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Owner’s Manual

Brave Hydra Buddy™ Hydraulic Power Pack

OPERATION AND MAINTENANCE

About Your Hydraulic Power Pack

Product Suitability and Limitations

Our self-contained hydraulic power units are compact and offer portable hydraulic power for remotely powering

hydraulic equipment. Our power units can also be mounted into equipment as a primary hydraulic power source given

the flow, pressure, reservoir capacity, and duty cycle are carefully considered. Typical applications include agriculture,

construction, trades, lifting, jacking, equipment repair, and fabrication work.

HBHR units come factory with a 4-way directional control valve with integral system relief valve. HBHR units are

equipped with ½” quick-disconnects that are installed into the work ports of the directional control valve. HBHS units

come factory with a system relief valve.

The HBHS units can also be field retrofitted to include optional bulkhead mounted ½” quick-disconnects with

appropriate plumbing kit, and a single 4-way directional control valve with integral relief valve.

The HBHS units driven by the Honda GX630 V-Twin engine can also be field retrofitted with a return line heat

exchanger for applications that run more continuous and require additional cooling of the hydraulic fluids. The return

line heat exchanger kit comes with a mounting bracket assembly, 12 VDC fan cooler, appropriate plumbing, wire

harness, and hardware.

Each unit has a specific flow and pressure rating that should be carefully reviewed to ensure the power pack will provide

adequate system flow, pressure, & reservoir capacity for the given application being considered.

Only the HPHS units with the Honda V-Twin engine can support the 12 Volt heat exchanger (cooler) due to the required

amp draw from the 12 VDC fan and on-board charging system of the Honda GX630 engine.

Power packs without a return cooler should not be used in applications where hydraulic oil temperatures exceed 180

degrees F for any amount of time. If the hydraulic system reaches 180 degrees F. the system should be shut down

immediately and the application should be reviewed.

Contact Brave Customer Service at 1-800-350-8739 about the appropriate use of this Hydraulic Power Pack, optional

accessories or any other questions.

Hydraulic Hose and Fitting Requirements

The rated working pressure of hydraulic hoses must be equal to or higher than the maximum pressure rating of the

hydraulic unit. Each of the HBHR and HBHS units have a unique pressure rating they are capable of achieving. Please

refer to the specific assembly flow and pressure rating and size hydraulic hose and fittings appropriately.

½” quick-disconnects can be provided for each HBHS unit upon request. If the couplers provided do not interchange

with the powered equipment, replace with couplers that match. Brave recognizes that couplers are a necessity for

quickly connecting and disconnecting equipment however feel that if the self-contained power pack is mounted into a

piece of equipment for final assembly that quick-disconnects, adapter fittings, and hydraulic hose plumbing are carefully

reviewed to maximize the performance of the hydraulic system. Adding unnecessary couplers, adapter fittings, etc. will

increase pressure drop in a hydraulic system and reduce the efficiency of the hydraulic system.

MHBHR280A

Model Number: HBHR280GX, HBHR350GX,

HBHS300GX, HBHS310GX, HBHS600GXE,

HBHS610GXE, HBHS620GXE

Summary of content (38 pages)

