PortaCo D-60S09-F7-S Operation, Maintenance, And Repair Manual

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MODEL

D-60S09-F7-S

POWER UNIT

1805 2ndAVENUE NORTH * MOORHEAD, MN, USA 56560-2310

E-MAIL ADDRESS; [e-mail] * INTERNET ADDRESS: www.portaco.com

OPERATION,

MAINTENANCE,

AND REPAIR MANUAL

PHONE [phone] * FAX [phone]

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TABLE OF CONTENTS

1.0 Introduction

1.1 General Information

1.2 Features

1.3 Options

1.4 Safety Summary

1.5 General Safety Precautions

1.6 Warning and Caution
Statements

1.7 Training Requirements

2.0 Installation Instructions

2.1 Unpacking Instructions

2.2 Engine Preparation

2.3 Hydraulic Power Unit
Preparation

2.4 Testing

2.5 Hose Requirements

2.6 Tool Connecting Procedures

2.7 Work Area Safety

Precautions

3.0 Operating Instructions

3.1 Description of Power Unit

3.2 Controls and Graphics

3.3 Before Start Up

3.4 Positioning the Power Unit

3.5 Startup

3.6 Shutdown

3.7 Cold Weather Operation

3.8 Storage Preparation

4.0 Maintenance Instructions

4.1 Routine Servicing and

Inspection Schedule

4.2 Assembly View and Parts

List

4.3 Hydraulic Fluids and engine

maintenance

4.4 Trouble Shooting

4.5 Technical Specifications

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1.0 INTRODUCTION

1.1 General Information

This manual presents installation,
operation, and maintenance information
for the D-60S09-F7-S PortaCo, Inc.
Hydraulic Power Unit. Its main purpose
is to provide auxiliary hydraulic power
for steering, electrical power for lights
and break modulation for towing a
disabled Off-Highway Truck.

Other uses are to provide hydraulic
power for unloading a disabled loaded
truck, to make towing easier and can be
used as a portable 35 Amp-24 Volt DC
battery charger.

The D-60S09-F7 Power Unit must be
used with additional Attachment Groups.
The Attachment Groups contain all the
necessary hydraulic fittings, hoses, and
electrical cables to connect to Off­Highway Trucks The power unit can
provide up to 3600psi at 9gpm (248 bar
at 34 lpm).

the electrical pump controls. A Group 24
Battery is used on the power unit.

The power unit features a Caterpillar
diesel engine and is shipped with a
Caterpillar operator’s manual. See the
engine manual for operating and
maintenance information concerning the
engine.

The engine is equipped with its own 12
Volt DC charging system and will
maintain the charge on the 12 Volt
battery in the power unit.

The power unit comes with a lockable
fuel cap to prevent unauthorized access
and lifting eye bolts so the power unit
can be lifted with a crane hook (Fig

1.2A).

NOTE: The hydraulic power unit must
be connected to the truck’s hydraulic
system before engaging the pump
engage switch.

1.2 Features

The main features of the D-60 PortaCo
series power unit are as follows:

Length 191.77 cm 75.5 in
Width 68.58 cm 27 in
Height 106.68 cm 42 in

The power unit is shipped without a
battery. A 12 Volt Battery is required for
starting the diesel engine and operating

Fig 1.2A

1.3 Options

There are no options at this time.
Consult PortaCo, Inc. at 218-236-0223
for any special requirements.

1.4 Safety Summary

Power unit operators and maintenance
personnel must always comply with the
safety precautions given in this manual

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and on the stickers and tags attached to
the unit.

These safety precautions are given for
your safety. Review them carefully
before operating the power unit and
before performing maintenance or
repairs.

Supervising personnel should develop
additional precautions relating to the
specific work area and local safety
regulations.

1.5 General Safety Precautions

The PortaCo Inc. D-60 Series Hydraulic
Power Units are designed to provide safe
and dependable service if operated
according to the instructions provided in
this manual. Read and understand this
manual and any stickers attached to the
power unit before operating. Failure to
do so could result in personal injury or
equipment damage. Check the rules and
regulations at your location. The rules
may include employer’s work safety
program. Regulations may identify
hazards such as working around utility
supply lines or hazardous slopes.

