PortaCo G-18S10-54-W Operation Manual Download Page 3

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HYDRAULIC POWER UNIT G-18S10-54-W

OPERATION MANUAL

Change overview

Auditing

Date

Comment, including chapter

Changed by

01
02

03

04-25-2018
04-30-2018

07-09-2018

Creation
Table 8.1 maintenance, DOC # 6253-OOP,4.2 Table length,
4.3 max pressure, 8.2 table changed sealings to seals.
Updated Title, Tables

Sven Kummer
Jesse Bunn

Garrett Lee

Summary of Contents for G-18S10-54-W

Page 1: ...OPERATION MANUAL HYDRAULIC POWER UNIT G 18S10 54 W ...

Page 2: ...HYDRAULIC POWER UNIT G 18S10 54 W OPERATION MANUAL 2 ...

Page 3: ...iew Auditing Date Comment including chapter Changed by 01 02 03 04 25 2018 04 30 2018 07 09 2018 Creation Table 8 1 maintenance DOC 6253 OOP 4 2 Table length 4 3 max pressure 8 2 table changed sealings to seals Updated Title Tables Sven Kummer Jesse Bunn Garrett Lee ...

Page 4: ...ification of the operating and maintenance personnel 14 3 5 Emergency information safety devices 14 4 Design and function 15 4 1 Design 15 4 2 Specifications 16 Table 2 Specifications 16 4 2 1Hydraulic fluid 16 Table 3 Hydraulic fluid 16 Table 4 Types of hydraulic fluid 16 4 2 2Fuel and oil 17 Table 5 Types of oil 17 4 2 3Supply interfaces and connections 17 4 3 Function 17 4 4 Boundaries and inte...

Page 5: ...sting the hydraulic system 23 7 3 Remove condensation 23 7 4 Change Refill of engine oil 24 7 5 Change Refill of hydraulic fluid 25 7 6 Refill fuel 26 8 Maintenance and repairs 27 8 1 General information for maintenance and repairs 27 8 2 Troubleshooting and repairs 27 Table 7 Troubleshooting 27 9 Shutdown and re commissioning 28 10 Storage 28 11 Dismantling and disposal 28 ...

Page 6: ...OPERATION MANUAL 6 Publisher PortaCo Inc 1805 2nd Ave N Moorhead MN 56560 Phone 1 218 336 0223 Fax 1 218 233 5281 info portaco com www portaco com Date of publication 04 25 2018 Documentation version 1 0 Document number 6253 OOP_rev1 0 ...

Page 7: ... company s specialized staff In addition to the operation manual the spare part catalogue and the maintenance manual of the manufacturers of the individual components are to be observed WARNING Operating errors using the device e g by instruction errors may lead to personal injury or damage to the device The instruction for use must be accessible to operators and maintenance personnel at all times...

Page 8: ...le for safe transport Furthermore there is a pedestal across from the wheels for parking the hydraulic unit Fuel and auxiliary materials for operating the combustion engine are not included in PortaCo Inc s scope of service Additional design information is shown and described in chapter 4 Regarding ergonomics the stresses and strains resulting from the device are typical for a device in the constr...

Page 9: ...s The machine is designed for use on construction sites outdoors It can be used at temperatures between 20 C to 45 C 4 F to 113 F The temperature of the hydraulic fluid should be at least 10 C 50 F The statutory minimum distance must be observed around power lines and conductor rails When working in tunnels the country specific safety regulations must be observed 2 3 2 Emissions In technically per...

Page 10: ...ons of the device cannot be captured and depicted within this manual Modifications to the machine must be made by the distributing company In this case this instruction for use and the system documentation of the machine also be adapted The chapter on safety regulations serves to explain the depiction of the safety regulations and symbols inform users about dangers residual risks and measures for ...

Page 11: ... the hydraulic hoses is possible Only use the machine within the prescribed limits Before disconnecting the hydraulic couplings make sure that the pressure is relieved The machine must be maintained at regular intervals the intervals are specified by the operator s risk assessment DANGER Contact with live parts results in the worker sustaining a lethal electric shock In the case of railway tracks ...

Page 12: ...transport Always park the device securely on the pedestal Ensure that the air pressure in the tires is sufficient Wear safety shoes Use the lifting lugs intended for this purpose during transport Do not stand under suspended loads WARNING Improper maintenance or maintenance not carried out on time may result in damage to the machine or injury to persons Maintenance intervals are to be determined b...

Page 13: ...ng the device e g by instruction errors may lead to personal injury or damage to the device The instruction for use must be accessible to operators and maintenance personnel at all times A copy of the technical documentation including the instruction for use must be kept in a suitable and accessible place CAUTION The hydraulic oil heats up during operation Leaking hydraulic oil can easily burn the...

Page 14: ...e functions operators instruction for use operators Conduct in work area all Location of safety devices operators Personal protective equipment all Furthermore operators should possess the necessary physical and mental capacities which are required to operate and service the machine The operating personnel must wear personal protective equipment according to the job at hand and dangers of the envi...