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MHBHR280A Model Number: HBHR280GX, HBHR350GX, HBHS300GX, HBHS310GX, HBHS600GXE, HBHS610GXE, HBHS620GXE Owner’s Manual Brave Hydra Buddy™ Hydraulic Power Pack OPERATION AND MAINTENANCE About Your Hydraulic Power Pack Product Suitability and Limitations Our self-contained hydraulic power units are compact and offer portable hydraulic power for remotely powering hydraulic equipment.
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Warranty Registration Please fill in the warranty registration information in the back of this manual and have it on hand when you call in about a warranty claim or for replacement parts you may need. Renting or Loaning NOTICE: Make Owner’s Manual Available All persons to whom you rent/loan the Hydraulic Power Pack must have access to and read this manual. Keep this owner’s manual with the Hydraulic Power Pack at all times and advise all persons who will operate the machine to read it.
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Table of Contents About Your Hydraulic Power Pack............................................................................................................................................. 1 Receiving and Transporting ......................................................................................................................................................... 4 Machine Component Identification .......................................................................................................
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Receiving and Transporting Initial Inspection: Regardless of the source, immediately inspect the Hydraulic Power Pack for damage or any missing components. See the “Machine Component Identification” section of this manual for a diagram of the Hydraulic Power Pack and its components. Your purchase will result in delivery through one of the following sources: Truck Delivery Note: Shipping damage claims are not covered by Brave warranty.
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Machine Component Identification HBHR280GX and HBHR350GX 2 3 ^6 5 HBHS300GX and HBHS310GX 9 10 8 2 7 1 9 4 10 1 8 7 11 HBHS600GXE, HBHS610GXE, and HBHS620GXE 8 9 4 2 1 11 7 6 10 4 11 6 Reference 1 2 3 4 5 6 7 8 9 10 11 Part Description Hydraulic Tank Hydraulic Fill Cap Control Valve Handle (HBHR only) Return Line Filter Control Valve (HBHR only) Hydraulic Pump *Engine Sight Gauge Fuel Tank Engine On/Off Switch Nameplate/serial number *See Engine Manual for Engine Component Identification
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Specifications Engine Engine Oil Type Pump Capacity Pump Displacement Hydraulic Fluid Type Hydraulic Tank Volume (nominal, actual, useable) Hydraulic Tank Material Hydraulic Relief Setting Hydraulic Valve Type Connection Ports Filter Replacement Part Number Overall Dimensions Dry Weight HBHR280GX Honda GX270 5.5 GPM .36 CIR 8, 7.3, 5.
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Safety Hazard Signal Word Definitions This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death. DANGER DANGER (red) indicates a hazardous situation, which if not avoided, will result in death or serious injury. WARNING WARNING (orange) indicates a hazardous situation, which if not avoided, could result in death or serious injury.
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Safety Decal Locations WARNING ALWAYS make sure safety labels are in place and in good condition. If a safety label is missing or not legible, order new labels from Brave Customer Service at 1-800-350-8739.
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Safety Decals WARNING ALWAYS make sure safety labels are in place and in good condition. If a safety label is missing or not legible, order new labels.
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Operation Pre-Start Checklist CAUTION: No Oil in Engine Crankcase Add the correct amount of oil to engine crankcase or engine will be damaged beyond repair and not covered by warranty. CAUTION: No Hydraulic Oil in Tank Add the correct amount of hydraulic oil to the reservoir before use. 1.
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Operation (Continued) 5. Check implement hydraulic system Check hydraulic system and lines of the implement to be attached to the Hydraulic Power Pack. Small leaks in hydraulic lines can be an indication of catastrophic failure in the near future. The life of hydraulic hoses may be from a few months to a few years, depending on use and storage patterns. WARNING: Pressurized Fluid Hazard High fluid pressures and temperatures are developed in Hydraulic Power Packs. NEVER check for leaks with your hand.
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Starting and Warm-up Before Use 1. If the hydraulic power unit is equipped with a directional control valve, place the Hydraulic valve handle in the neutral position. If unit not equipped with a directional control valve, skip directly to step 6. CAUTION: HBHS users without installed directional control valve If the unit is not equipped with a directional control valve, please ensure the power unit is properly plumbed to the powered equipment prior to attempting to start the engine.
