecausethereliefvalveisallowingfluidtoby-passtothehydraulicreservoir.The“crackingpressure”ispresetatthefactoryandifitisnotwithintheaboverange,thereliefvalvemustbere-setasfollows:

A. The relief valve is located on the right side of the unit just behind the dash panel. It protrudes out from the manifoldassembly.Useaopenendorboxendwrenchtoloosenthenutonthereliefvalve.

B.UseanAllenwrenchtoadjustthereliefvalve.Turnclockwisetoraisethepressureandcounterclockwisetoreducethepressure.UseanAllenwrenchtoadjustthereliefvalve.Turnclockwisetoraisethepressureandcounterclockwise to reduce the pressure.

C. Tighten the nut and retest.



19

TROUBLESHOOTING

TROUBLESHOOTING

PROBLEM CAUSE REMEDY

Engine will not start

Flow selector switch not in the OFF position

MakesuretheflowselectorswitchintheOFFposition when starting

Battery not connected Attch battery cables, check wires

Weakbattery Test battery, charge or replace

No fuel Add fuel

Fuel filter plugged Replace fuel filter

Defective spark plugs Remove plugs, check gap, clean or replace

Fluid blowing out of fluid reservior vent

Hydraulictankoverfilled Correct the fluid level

Pumpsuctionleak Check suction connections, Tighten

Hydraulic tool won't operate

Flow selector switch not switched ON

Check that the flow selector switch is set to 5 or 8 gpm

Incorrect hose connection tool Makesurethetoolhosecircuitgoesfromleft(pressure)fittingtotoolandbacktotherightfitting(return),fluidalwaysflowsformthemaletothefemale fittings

Quickdisconnectfittingsdefective

Detach from hose, connect set together and check for free flow

Hydraulicfluidlevellow Check for correct fluid level, fill using the recommended fluid

Pumpcouplingdefective Withtheenginenotrunning,checkthecouplingbetween the pump and engine that is engaged and is not damagedCAUTION:keephandsclearofrotatingobjects

Relief valve stuck open Adjust or replace valve

Suction hose kinked Makesuresuctionhosefromfluidreservoirtopump inlet has a smooth curve

Solenoid not working Check solenoid operation and electrical connections

Tool is defective Refer to tool manul


ICS, Blount Inc.4909 SE International Way

Portland, OR 97222Tel 800-321-1240 Fax 503-653-4393

icsbestway.com

P95OPERATOR'SMANUAL

Documents

MultiFlow Hydraulic Powerpack - file.yizimg.comfile.yizimg.com/196154/2007112711140589.pdf · P95 OPERATOR’S MANUAL 4 SYMBOLS & LABELS THE FOLLOWING SYMBOLS & DEFINITIONS ARE FOUND