Instruction manual Rerailing equipment Hydraulic power units GC/PC 650 GC 650 PC 650 1450000085 EN Edition 08.
Content Page 1. Danger classifications 5 2. Product safety 6 3. Proper use 10 4. Assembly marking 11 5. Functional description 11 5.1 General information 11 5.2 Layout of the units 12 5.3 Motor variants 13 5.4 Valve variants 14 5.5 Pumps 15 5.6 Frame with side sections 15 5.7 Connection to the control table 15 6. Connecting the hoses / devices 16 7. Erection and start-up 17 7.1 Set-up 17 7.2 Start-up 17 8.1 Starting the engines 18 8. Operation 18 8.
Content Page 12. Troubleshooting 34 13. Technical data 40 13.1 GC 650-2POWER 41 13.2 GC 650-4POWER 42 13.3 GC 650E-2POWER 13.4 GC 650E-4POWER 43 44 13.5 PC 650-2POWER 13.6 PC 650-4POWER 45 46 13.7 Noise emissions of the power units 47 13.8 Sparking plug 47 13.9 Sparking plug spanner 47 13.10 Fuel 47 13.11 Engine oil 48 13.12 Hydraulic fluid recommendation 48 13.13 Operating and storage temperature range 48 14. EC Declarations of conformity 49 15.
1. Danger classifications We differentiate between various different categories of safety instructions. The table shown below provides an overview of the assignment of symbols (pictograms) and signal words to the specific danger and the possible consequences.
2. Product safety LUKAS products are developed and manufactured to ensure the best performance and quality when used as intended. The safety of the operator is the most important consideration in product design. Furthermore, the operating instructions are intended to help in using LUKAS products safely.
In the event of malfunctions, immediately deactivate the device and secure it. Repair the fault immediately. Do not carry out any changes (additions or conversions) to the equipment without obtaining the approval of LUKAS beforehand. Observe all safety and danger information on the device and in the operating instructions. All safety and danger information on the device must always be complete and in a legible condition.
If you spill any fuel when using combustion engines, you must remove the spilled fuel completely before starting the engine. Refuelling whilst the engine is running is strictly prohibited! Keep combustion engines and their fuels away from sources of ignition since otherwise there will be a danger of explosion. All damaged electrical components e.g. scorched cables, etc.
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. WARNING/CAUTION! The device is intended exclusively for the purpose stated in the operating instructions (see chapter "Proper Use"). Any other use is not considered to be as intended.
3. Proper use LUKAS hydraulic power units are specially designed to supply LUKAS rerailing equipment with hydraulic fluid and pressure. LUKAS rerailing equipment, such as a traversing unit or one or more hydraulic cylinders is used for erecting and rerailing of rail-bound vehicles. Their use for supplying pressure / fluid to rescue equipment of other manufacturers is possible, yet requires the technical inspection and approval by LUKAS in each individual case.
4. Assembly marking GC 650 E - 2POWER Type group Motor variants and coding for hydraulic power units with electric starter Valve variants Valve variants: 2POWER = 4POWER = Simultaneous operation Four circuit operation Motor variants: PC = GC = Electric motor (operation via mains supply) Petrol engine 5. Functional description 5.1 General information On all LUKAS hydraulic power units, a hydraulic pump is always driven by a motor (combustion engine or electric motor).
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5.3 Motor variants WARNING / CAUTION / ATTENTION! For all motor variants, also comply with the separate operating instructions of each motor manufacturer. 5.3.1 Electric motor These hydraulic units are equipped with an electric motor. The electric motor is fed with power from the mains or with power produced by generators.
5.4 Valve variants The valves are always rigidly mounted in a connection block. This block is directly integrated in the hydraulic power unit. The hoses (pressure and return) are always connected to the connection block. The units are equipped with either a 2POWER or a 4POWER connection block. The hoses and equipment are connected with the connecting block via plug couplings. 5.4.1 Control valve "Two flow mode" (2POWER) This valve enables the connection of two double-acting hydraulic units.
5.5 Pumps LUKAS hydraulic power units are fitted with a two circuit or a four circuit pump, depending on the type. The pumps are rigidly connected to the connecting block. Double-flow pump for operating with 2POWER valve For-flow pump for operating with 4POWER valve The pumps used always have two pressure stages per pump feed flow, one low pressure and one high pressure.
6. Connecting the hoses / devices ATTENTION! When connecting the hose lines, always ensure that the connection components are not dirty. If necessary, clean before connecting! NOTE: Before connecting or disconnecting the hoses on the hydraulic power unit, make sure that the power unit is switched off or, with a unit with an electric motor (PC 650) that it is isolated from the mains (pull the plug out)! This represents an increased safety measure in order completely to prevent any movement of the equipment.
