Operating instructions Rerailing Equipment Hydraulic units 84072930085 GB Edition 08.
Content Page 1. Hazard classes 4 2. Product safety 5 3. Proper use 8 4. Labelling of the units 8 5. Functional description 9 5.1 General 9 5.2 Motor variants 10 5.3 Pumps 10 5.4 Frames 11 5.5 Connection to the control unit 11 5.6 Connection options 11 5.7 Optional accessories 11 6. Connection of the hoses 12 6.1 Connection of quick-connect couplings 12 6.2 Direct connection 13 7. Set-up and start-up 13 7.1 Installation 13 7.2 Start-up 14 8. Operation 15 8.
12. Troubleshooting 31 13. Technical data 34 13.1 Hydraulic power pack 34 13.2 Recommended hydraulic fluid 37 13.3 Hoses 37 13.4 Operating temperature and storage temperature ranges 37 14.
1. Hazard classes We distinguish between various categories of safety instructions. The table below gives you an overview of the assignment of symbols (pictograms) and key words to the specific hazard and possible consequences.
2. Product safety LUKAS products are developed and manufactured in order to guarantee the best performance and quality when used properly. Operator safety is the most important aspect of the product design. Moreover, the operating instructions are intended to ensure LUKAS products are used safely. The generally applicable legal and other binding regulations pertaining to the prevention of accidents and protection of the environment apply and are to be complied with in addition to the operating instructions.
In the event of malfunctions, immediately shut down the equipment and secure it. The malfunction is to be repaired immediately. Do not carry out any changes (additions or conversions) to the equipment without obtaining the prior approval of LUKAS. Comply with all the instructions regarding safety and danger on the equipment and in the operating instructions. All the instructions regarding safety and danger on the equipment are to be kept complete and in a legible condition.
Keep combustion engines and their fuel away from ignition sources, as otherwise there is the danger of an explosion. All damaged electrical components e.g. scorched cables, etc. are to be replaced immediately. To avoid the risk of fire, ensure adequate ventilation during combustion engine operation and maintain a minimum safety distance of 1 m (39.4 in.) from walls and other shielding installations.
The generally applicable, legal and other binding national and international regulations pertaining to the prevention of accidents and protection of the environment apply and are to be implemented in addition to the operating instructions. WAR N IN G / D A N GE R / CAUT I O N! The equipment is to be used exclusively for the purpose stated in the operating instructions (see chapter "Proper use"). Any form of use beyond this is not considered proper use.
5.1 General 5.
5.2 Motor variants WARNING / DANGER / CAUTION! For all motor variants, also comply with the separate operating instructions of each motor manufacturer. 5.2.1 Electrical 5.2.2 Gasoline / petrol 5.2.3 Diesel These hydraulic units are equipped with an electric motor. The electric motor is driven by electricity from the mains supply or by electricity produced by generators.
WARNING / DANGER / CAUTION! In the interests of safety, the pressure set at this pressure limiting valve must not be adjusted (without direct approval of LUKAS). 5.4 Frames All hydraulic units for the rerailing equipment are supplied with a frame. The frame enables optional accessories to be attached directly to it. In addition, the frame makes the unit easier to transport, thanks in particular to the integral carry handles. 5.
6. Connection of the hoses CAUTION! When connecting the hose assemblies, always ensure that the connection components are not soiled; clean beforehand if necessary. REMARK: Before you attempt to connect or disconnect hose lines to or from the hydraulic unit, including hose lines with quick-disconnect couplings, always make sure that the pump assembly is switched off. Electric pumps must be disconnected from the power supply.
6.2 Direct connection REMARK: To be able to screw the hoses onto the connecting block directly, you must check first whether the corresponding connection nipples are fitted inside the connecting block. The hydraulic hoses are screw-connected to the connecting block of the hydraulic unit. The connecting block must contain the necessary connection nipples. The hoses are fastened to these connection nipples directly by union nuts.
7.2 Start-up Please proceed as follows: 1. First of all, check the hydraulic fluid level of the unit. Depending on the unit model, the fluid level is indicated by a fluid sight glass (maximum = centre of sight glass; refill required if fluid level no longer visible in the sight glass) or a dipstick (usually attached to a filler screw). If necessary, you should top up the fluid to the maximum MAXIMUM level. MINIMUM MINIMUM MAXIMUM 2.
8. Operation CAUTION! Before the motor is started, the hydraulic unit and the control unit must be switched to depressurised circulation (for the hydraulic unit, this means connecting the supply and return lines together, for example). Only in this way is it possible to start the unit without a hydraulic load. 8.1 Starting the motors 8.1.