Read and understand any manuals for
additional or optional equipment, which
maybe shipped with the power unit.

1.6 Warning and Caution Precautions

Warning and Caution statements have
been strategically placed throughout the
text, prior to operating or maintenance
procedures, practices, or conditions,
considered essential to protection of
personnel or equipment and property.

WARNING: HIGHLIGHTS AN
ESSENTIAL OPERATING OR

MAINTENANCE PROCEDURE,
PRACTICE, CONDITION
STATEMENT, ETC. WHICH IF
NOT STRICTLY OBSERVED,
COULD RESULT IN INJURY TO,
OR DEATH OF, PERSONNEL OR
LONG TERM HEALTH HAZARDS.

CAUTION: HIGHLIGHTS AN
ESSENTIAL OPERATING OR
MAINTENANCE PROCEDURE,
PRACTICE, CONDITION
STATEMENT, ETC. WHICH IF
NOT STRICTLY OBSERVED,
COULD RESULT IN DAMAGE TO,
OR DESTRUCTION OF,
EQUIPMENT OR LOSS OF
MISSION EFFECTIVENESS.

1.7 Training Requirements

Operator training should consist of
information found in this manual for the
hydraulic power unit. In addition the
operator must receive instructions both
through demonstrations and verbally
with the tools or applications in which
the power unit is going to be used. The
new operator must start in an area
without bystanders and use all controls
until able to fully operate the power unit
under the conditions for the work area.

2.0 INSTALLATION
INSTRUCTIONS

2.1 Unpacking Instructions

Upon receiving your hydraulic power
unit, promptly remove it from shipping
container. Always keep top side of
container up. Inspect unit for damage
which may have incurred during
shipping and report it to carrier for
claim.

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2.2 Engine Preparation

CAUTION: READ AND
UNDERSTAND ENGINE MANUAL
WHICH IS PROVIDED IN
ADDITION TO THE PORTACO
MANUAL BEFORE STARTING
THE POWER UNIT.

CAUTION: ALWAYS CHECK
ENGINE OIL BEFORE STARTING
POWER UNIT.

Make sure engine oil is at the “FULL”
mark on the dipstick.

CAUTION: DO NOT START THE
POWER UNIT WITHOUT IT
BEING COMPLETELY
CONNECTED TO THE TRUCK.
DAMAGE TO THE HYDRAULIC
SYSTEM COULD ACCURE IF NOT
PROPERLY CONNECTED.

Check the hydraulic fluid level of the
truck being serviced and add fluid to the
full mark as specified in the vehicles
operators manual. Always use oils
recommended by the vehicle being
serviced manufacturer.

See engine manual for recommended oil
and checking procedures.

NOTE: clean up oil and fuel spills
immediately. Do not over fill fluids

Inspect the belts for wear and replace as
required.

Check the water level and add fluid as
instructed in the engine operators
manual.

2.3 Hydraulic Power Unit Preparation

Check the fuel reservoir gauge and add
fuel as required. Inspect the hoses and
fitting for leaks or damage. Replace
leaking or damaged components before
operating.

WARNING: DO NOT ATTEMPT TO
LOCATE HYDRAULIC LEAKS BY
FEELING AROUND HOSES OR
FITTINGS WITH HANDS. “PIN
HOLE” LEAKS CAN PENETRATE
THE SKIN CAUSING INJURY OR
DEATH.

2.4 Testing

All power units are tested at the factory
and their flows and pressures are
recorded on the test report, which is
shipped with the power unit. Testing of
the power unit is not required unless it is
damaged during shipping.

Special test procedures are required
when testing the power unit. If the
power unit requires pressure and flow
tests consult PortaCo, Inc. for proper
procedures.

2.5 Connecting Procedures.

Inspect hose for cuts, crushing, leaks, or
abrasion which maybe a safety hazard or
reduce fluid flows.

WARNING: DO NOT ATTEMPT TO
LOCATE HYDRAULIC LEAKS BY
FEELING AROUND HOSES AND FITTING
WITH HANDS. “PIN-HOLE” LEAKS
CAN PENETRATE THE SKIN.