7. Erection and start-up 7.1 Set-up WARNING / CAUTION / ATTENTION! Because of possible spark formation, combustion engine units and electrical equipment must not be used in an explosion-risk area. Units with combustion engines must not be used in enclosed spaces, as there is a danger of poisoning and asphyxiation! The unit is to be set up in a suitable location (secure location / flat surface / sufficient distance from vehicles, loads, sources of ignition, etc.).
b) Electric motor (mains operation): - switch the motor on and switch it off again after approx. 15 seconds. Repeat this process several times. (Before switching back on, the motor must be at a standstill!) This procedure makes sure that the pump draws fluid slowly and is well bled. The hydraulic fluid tank is equipped with automatic bleeding, so that additional bleeding measures are not required. 4. Check the levels of fluid in the tanks again. If necessary, you should top up with fluid. 8.
8.1.2 Electric motors Before starting the motor, check that all electrical connections and cables are in a good condition. Then connect the mains cable (for motors with mains power supply) to the supply socket. Starting is carried out by pushing the ON/OFF switch on the side part of the power unit. The ring around the switch lights up when the power unit is switched on. ATTENTION! Electric motors pull a very high start-up current for a short period.
8.3 Topping up with fuel (only on combustion engines) The engine must be switched off for refuelling! Procedure: 1. Open the fuel tank cap. 2. Top up the tank with fuel to the maximum level (top of petrol filter insert). WARNING / CAUTION / ATTENTION! Be sure not to spill fuel. In particular, hot engine parts must not come into contact with fuel; danger of fire otherwise! If fuel is spilled, it must be cleaned up immediately with a suitable absorbent cloth.
8.4.2 Control valve "Four flow mode" (4POWER) There are four levers mounted on the connection block of this valve. Each of the four small levers is assigned to one pressure port. The pressure application of the corresponding pressure hose is controlled (" ") or the connection is depressurised (" ") by switching the relevant lever over. NOTE: All switching levers must always be completely switched on up to the end stop.
9. Dismantling the equipment / deactivation following operation After completing the work and before stopping the unit, place all connected units to the base setting (storage setting). You can then stop, or switch off, the motor on the unit, and if you are using an electric motor this should be disconnected from the mains.
10. Tests The hydraulic power units are subject to very high levels of stress. A visual inspection must therefore be carried out after every use and at least one visual inspection must be carried out every six months. This reveals signs of wear in good time and punctual replacement of these wear parts prevents damage to the equipment. Also check regularly that all the securing screws are tightened (if applicable, comply with prescribed tightening torques).
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10.3 Hydraulic units with electric motor Visual Inspection Hydraulic power units • Check that all hydraulic connections are still tight • General tightness, no leaks (sweated oils do not have any influence on the function), • Is there any damage apparent to the motor, valve blocks or on the casing? • Side plates present and tightened, • Presence and legibility of the identification plate, all actuation signs, instruction signs, markings and warnings, • The presence and perfect condition of all covers (e.g.
11. Maintenance and repair 11.1 General information LUKAS hydraulic power units type GC and PC 650 have a complex structure and therefore require only a small amount of maintenance. For general service work, special training is not necessary; however, knowledge about the function of the power units, the legal safety instructions and dealing with the required tools are basic prerequisites.
11.2 Service work on the hydraulic unit 11.2.1 Care instructions The exterior of the device must be cleaned from time to time (not the electrical contacts) and the metallic surfaces (not the electrical contacts) must be treated with a suitable agent to protect against corrosion. (In case of doubt, contact your authorised LUKAS dealer or LUKAS directly!) 11.2.2 Function and load test If there is any doubt regarding the safety or reliability of the equipment, a function and load test must also be performed.
Procedure for hydraulic fluid replacement: 1. 2. 3. Switch the engine off or isolate the electric motor from the mains. Place the power unit on a slightly elevated base so that the drain plug for the hydraulic fluid can be easily reached. Place a suitable collection vessel under the drain screw "A" or the hydraulic oil drain opening into which it is screwed. Remove the side panel to gain access to the hydraulic tank closure.
11.2.4 Changing decals All damaged and/or illegible decals (safety notices, type plate etc.) must be replaced. Procedure: 1. Remove damaged and/or illegible decals. 2. Clean surfaces with industrial alcohol. 3. Affix new decals. Take care to affix the decals in the correct positions. If this is no longer known, you should ask your authorised dealer or contact LUKAS directly. 11.