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Using Hydraulic Motor Implement NOTICE: Match Quick Disconnect Couplers If necessary, replace coupler fittings with implement-matching couplers. Brave does not recommend using multiple adapters; they may restrict flow and limit operation. 1. Connect Hoses (Engine Off) • • • Before connecting your implement hoses to the Hydraulic Power Pack, you must determine which hose is the pressure or forward acting hose. Consult your implement owner’s manual or labels to determine which hose is the “SUPPLY” hose.
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Using Hydraulic Motor Implement (Continued) 4. Stopping or Removing Attached Implement with Hydraulic Motor: • • • • • • • To turn off the engine, verify the valve handle is in the center (neutral) position which should cause the hydraulic motor to come to a complete stop. Turn the engine off using on/off switch located on engine. Confirm the hydraulic motor has come to a complete stop. Operate any switches or valves in the system to relieve pressure.
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Using Hydraulic Cylinder Implement NOTICE: Match Quick Disconnect Couplers If necessary, replace coupler fittings with implement-matching couplers. Brave does not recommend adapters; they may restrict flow and limit operation. 1. Connect Hoses (Engine Off) • • • Before connecting your implement hoses to the Hydraulic Power Pack, you must determine which hose is the pressure or forward acting hose. Consult your implement owner’s manual or labels to determine which hose is the “SUPPLY” hose.
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Using Hydraulic Cylinder Implement (Continued) 2. Start Engine: • • • • Confirm the valve handle is in the neutral position (all units used to run cylinders should have a valve present in the system). Confirm supply and return lines are properly plumbed to the driven equipment safely and securely. Start engine per manufacturer’s instructions. Place the engine throttle control lever in the fast position. 3.
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Refueling WARNING: Fire Hazard Allow the engine to cool for at least five (5) minutes before refueling, moving to storage or transporting. A hot engine can be a fire hazard. Refueling at Work Sites: • • • • • • • • • • • Before removing gas cap, turn engine off and allow to cool for at least FIVE (5) minutes.
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Storing Allow engine to cool before inspecting and storing 1. Inspect for worn or damaged parts 2. Choose a covered storage location 3. Start engine every 4 weeks; -OR4. Prepare engine for long-term (seasonal) storage if needed. 1. Inspect for worn or damaged parts: Inspect the Hydraulic Power Pack for worn or damaged parts and tighten any nuts or screws that may have become loose. Check for any fuel or hydraulic system leaks. 2.
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Storing (Continued) 4. Prepare engine for long-term (seasonal) storage if needed: If you will not be able to start the engine regularly, you must prepare the engine for long term storage to prevent gum deposits from forming and causing malfunction of the engine. Prepare engine for long-term storage by either removing all gasoline from the tank and carburetor, OR by adding fuel stabilizer to the gasoline.
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Maintenance & Repair Regular Maintenance Perform regular maintenance to keep the Hydraulic Power Pack in safe and functional working condition. WARNING ALWAYS shut off the engine, make sure the engine is cool, and disconnect the spark plug before cleaning, adjusting, or servicing the Hydraulic Power Pack. 1. Follow safety rules: Turn off the Hydraulic Power Pack. To prevent accidental starting, always turn off the Hydraulic Power Pack and remove spark plug or spark plug wire. Avoid burns.
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Maintenance & Repair (Continued) 5. Hydraulic oil & filter change: Each self-contained HBHR and HBHS unit is equipped with a filter condition indicator gauge. This gauge should be monitored and when the indicator gauge is no longer in the green the filter element should be replaced. In the event that water is present in the hydraulic oil the system should be completely drained, lines flushed, and oil replaced. Brave recommends an oil change every 100 hours of operation. Add 10 wt.
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Troubleshooting WARNING Before troubleshooting or attempting to service, read the following safety instructions to avoid serious injury to the operator or bystanders from moving parts that can crush or cut, burns, fire or explosion, or escaping high pressure hydraulic fluid. Important Safety Instructions: Engine off. Always make sure the engine is off before cleaning, repairing or adjusting the Hydraulic Power Pack, except as recommended by the manufacturer. Hydraulic safety.
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Troubleshooting (Continued) Problem Engine stalls when valve engaged Motor or cylinder moves slow Engine appears to be seized Motor or cylinder moves erratically Engine won’t turn or stalls at no load Pump shaft seal leaks Cause 1. Bad connection at hydraulic coupler. (E, J) 2. Lines reversed. (C) 3. Worn ball seat on coupler. (E) 4. Auger plugged or jammed. 5. Lower hydraulic oil in reservoir. (A, H) 6. Pressure lock. (B, D, E, J) 7. Defective pump. (L) 8. Defective engine. (L) 9. Air in system (A, I) 10.