An electric starter is available from the LUKAS range of accessories for some units. (For specific details, please consult the LUKAS range of accessories or contact your LUKAS dealer). On these units, after checking the fluid levels, proceed as follows: 1. Switch to "START ENGINE" 2. Turn the ignition key clockwise. Charge the accumulator of the electric starter: 1. Switch to "CHARGE BATTERY" 2. Connect the supplied charger to the mounted socket. 8.1.
2. When the engine has come to a standstill, close the fuel tap. Procedure for stopping Honda engines: 1. Set the ON / OFF switch to the OFF position. 2. When the engine has come to a standstill, close the fuel tap. Please consult the separate operating instructions of the motor manufacturer for the precise procedure for stopping combustion engines. WARNING / CAUTION! Never touch the hot motor / engine parts: this could result in severe burns. 8.2.
10. Maintenance and service The hydraulic units are subject to very high mechanical loads. For this reason, visual inspections and function tests must be carried out at regular time intervals. These inspections and tests enable signs of wear to be identified in good time. Prompt replacement of wear parts can then prevent damage to the equipment. Also check regularly that all fastening screws are tightened securely (observe tightening torques where applicable).
10.2 Hydraulic units with combustion engine Visual inspection Hydraulic units • Check that all hydraulic connections are tightened • General tightness, no leakage (the hot oils do not have any influence on the function) • Is there damage to the motor, connecting block or housing? • Frame present, undamaged and securely assembled? • Are type plate, all activation plates, signs, identification marks and warning labels are present and legible? • Are all covers (e.g.
Function test • No suspicious noises • Checks at nominal pressure (75% of maximum pressure) (Recommendation: Carry out the load test with a fully assembled rerailing system. LUKAS also offers a range of appropriate test equipment.) 11. Repairs 11.1 General Servicing may only be carried out by the manufacturer or personnel trained by the manufacturer and by authorised LUKAS dealers.
11.2 Preventive service 11.2.1 Care instructions The exterior of the equipment is to be cleaned from time to time in order to protect it from external corrosion. Oil is to be applied to the metallic surfaces. 11.2.2 Replacing the hydraulic fluid - After approx. 200 deployments, but after three years at the latest, replace the hydraulic fluid - The fluid should be replaced when it is warmed up. - The motor must be switched off. - The old hydraulic fluid must be disposed of properly. Procedure: 1.
4. Then loosen fastening nuts “J” on the hydraulic fluid reservoir and remove them along with retaining washers “K”. 5. Remove pump carrier plate “L” and tank seal “M” underneath.
6. Take care not to lose spacer rings “N”. Free the entire reservoir of dirt using a smooth cloth.
7. When you refit the reservoir, exchange the reservoir seal and fasten the securing bolts (for tightening torque, see spare parts list). L M N 8. Also replace the seal ring of the drain plug and fit it as specified in the spare parts list. 9. Add the new hydraulic fluid to the reservoir through the filling plug. 10.
11.3 Repairs When carrying out permitted repairs, please observe the relevant spare parts lists with the remarks and drawings they contain. Should there be any uncertainties regarding the repairs, please contact your authorised LUKAS dealer or LUKAS Customer Service. CAUTION! As LUKAS hydraulic units are designed for extremely heavy loads, it is prohibited to attempt any repairs other than those described in the operating instructions.
11.3.3 Direct connection The screw-in sleeves must be replaced in the event of: - external damage - hydraulic fluid continually leaking in connected / unconnected state. Procedure: 1. Remove the screw-in sleeve from the valve block. 2. Position the new screw-in sleeve and tighten it with a torque of MA = 40 Nm. 11.3.4 Replacing hoses (if fitted) Replace hoses if they are leaky or defective, and if they are older than 10 years.
2. Pull the engine / motor off. Please ensure that you do not damage the engine / motor shaft mount. 3. Equip the shaft of the new engine / motor with an appropriate adjusting key (provided it is not already in place). 4. Grease the shaft of the new engine / motor and push the shaft of the new engine / motor into the engine / motor shaft mount. Ensure that the adjusting key of the engine / motor shaft is inserted into the correct guide of the engine / motor shaft mount. 5.
11.4 Installation and repair of optional accessories 11.4.1 Fitting attachment hose reels to the frame Attachment hose reels usually come prefitted and do not need to be removed unless the complete hose reel is to be exchanged. A retrofit kit is available and it contains all the necessary fasteners. The hose reels differ depending on which side they are to be fitted (left or right). Be sure to fit the hose reels to the correct side.