11.3.1 Replacing and cleaning the air filter Keeping the air filter in good condition is extremely important. Penetrating dirt leads to damage and wear in the engine in case of incorrect installation, incorrect servicing or unsuitable filter inserts. Always keep the air filter insert clean. Procedure: 1. Remove the rear side panel on the hydraulic power unit by releasing the fixing clips and lifting the panel away. 2.
11.3.2 Replacing, cleaning and setting the sparking plug Procedure: 1. Remove the right side panel on the hydraulic power unit by releasing the fixing clips. 2. Remove the sparking plug lead. The plug is very tight, but is only a push-fit. However, when releasing it make sure that you do not tilt the plug or apply a side load to the sparking plug. In the worst case, this can destroy the sparking plug and it can cause expensive repairs as a consequence. 4.
from the power unit before you can drain the engine oil. See the relevant LUKAS spare parts list. Engine oil dipstick (Engine oil filler opening) Oil drain screw 11.3.4 External charging or replacing the starter battery Procedure: 1. Remove the left side panel "A" on the hydraulic power unit by releasing the fixing clips "B". 2. You can now see the starter battery "C". First remove the negative terminal ("-") from the battery and then the positive terminal ("+").
C D 3. If you want to charge the battery using an external charger you need to connect it now. (Observe the operating instructions for the charger being used) If the battery is defective it needs to be replaced. To do this, release the fixing strap "D" by pulling the tab downwards and unhooking it to the side. Remove the battery. Take care when inserting the battery to make sure you are doing it correctly (see illustration, left). Installation of the battery is carried out in reverse order. 11.
12. Troubleshooting In the case of defects which directly affect the motor / engine, please consult the separate operating instructions of the motor / engine manufacturer.
Fault Combustion engine will not start Check Check fuel level in tank Cause Fuel tank empty Solution Top up with fuel Electric starter present? Electric starter battery flat Check fuel line Fault in the fuel line Check starter button and motor switch Starter button or cable-pull starter not actuated Engine switch not set to Choke Ambient temperature too low Charge electric starter battery or use cablepull starter Shut down immediately and have it repaired by an authorised dealer, engine manufactur
Fault The engine is running, but the connected equipment does not move upon activation of the valve. The connected rescue equipment does not move on activation of the valve, or moves only very slowly or unevenly. Check Check hose Cause Hose assembly not connected properly or damaged Solution Check connection of hose and reconnect if necessary. Check the switch position of the valve lever on the pump block of the hydraulic unit Valve not switched to supply line pressurisation.
Fault Connected equipment does not reach its end position Check Check hydraulic fluid volume in hydraulic tank Connected equipment does not reach its performance data (force) Cause Insufficient fluid in the hydraulic tank Solution Top up hydraulic fluid to the maximum fill level Attention! Before topping up, return the connected equipment to the base position! Usable hydraulic fluid volume of the unit is insufficient Use a different unit with a demand quantity below the maximum usable quantity of the
Fault Fluid coming out of hydraulic fluid tank Check Connected unit not in rest position yet and fluid coming out of filler cap? Cause Returning the hydraulic fluid from the equipment exceeds the tank’s maximum capacity.
Fault It is frequently not possible to couple hose assemblies Check Cause Hydraulic fluid not adapted to the application situation Solution Hydraulic fluid must be replaced (see chapter “Recommended Hydraulic fluids”) Coupling defective Coupling must be replaced immediately Leak from the couplings Coupling defective Coupling must be replaced immediately Fluid leak on the hoses or the fittings Leak, possible damage Replace hoses Damages on the surface of the hoses Mechanical damage or contact wit
13. Technical data Since all values are subject to tolerances, minor differences may occur between the data on your equipment and the data in the following tables. The values may also differ because of reading inaccuracies and/or tolerances in the measuring equipment used. NOTE: The following tables contain only the most important Technical Data. Additional data concerning your unit can be obtained from LUKAS on request.
13.1 GC 650-2POWER Device type GC 650-2POWER Item number 70-10-10 Dimensions Operating pressure Delivery quantity lxwxh max. Highpressure Change-over pressure Delivery quantity Motor Low pressure Power Idle speed Volume of hydraulic fluid max. Ambient temperature Weight Units 537 x 451 x 600 mm 21.1 x 17.8 x 23.6 in. 53 MPa 7700 psi 2 x 0.9 l/min 2 x 0.24 gpm 14 MPa 2000 psi 2 x 3.1 l/min 2 x 0.82 gpm 4.2 kW 3300 rpm 27.5 / 23 l 7.3 / 6.1 gal.
