Lukas PC 650 User Manual

Instruction manual

Rerailing equipment

Hydraulic power units GC/PC 650

GC 650

PC 650

1450000085 EN

Edition 08.2014

(Translation of the original instruction manual)

Content Page

1. Danger classiﬁ cations 5

2. Product safety 6

3. Proper use 10

4. Assembly marking 1 1

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

8.2 Stopping the engine 19

8.3 Topping up with fuel (only on combustion engines) 20

8.4 Controlling the valves 20

9. Dismantling the equipment / deactivation following operation 22

10. Tests 23

10.1 Recommended test intervals 23

10.2 Hydraulic units with combustion engine 24

10.3 Hydraulic units with electric motor 25

10.4 Hoses (optional pairs of hose extensions) 25

11.1 General information 26

11. Maintenance and repair 26

11.2 Service work on the hydraulic unit 27

11.3 Additional service work on unit with combustion engine 29

11.4 Couplings 33

Content Page

12. Troubleshooting 34

13. Technical data 40

13.1

13.2 GC 650-4POWER 42

13.3 GC 650E-2POWER 43

13.4 GC 650E-4POWER 44

13.5 PC 650-2POWER 45

13.6 PC 650-4POWER 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 ﬂ uid recommendation 48

13.13 Operating and storage temperature range 48

14. EC Declarations of conformity 49

15. Notes 50

GC 650-2POWER 41

1. Danger classiﬁ cations

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 speciﬁ c danger and the possible consequences.

Pictogram

Damage /

injury to

Persons

Property

- NOTE

Key word Deﬁ nition Consequences

DANGER! Immediate danger

Potentially

WARNING!

CAUTION!

ATTENTION!

dangerous

situation

Less dangerous

situation

Danger of damage

to property/

environment

Handling tips and

other important/

useful information

and advice

Death or severe

injury

Potential death or

serious injury

Minor or slight

injury

Damage to the

equipment,

damage to the

environment,

damage to

surroundings

No injury/damage

to persons/

environment/

device

Wear a helmet with a face guard

Wear protective gloves

Wear safety shoes

Proper recycling

Protect the environment

Read and follow the operating instructions

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. 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. The equipment must only be operated by persons with appropriate training in the safety aspects of such equipment – otherwise, there is a danger of injury. We would like to point out to all users that they should read carefully the operating instructions and the instructions contained therein before they use the equipment, and that they should carefully follow such. We further recommend you have a qualiﬁ ed trainer show you how to use the product.

CAUTION!

The operating instructions for the hoses, the accessories and the connected devices must also be heeded!

Even if you have already received instruction on how to use the equipment, you should still read through the following safety instructions again.

CAUTION!

Ensure that the accessories and connected equipment are suitable for the maximum operating pressure!

Please ensure that no body parts or clothing get stuck between the visibly moving parts.

Wear protective clothing, safety helmet with visor, safety shoes and protective gloves.

Working under suspended loads is not permitted where such loads are being lifted only by means of hydraulic devices. If working under suspended loads is unavoidable, suitable mechanical props are also required.

Immediately report any changes that occur (including changes in operating behaviour) to the appropriate persons/ departments! If necessary, the equipment is to be shut down immediately and secured!

Check the equipment for visible ﬂ aws or damage before and after use.

Check all lines, hoses and screwed connections for leaks and externally visible damage, and repair immediately! Escaping hydraulic ﬂ uid can cause injuries and ﬁ res.

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.

Please ensure that all safety covers are present on the equipment and that they are in proper and adequate condition.

Safety devices must never be disabled!

Make sure before switching on/starting up the device and during its operation, that this will put no one in danger.

When working close to live components and cables, suitable measures must be taken to avoid current transfers or high-voltage transfers to the equipment.

All safety and danger information on the device must always be complete and in a legible condition.

Any mode of operation which compromises the safety and/ or stability of the device is forbidden!

The maximum operating pressure set on the equipment must not be changed!

Observe all intervals for recurring tests and/or inspections that are prescribed or stated in the operating instructions.

Only genuine LUKAS accessories and spare parts are to be used for repairs.

When working with this equipment or when transporting it, ensure that you do not get caught up in the hose or cable loops and trip.

The build-up of static charge and therefore possible sparking must be avoided when handling the device.

Motorised pumps must not be operated in areas at risk of explosion!

Do not touch the engine and exhaust system when running with combustion engine pumps because of the danger of burning.

Combustion engines must not be operated in enclosed spaces because of the danger of poisoning and / or smothering.

If you spill any fuel when using combustion engines, you must remove the spilled fuel completely before starting the engine.

Keep combustion engines and their fuels away from sources of ignition since otherwise there will be a danger of explosion.

Refuelling whilst the engine is running is strictly prohibited!