CAUTION: DO NOT START THE
POWER UNIT WITHOUT IT
BEING COMPLETELY

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CONNECTED TO THE TRUCK
BEING SERVICED. DAMAGE TO
THE HYDRAULIC SYSTEM
COULD ACCURE IF NOT
PROPERLY CONNECTED
BEFORE ACTIVATING THE
HYDRAULIC SYSTEM.

Make sure the clutch engagement lever
is in the “out” position

Make sure all hoses are connected for
correct flow direction to and from the
truck being serviced. When routing hose
in the work area, position them where
personnel will not be at risk of tripping
over them or where vehicles can run
over the hoses. Do not lay hose over
sharp projects.

WARNING: PRESSURIZED FLUID
ESCAPING FROM A DAMAGED
HOSE CAN PENETRATE THE
SKIN AND BE INJECTED IN THE
BODY CAUSING INJURY OR
DEATH.

2.6 Work Area Safety Precautions

- Never operate the power unit in a
closed space. Inhalation of
engine exhaust can be fatal.

- Keep clear of hot exhaust.

- Do not use PortaCo hydraulic
power units in potentially explosive
atmospheres such as near
wastewater drains or landfill sites.

- Do not operate if flammable gases
or vapors are present.

- Keep the power unit at least 1meter
(3.3 ft) away from buildings, obstructions,
and flammable objects. Do not aim engine
exhaust at materials that could catch fire.

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

- PortaCo hydraulic power units must
not be located below overhead
gantries, power lines, or walkways
where there might be a risk of
falling objects.

- Provide ambient light intensity of
200 Lux for working indoors or
outdoors particularly if working at
night.

- Always wear appropriate safety
equipment such as goggles, ear
protection, and foot protections.

- Operate only tools which fit into
the specifications prescribed in
section 1.1 of this manual.

- Do not stand on power unit.

3.0 Operating Instructions

3.1 Description of Power Unit

The PortaCo D-60 series
Hydraulic Power Unit has been designed
for the purpose of supplying a portable
battery charger for 24 Volt batteries or
as an alternative power source for a
disabled vehicle equipped with a 24 Volt
system. The power unit can also be used
as the hydraulic power source to unload
the body of the Off-Highway Trucks and
it can provide auxiliary hydraulic power
for steering and 24 Volt DC for
electrical power for the brake release
pump and lights on an Off-Highway
Truck that has been disabled due to
engine failure.

This power unit produces 9 gpm/ 34 lpm
at 3600 psi/ 248 bar. The standard
engine is a Caterpillar 60 hp. See
section 1.2 features of this manual for
specifications. See the technical manuals
supplied by the engine manufacture
included with this power unit for
detailed technical specifications.

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PortaCo Hydraulic Power Units have
been designed for use indoors and
outdoors. PortaCo power units should
not be operated under wet conditions, or
at ambient operating temperatures,
outside the recommended temperature
range of -28° C to 43° C. (-20° F to
110° F).

3.2 Controls and Graphics

WARNING: FAILURE TO
FOLLOW THE PROCEDURES
LISTED IN THIS MANUAL AND
THE ENGINE’S OWNER’S
MANUAL COULD RESULT IN
PERSONAL INJURY OR
EQUIPMENT DAMAGE.

Brake Pressure PSI
(Fig 3.2B arrow A)

Steering & Hoist PSI
(Fig 3.2B arrow B)

Disconnect Switch
(Fig 3.2B arrow C)

Brake Pressure Adjust
(Fig 3.2B arrow D)

Steering & Hoist Adjust
(Fig 3.2B arrow E)

24 Volt Ammeter
(Fig 3.2B arrow F)

Refer to the engine owner’s manual for
explanation of controls and symbols
located on the engine.

The following decals are placed on the
power unit to aid in its operation and
maintenance. The operator should locate
and understand them before using this
power unit.

Clutch engagement
(Fig 3.2A)

Fig 3.2A

24 Volt Plug
(Fig 3.2B arrow G)

Fuel Level
(Fig 3.2B arrow H)

40 Amp Breaker
(Fig 3.2B arrow I)

Vehicle Hydraulic Tank APU Return
(Fig 3.2C arrow A)

Brake Pressure Out
(Fig 3.2C arrow B)

Steering & Hoist Out
(Fig 3.2C arrow C)

Vehicle Reservoir APU Suction
(Fig 3.2C arrow D)