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Summary of Important Safety Information This section provides a summary of the various safety procedures and measures that have been presented through the manual. Keep this summary handy and refer to it to refresh your memory about how to safely use your Hydraulic Power Pack. WARNING Carefully read and make sure you understand the following safety information before using the Hydraulic Power Pack.
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Summary of Important Safety Information (Continued) Hot exhaust – fires. Exhaust from engine can be extremely hot and cause fire. Position muffler at least 7 feet from combustible objects during operation. Fire extinguisher. Keeping a fire extinguisher rated “ABC” by the National Fire Protection Association nearby is always recommended when using gasoline-operated machinery. Keep it properly charged and be familiar with its use. Personal Protective Equipment Hearing protection.
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Summary of Important Safety Information (Continued) Do not adjust the pressure setting of the pump or valve. Do not check for leaks with your hand. Leaks can be located by holding a piece of cardboard or wood (at least two feet long) with your hand at one end and passing the other end over the suspected area (wear eye protection). Look for discoloration of the cardboard or wood.
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Summary of Important Safety Information (Continued) Safety – After Use Cool engine before storing. Let engine cool for at least five (5) minutes before storing. A hot engine can be a fire hazard. Shut off fuel supply. If equipped, make sure gasoline shut-off lever is in the closed position (to the left). Prevent accidental starting.
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Special Safety Information on Static Electricity Accidents Involving Static Electricity Static electricity and filling gasoline containers. Static electricity can initiate from ungrounded gasoline tanks or containers, from flowing gasoline, and from persons carrying a static electric charge. Static electricity on numerous occasions has explosively ignited gasoline vapors that were present during fueling processes, resulting in serious burns to nearby persons.
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HBHR350GX & HBHR280GX Exploded View – Rev A 29
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HBHR350GX & HBHR280GX Parts List - Rev A Ref # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 Part 1010330 1010353 1010427 1010264 1010433 1010249 1010435 1010419 1010464 1012902 1013178 1013939 1014003 1014103 1014236 1014312 1014313 1014328 1014938 1014939 1014952 1014971 1014985 1014986 1015055 1015063 1015073 1015194 1015206 1023992 1024201 1037197 1058437 1102641 1067976 1068113 1068117 1068125 10
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HBHS300GX & HBHS310GX Exploded View – Rev A 31
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HBHS300GX & HBHS310GX Parts List - Rev A Ref # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 Part 1010412 1010413 1011765 1013333 1013500 1013938 1013939 1013952 1014008 1014312 1014425 1014905 1014971 1014986 1014987 1030822 1030832 1031121 1037197 1046260 1067914 1067982 1068113 1068117 1068125 1068422 1069273 1072535 1080381 1086461 1087964 1090169 1090428 1090478 1091091 1102641 1115360 1124173 1124188 1124332 1157513 11
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HBHS600GXE, HBHS610GXE, & HBHS620GXE Exploded View – Rev A 33
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HBHS600GXE, HBHS610GXE, & HBHS620GXE Parts List - Rev A Ref # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 Part 1010303 1010412 1010413 1010572 1011119 1011765 1013500 1013618 1013649 1013938 1013939 1014312 1014425 1014971 1014986 1014987 1015046 1015073 1015115 1030822 1030828 1030867 1030883 1031121 1037197 1046260 1067914 1067982 1068112 1068117 1068125 1
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Limited Warranty Policy Dear Valued Customer: The Brave product you just purchased is built with the finest material and craftsmanship. Use this product properly and enjoy the benefits from its high performance. By purchasing a Brave product, you show a desire for quality and durability. Like all mechanical equipment this unit requires a due amount of care. Treat this unit like the high quality piece of machinery it is. Neglect and improper handling may impair its performance.
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Brave Product Registration Form Your Information Full Name: Last First M.I. Address: Street Address Apartment/Unit # City State ZIP Code Alternate Phone: Home Phone: Email Address: Purchased From Company: Address: Street Address Apartment/Unit # City State Model Information Purchase Date: Application Type: □ Homeowner □ Commercial Model (i.e. HBHR350GX) □ Rental Serial # (i.e.
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20195 S.