Page 15: ...t 2 1 Drive motor 8 Filler neck gasoline 2 Refill opening motor oil 9 Filler neck hydraulic fluid 3 Dipstick motor oil 10 Ignition switch 4 Transport rolls 11 Display operating hours 5 Transport handle 12 Flow regulator hydraulic fluid 6 Locking mechanism for transport handle 13 Choke and gas 7 Pedestal 14 Connection hydraulic flow and return flow ...

Page 16: ...uid should meet the following requirements Criteria Value Viscosity at 10 C 95 cSt Viscosity at 38 C 27 42 cSt Viscosity at 60 C 16 5 cSt Pour point 23 C 10 F Viscosity index ASTM D2220 min 140 Flash point ASTM D92 min 171 C 340 F Pump wear test ASTM D2882 max 60 mg Demulsibility ASTM D1401 max 30 minutes Table 3 Hydraulic fluid The following hydraulic fluids or equivalent are suitable for use Man...

Page 17: ... with fuel for the combustion engine and with hydraulic fluid is carried out on the control panel of the Hydraulic Power Unit Oil filling for the combustion engine is carried out on the engine itself The quick couplings and filling openings are shown in chapter design 4 3 Function Hydraulic energy for operating hydraulic tools is provided by PortaCo Inc s Hydraulic Power Unit The hydraulic unit su...

Page 18: ...disassembly The Hydraulic Power Unit is equipped with a transport handle and two wheels The hydraulic unit can be pushed to the operation site using these 1 Flip the transport handle up and lock it in the upper position 2 Lift the Hydraulic Power Unit slightly and push the hydraulic unit 3 Flip the transport handle down after transport The Hydraulic Power Unit is also equipped with transport lugs ...

Page 19: ... up of the machine may only be carried out by qualified specialist personnel The start up engineer must be acquainted with the machine Requirements for start up are the Hydraulic Power Unit have been tested and is ready for operation safety devices have been tested and are ready for operation all detachable connections have been checked and tightened if necessary 6 2 Operation A visual inspection ...

Page 20: ...mately 3 to 5 minutes 8 Set the gas lever all the way to fast 9 Turn the flow regulator for the hydraulic fluid to the on position If the temperature of the hydraulic fluid is below 10 C 50 F then let the hydraulic unit idle to warm up Operation of the tools is carried out directly on the tool 6 2 2 Shutdown 1 Set the flow regulator for the hydraulic fluid to the OFF position 2 Set the gas lever t...

Page 21: ...aluation and risk assessment Observe the guidelines in the applicable directives Service and maintenance measures are permitted only by qualified specialist companies Maintenance must be documented by the operator It should be clear who carried out the work when and where proof of maintenance Only original spare parts as well as suitable tools may be used The recommended maintenance intervals and ...

Page 22: ...vel x Change x 1 x 2 x Air filter Check x Clean x Fuel filter Replace x Spark plug Replace x Oil filter Replace x Air pre filter Clean x Valve clearance Adjust x Fuel line Check every 2 years Filling level hydraulic fluid Check x Hydraulic fluid and filter Change x Hydraulic fluid Dry x Hydraulic system Check for leaks x Pump coupling Check replace if necessary every two years by specialist Hydrau...

Page 23: ...ic fluid to the on position 11 Set the gas lever all the way to fast 12 Check the flow and pressure The counter pressure should measure 17 bar 247 psi The flow rate should be 40 lpm 10 gpm 13 Slowly close the throttle on the hydraulic tester and watch the display for flow rate and pressure The pressure relief valve should open at a pressure between 145 and 155 bar 2 103 and 2 248 psi If the pressu...

Page 24: ...r oil 2 Unscrew the drain plug and let the motor oil drain off 3 Screw the drain plug back in 4 Place the tray under the filter and remove the oil filter 5 Mount a new oil filter Grease the sealing of the new oil filter beforehand with a little motor oil Turn the screw another half turn after the sealing has contact with the hydraulic unit 6 Fill with fresh motor oil Use a funnel to prevent contam...

Page 25: ...hydraulic fluid out 3 Screw the drain plug back in 4 Place the tray under the filter and remove the hydraulic filter 5 Mount a new hydraulic filter Lubricate the sealing of the new hydraulic filter with a little hydraulic fluid Turn the screw another half turn once the sealing has contact with the hydraulic unit 6 Fill with fresh hydraulic fluid approximately 20 liters 5 3 US gal Use a funnel to p...

Page 26: ...NUAL 26 7 6 Refill fuel The fuel filling level is determined by a float and can be read on the lid Figure 9 10 Fuel display Fill up the fuel no further than the full marking Use a funnel to prevent soiling the surroundings Figure 11 12 Top off fuel ...

Page 27: ...ly work on electrical system parts may only be made by electrical specialists 8 2 Troubleshooting and repairs Malfunction Possible causes Remedy Device not working or too slow Hydraulic fluid level too low Top off hydraulic fluid or replace Connection not airtight or loose Check connections and seals and tighten or replace seals Air in device Bleed system Mechanical error Check the entire device f...

Page 28: ...nsure that all connections and opening are well sealed Check for correct storage monthly If the hydraulic unit is stored for more than 3 months the quality of the hydraulic fluid must be checked and replaced if necessary before a new start up 11 Dismantling and disposal Before dismantling or disposal the machine must be decommissioned This must be followed by draining the hydraulic fluid and prope...

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