11.4.3 Connection of attachment hose reels with pipework Before you connect the pipework, you must check that suitable connection nipples (GE-08) are present inside the connecting block and attachment hose reels. In case of doubt, please contact your authorised LUKAS dealer or LUKAS directly. Procedure: 1. Lay out the necessary, preformed pipe. 2. If not present, screw a “G” (GE-08) connection nipple into the connecting/valve block or attachment reel. (tightening torque MA = 40 Nm) 3.
11.4.4 Replacing the connecting block or drain valve The connecting block or drain valve must be exchanged if the assembly is damaged, if continued and correct function is no longer guaranteed or if a permanent leak has developed in the assembly. It is possible to convert from a connecting block to drain valve arrangement and vice versa. Procedure: 1. Much of the procedure is identical to the procedure involved in changing the hydraulic fluid including removal of pump carrier plate “O” with engine / motor.
12. Troubleshooting For malfunctions directly related to combustion engines, please refer to the separate operating instructions issued by the engine manufacturer.
Trouble Motor runs but connected implement does not move in response to control command.
Trouble Fluid leaks from the hydraulic fluid reservoir (especially from the filler screw) Cause Due to hydraulic fluid returning from the implement, the maximum capacity of the tank is exceeded Solution Reduce the level in the hydraulic fluid reservoir to the mark on the dipstick or inspection glass Defective seal Have repaired by authorised dealer or directly by LUKAS Leaking fluid between engine and flange bearing Radial shaft seal on the drive shaft is defective Have repaired by authorised dealer
13. Technical data As all values are subject to tolerances, there may be minor differences between the data achieved by your equipment and the data specified in the following table. 13.1 Hydraulic power pack 13.1.1 Basic data type ref.no. dimensions lxwxh [mm] [in.] motor type [kW] [HP] [min-1] rotation speed [rpm.] [MPa]3) max. operating pressure (HP)1) [psi.] [MPa]3) max. operating 2) pressure (LP) [psi.] flow rate [l/min] (HP)1) [gal.
type ref.no. dimensions lxwxh GC-6 840729317 560 x 540 x 665 22.04 x 21.26 x 26.18 4-stroke gasoline engine 3,5 4.69 [mm] [in.] motor type [kW] [HP] [min-1] motor power rotation speed 3100 [rpm.] [MPa]3) [psi.] [MPa]3) max. operating pressure (LP)2) [psi.] flow rate [l/min] (HP)1) [gal.-US/min] [l/min] flow rate (LP)2) [gal.-US/min] [l] max. fill-up quantity [gal.-US] [l] max. useable quantity [gal.-US] weight (incl. all [kg] max. fluid fill-up [lbs.
type ref.no. dimensions lxwxh [mm] [in.] motor type [kW] [HP] [min-1] rotation speed [rpm.] 3) [MPa] max. operating pressure (HP)1) [psi.] [MPa]3) max. operating 2) pressure (LP) [psi.] flow rate [l/min] (HP)1) [gal.-US/min] [l/min] flow rate (LP)2) [gal.-US/min] [l] max. fill-up quantity [gal.-US] [l] max. useable quantity [gal.-US] weight (incl. all [kg] max. fluid fill-up [lbs.] quantities) motor power [°C] [°F] ambient temperature DC-6 840729319 550 x 480 x 742 21.
13.1.2 Noise emissions (in accordance with EN ISO 3744): type ref.no. PC-6 GC-6 DC-6 840729316 840729317 840729319 idle running [dB(A)] 73 85 93 full load [dB(A)] 78 89 93,7 idle running [dB(A)] 65 82 82 full load [dB(A)] 67 85 83,5 (measuring distance: 1m) (measuring distance: 1m) (measuring distance: 5m) (measuring distance: 5m) 13.
14.
WARNING / DANGER / CAUTION! Before connecting equipment, make sure that all the components used are suitable for the maximum operating pressure of the hydraulic unit. In cases of doubt, you must consult LUKAS directly before connecting the equipment. Please dispose all packaging materials and dismantled parts properly. LUKAS Hydraulik GmbH Tel.: (+49) 0 91 31 / 698 - 0 Fax.: (+49) 0 91 31 / 698 - 394 e-mail: lukas.info@idexcorp.com Made in GERMANY Aggregate_BA_GB_84072930085_0809.