All damaged electrical components e.g. scorched cables, etc. must be replaced immediately!

In order to prevent the danger of ﬁ re, you should ensure adequate ventilation when operating combustion engines and you must keep a safety distance of at least 1m (39.4 in.) to walls and other screens.

Make sure that the combustion engines are always standing on as ﬂ at and horizontal a surface as possible to prevent fuel from leaking out.

The equipment is ﬁ lled with hydraulic ﬂ uid. This hydraulic ﬂ uid can be detrimental to health if it is swallowed or its vapour is inhaled. Direct contact with the skin must be avoided for the same reason. Also, when handling hydraulic ﬂ uid, note that it can negatively affect biological systems.

Make sure there is adequate lighting while working.

Always keep these operating instructions easily accessible at the place of operation.

Damage to electrical components must only be repaired by a qualiﬁ ed electrician in compliance with all applicable national and international safety guidelines and regulations.

When setting up the units, you must make sure that they are not impaired by the inﬂ uences of extreme temperatures.

When working with or storing the equipment, ensure that the function and the safety of the equipment are not impaired by the effects of severe external temperatures or that the equipment is damaged in any way. Please note that the equipment can also heat up over a long period of use.

Before transporting the equipment, always ensure that the accessories are positioned in such a way that they cannot cause an accident.

Ensure the proper disposal of all removed parts, leftover oil, hydraulic ﬂ uid and packaging materials.

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. The

manufacturer/supplier is not liable for any damage resulting from use not as intended. The user bears sole responsibility for such use. Proper use includes observance of the operating instructions and compliance with the inspection and maintenance conditions.

Never work in a fatigued or intoxicated state!

WARNING / CAUTION / ATTENTION!

However, if you still injure yourself on the hydraulic unit, clean the wound immediately and consult a doctor to have it attended to! If you get hydraulic ﬂ uid in your eye, rinse it immediately several times with clear, clean water and consult a doctor! Also, if you swallow hydraulic ﬂ uid you should consult a doctor!

3. Proper use

LUKAS hydraulic power units are specially designed to supply LUKAS rerailing equipment with hydraulic ﬂ uid 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 / ﬂ uid to rescue equipment of other manufacturers is possible, yet requires the technical inspection and approval by LUKAS in each individual case. The equipment is not designed to operate without hoses or equipment (operating time without hoses or equipment < 15 minutes). The equipment type groups GC and PC 650 have been developed for rerailing technology and for use in combination with the control table.

When working with the units described here, make sure that participating and non-participating persons in the vicinity of the work and during the lifting procedure are not endangered by the connected hoses and equipment.

WARNING / CAUTION / ATTENTION!

The safety instructions in this operating instruction manual concerning the site of erection and type of erection must always be observed! LUKAS units type GC and PC 650 are not explosion protected!

You can obtain accessories and replacement parts for the hydraulic power unit from your authorised LUKAS dealer!

ATTENTION!

When selecting the units to connect to the unit, bear in mind that the maximum possible useable volume of hydraulic ﬂ uid is limited. The sum of the max. required operating volume of oil (hydraulic ﬂ uid) of all connected equipment must not exceed the maximum possible usable volume of the power unit!

NOTE:

Always register your hydraulic unit on the LUKAS Hydraulik GmbH internet site. This is the only way to guarantee your extended warranty cover.

Before you use couplings from a different company , you must contact LUKAS or an authorised dealer.

4. Assembly marking

Motor variants and

coding for hydraulic

power units

Valve variants:

2POWER = Simultaneous operation 4POWER = Four circuit operation

Motor variants:

PC = Electric motor (operation via mains supply) GC = Petrol engine

650 E

Type group

with electric starter

2POWER

Valve variants

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). The pump conveys hydraulic ﬂ uid from the tank to the connected equipment and generates the hydraulic pressure. The ﬂ uid distribution is then controlled by valves.

5.2 Layout of the units

10 14

1 Hydraulic ﬂ uid tank

2 Petrol tank 3 Petrol engine with hydraulic pump 4 Connection block with control valves

(2 or 4 valves) 5 Engine switch 6 Electric starter button 7 Cable-pull starter 8 Valve control lever 9 Quick-disconnect coupling (female) 10 Quick-disconnect nipple (male) 11 Filler cover hydraulic ﬂ uid 12 Filler cover petrol 13 Frame 14 Side cladding (clip ﬁ xing) 15 Rubber buffer 16 ON - OFF -switch for electric motor 17 Telescopic carrying handle (can be

pulled out) 18 Drain screw for hydraulic ﬂ uid 19 Electric motor with hydraulic pump 20 Sight window for hydraulic ﬂ uid

5 1

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. When operating with generators you must make sure that voltage ﬂ uctuations are not produced because these will have a direct effect on the feed rate and durability of the hydraulic power unit. The possible operating voltage and current frequency required can be taken from the Chapter "Technical Data".