13.2 GC 650-4POWER Device type GC 650-4POWER Item number Dimensions Operating pressure Delivery quantity Motor max. Highpressure Low pressure Power Idle speed Volume of hydraulic fluid max. Ambient temperature Weight 537 x 451 x 677 mm 21.1 x 17.8 x 26.7 in. 53 MPa 7700 psi 4 x 0.7 l/min 4 x 0.18 gpm 14 MPa 2000 psi 4 x 2.6 l/min 4 x 0.69 gpm 5.1 kW 3600 rpm 45 / 40 l 11.9 / 10.6 gal. -20 … +55 °C -4 … 131 °F 97 kg 214 lbs.
13.3 GC 650E-2POWER Device type GC 650E-2POWER Item number 70-10-15 Dimensions Operating pressure Delivery quantity lxwxh max. Highpressure Change-over pressure Units 537 x 451 x 600 mm 21.1 x 17.8 x 23.6 in. 53 MPa 7700 psi 2 x 0.9 l/min 2 x 0.24 gpm 14 MPa 2000 psi l/min Delivery quantity Low pressure 2 x 3.1 2 x 0.82 gpm Motor Power 4.2 kW 3300 rpm 27.5 / 23 l 7.3 / 6.1 gal. -20 … +55 °C -4 … 131 °F 80 kg 176 lbs. Idle speed Volume of hydraulic fluid max.
13.4 GC 650E-4POWER Device type GC 650-4POWER Item number 70-10-25 Dimensions Operating pressure Delivery quantity lxwxh max. Highpressure Change-over pressure Units 537 x 451 x 677 mm 21.1 x 17.8 x 26.7 in. 53 MPa 7700 psi 4 x 0.7 l/min 4 x 0.18 gpm 14 MPa 2000 psi l/min Delivery quantity Low pressure 4 x 2.6 4 x 0.69 gpm Motor Power 5.1 kW 3600 rpm 45 / 40 l 11.9 / 10.6 gal. -20 … +55 °C -4 … 131 °F 103 kg 227 lbs. Idle speed Volume of hydraulic fluid max.
13.5 PC 650-2POWER Device type PC 650-2POWER Item number 70-10-30 Dimensions lxwxh Units 537 x 451 x 577 mm 21.1 x 17.8 x 22.7 in. Operating pressure max. 53 MPa 7700 psi Delivery quantity Highpressure 2 x 0.7 l/min Change-over pressure Delivery quantity Motor Low pressure Power Idle speed Volume of hydraulic fluid max. Ambient temperature Weight Specification of hydraulic fluid 1) HD = High pressure 2 x 0.18 gpm 14 MPa 2000 psi 2 x 2.6 l/min 2 x 0.69 gpm 2.
13.6 PC 650-4POWER Device type PC 650-4POWER Item number 70-10-40 Dimensions lxwxh Units 537 x 451 x 672 mm 21.1 x 17.8 x 26.5 in. 53 MPa 7700 psi 4 x 0.6 l/min 4 x 0.16 gpm 14 MPa 2000 psi 4 x 2.2 l/min 4 x 0.58 gpm 3.5 (400/50) kW (VAC/ Hz) 2980 rpm 45 / 40 l 11.9 / 10.6 gal. Ambient temperature -20 … +55 °C -4 … 131 °F Weight 99 kg 218 lbs. Operating pressure max.
13.7 Noise emissions of the power units Device type Noise level L(WA) Idle Full load GC 650E-2POWER GC 650-2POWER 97 101 GC 650E-4POWER GC 650-4POWER 101 103 PC 650-2POWER 91 96 PC 650-4POWER 90 97 13.8 Sparking plug Sparking plug type: BR6HS (NGK) 13.9 Sparking plug spanner Sparking plug spanner with universal joint having a size of 21 mm 13.10 Fuel Fuel: Lead-free petrol ROZ 91 to ROZ 98 max.
13.11 Engine oil 13.12 Hydraulic fluid recommendation Mineral oil DIN ISO 6743-4 for LUKAS hydraulic equipment and others Oil temperature range -20 .... +55°C Oil designation HM 10 Viscosity rating VG 10 Remarks A Oil temperature range -4.0 .... +131°F Oil designation HM 10 Viscosity rating VG 10 Remarks A recommended range of viscosity: 10...200 mm²/s Supplied with HM 10 DIN ISO 6743-4. (10…200 cSt.
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WARNING / CAUTION / ATTENTION! Before connecting the 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 of all packaging materials and removed items properly. LUKAS Hydraulik GmbH A unit of the IDEX Corporation Tel.: (+49) 0 91 31 / 698 - 0 Fax.: (+49) 0 91 31 / 698 - 394 e-mail: lukas.info@idexcorp.com www.lukas.