NOTE:

When connecting to the mains, if a very long connecting cable is used, the power supply to the motor may be reduced as a result of the resistance in the cable. This will reduce the power of the motor.

5.3.2 Petrol engine

These hydraulic units are equipped with a combustion engine driven by the fuel "petrol". The units can be ﬁ tted with an electric starter in addition to the cable-pull starter (optional).

NOTE:

The engine installed in the LUKAS power units does not match every detail of the engine described in the manufacturer's separate operating instructions. On account of the speciﬁ c application in rerailing technology, and in order to ensure the safety of the entire hydraulic power unit, components have been modiﬁ ed or adapted to suit. Nevertheless, it is important that you follow all safety rules and operating, maintenance and storage instructions in the separate engine instructions as absolute since they are not affected by adjustments made by LUKAS.

The starter battery is automatically charged up by the integrated generator when the engine is running. If the battery has become ﬂ at after an extended storage period you should start the unit with the cable-pull starter. This causes the battery to be charged up automatically. If the battery is still not charged after running for about half an hour it could have the following causes:

- the contacts (connection plug) have come loose and need to be reconnected.

- battery is defective and needs to be replaced.

- there is damage to the generator or the engine. In these cases you should contact LUKAS customer service.

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 ﬂ ow mode" (2POWER)

This valve enables the connection of two double-acting hydraulic units. With this valve you can operate two units at the same time and independently of each other. You have two switching possibilities. The two switching levers can be used to pressurise or depressurise the individual connections.

5.5.2 Control valve "Four ﬂ ow mode" (4POWER)

This valve enables the connection of four double-acting hydraulic units. With this valve you can operate four units at the same time and independently of each other.

You have four switching possibilities. The four switching levers can be used to pressurise or depressurise the individual connections.

ATTENTION!

When operating several rerailing units with one unit, ensure that the usable volume of hydraulic ﬂ uid in the reservoir is greater than the maximum possible oil volume of all connected rerailing units. In the hydraulic ﬂ uid tank, we differentiate between the ﬁ lling volume and the usable volume.

5.5 Pumps

LUKAS hydraulic power units are ﬁ tted with a two circuit or a four circuit pump, depending on the type. The pumps are rigidly connected to the connecting block.

Double-ﬂ ow pump for operating with 2POWER valve For-ﬂ ow pump for operating with 4POWER valve The pumps used always have two pressure stages per pump feed ﬂ ow, one low pressure

and one high pressure. Low-pressure level (LP) = up to 14 MPa* High-pressure level (HP) = up to 53 MPa* The changeover from low pressure to high pressure is carried out automatically by the pump.

The maximum pressure is limited by a pressure limiting valve.

WARNING / CAUTION / ATTENTION!

For safety reasons, the pressure set on this valve must not be adjusted (without the approval of LUKAS directly)!

*) 1 MPa = 10 bar

5.6 Frame with side sections

All the hydraulic power units described here are enclosed in a frame. The frame and the side parts serve to protect the unit from external inﬂ uences (e.g. dirt, damage etc.) and also for transporting using the frame itself or the carrying handles. The starter system on units having combustion motors are also mounted on the frame or the side parts.

5.7 Connection to the control table

Connection to the rerailing equipment is exclusively via the control table. Either via the connecting hoses rigidly ﬁ xed to the control table or via additional pairs of hose extensions if the power unit is not installed directly under the control table. The hose extension pairs are supplied in various lengths. The individual hoses can, if required, also be marked with coloured snap rings to make it easier to allocate the hoses.

(For speciﬁ c details, please consult the LUKAS range of accessories or contact your LUKAS dealer.)

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.

WARNING / CAUTION / ATTENTION! Before connecting the equipment, make sure that allthe

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!

Coupling the Quick-disconnect couplings

The equipment is connected to the hydraulic pump via quick-disconnect coupling halves (male and female).

Before coupling, remove dust caps and then pull back and hold the locking sleeve of the female coupling half (position X). Connect the male and female couplings and release the locking sleeve. Then turn the locking sleeve to position Y. The connection has been made and locked. Uncoupling is done in the reverse order.

ATTENTION!

Always couple the return line (tank line - marked T on the pump block) ﬁ rst and then the supply line (pressure line - marked P on the pump block)!

On disconnecting, you should always disconnect the supply line  rst (pressure

line) and only then the return line!

NOTE:

Coupling is only possible if the hoses are depressurised.

For dirt protection, the supplied dust protection caps must be reﬁ tted.

WARNING / CAUTION / ATTENTION! Some quick-disconnect couplings have special functions.Therefore, you must

not unscrew them from the hoses or swap them over!

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