LUCAS 84072930085 Operating Instructions Manual Download

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Operating instructions

Rerailing Equipment

Edition 08.2009

84072930085 GB

Hydraulic units

(Translation of the original operating instructions)

Summary of Contents for 84072930085

Page 1: ...Operating instructions Rerailing Equipment Edition 08 2009 84072930085 GB Hydraulic units Translation of the original operating instructions ...

Page 2: ... 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 1 Starting the motors 15 8 2 Stopping the motors 16 9 Dismantling the equipment deactivation following operation 17 10 Maintenance and service 18 10 1 Recommended inspection intervals 18 10 2 Hydraulic units with combustion engine 19 10 3 Hydraulic units with electric motor ...

Page 3: ...3 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 Notes 38 ...

Page 4: ...zard and possible consequences Hazard classes 1 Pictogram Damage injury to Key word Definition Consequences human DANGER Immediate danger Death or major injury WARNING Potentially dangerous situation Potential death or major injury CAUTION Less dangerous situation Minor or slight injury device CAUTION Danger of damage to device environment Damage to the equipment damage to the environment damage t...

Page 5: ...erating instructions for the hoses the accessories and the connected hydraulic equipment must also be observed Even if you have already received instructions on how to use the equipment you should still read through the following safety instructions once again WARNING CAUTION Ensure that the accessories and connected equipment used are suitable for the maximum operating pressure Please ensure that...

Page 6: ... the operation of the equipment Comply with all specified dates or dates specified in the operating instructions pertaining to regular checks inspections of the equipment When working close to live components and cables suitable measures must be taken to avoid current transfers or high voltage transfers to the equipment Only original LUKAS accessories and spare parts may be used for repairs During...

Page 7: ...e influences of extreme temperatures The equipment is filled with hydraulic fluid These hydraulic fluids can be harmful to your health if swallowed or if their vapours inhaled Direct contact with the skin is to be avoided for the same reason Please also note that hydraulic fluids can also have a negative effect on biological systems When working with or storing the equipment ensure that the functi...

Page 8: ... proper use Never work when you are overtired or intoxicated Proper use 3 Accessories and spare parts for the rerailing equipment are available from your authorised LUKAS dealer WARNING DANGER CAUTION Always observe the safety notes of these operating instructions with regard to place of installation and type of installation The units must not be used in all atmospheres since there could be a dang...

Page 9: ... combinable LUKAS components unit implements etc of your system arrangement will continue to function correctly and that risks to persons and equipment are eliminated Operation without an attached or external control unit is NOT permitted 1 Fluid reservoir 2 Motor 3 Pump 4 Frame 5 Connecting block As a general principle on all LUKAS hydraulic units a hydraulic pump is operated with a motor combust...

Page 10: ...tails please consult the separate operating instructions of the engine manufacturer 5 2 3 Diesel These hydraulic units are equipped with a combustion engine driven by the fuel diesel For specific details please consult the separate operating instructions of the engine manufacturer 5 3 Pumps Depending on the model LUKAS hydraulic units contain a single flow or multi flow pump Single flow pump 1 pum...

Page 11: ... 5 7 Optional accessories 5 7 1 Hose reels Some hydraulic unit frames allow hose reels to be fitted The use of attachment reels makes it possible to route the optimum length of hose for a specific application and to keep the amount of hose needed in the work area to a minimum The hose reels are connected to the pump assembly mechanically and hydraulically The hydraulic connection is achieved eithe...

Page 12: ...draulic pump via quick disconnect coupling halves male and female Before coupling remove the dust protection caps then pull back and hold the locking sleeve of the female coupling position X Fit the socket and plug together and release the locking sleeve Then turn the locking sleeve to position Y The connection has now been made and locked Disconnection is made in the reverse order WARNING DANGER ...

Page 13: ...onto the connecting block directly you must check first whether the corresponding connection nipples are fitted inside the connecting block CAUTION Always connect the return hose first and then the supply hose Set up and start up 7 7 1 Installation WARNING DANGER CAUTION Combustion engine units and most electrical units must not be used in a potentially explosive situation danger of the formation ...

Page 14: ...ate operating instructions for the control unit concerned The actual venting is carried out in the units in a different manner depending on the drive motor a Gasoline petrol engine Remove plug connector from the spark plug Slowly turn the starter rope several times For a motor with electric starter activate the starter several times Then replace the plug connector b Diesel engine Slowly turn the s...

Page 15: ...on C 3 Pull the starter rope or activate the E starter Procedure for starting Intek engines 1 Open gasoline petrol tap 2 Move top lever from switching position E to switching position F 3 Move bottom lever choke from switching position G to switching position H 4 Pull the starter rope or activate the E starter 5 When the motor is running switch bottom lever back to switching position G Procedure f...

Page 16: ...enerator you should therefore check to see that it can also supply the relevant current strength For motors rated up to 1 5 kW the power supply must be protected by a fuse with a minimum rating of 25 A slowblow For motors rated over 1 5 kW the minimum fuse rating is 30 A slowblow As the information above may vary depending on individual circumstances and on the type of motor used you should always...

Page 17: ...ngs Ensure that you replace the dust protection caps onto the mono coupling halves Clean heavy soiling caused during use of the hydraulic unit before storage Direct connection This connection should only be unscrewed when it is absolutely necessary e g when you have a longer storage time when decommissioning for maintenance tasks etc If the connected hose assemblies have to be dismantled during sh...

Page 18: ...ce and repair work tools appropriate for the job and personal protection equipment obligatory including protective covers 10 1 Recommended inspection intervals Operating time per day Function test up to 1 hour 1 x annually up to 8 hours 1 x per quarter up to 24 hours 1 x per month In addition to these inspection intervals a function test should be performed if the unit is making suspicious noises ...

Page 19: ...ks 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 10 2 Hydraulic units with combustion engine 10 3 Hydraulic units with electric motor Visual inspection Hydraulic units Check that all hydraulic connections are tightened General tightness no leakage the hot oils do not ...

Page 20: ... only be carried out by the manufacturer or personnel trained by the manufacturer and by authorised LUKAS dealers Only LUKAS spare parts may be used to replace all components see spare parts list since special tools assembly instructions safety aspects inspections might have to complied with see also chapter Maintenance and service Duringallinstallationwork payparticularattentiontothecleanlinessof...

Page 21: ...c 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 Place the collection basin underneath the drain plug of the unit 2 Loosen filler screw C or D drain plug A and seal ring B on the unit and collect the fluid in the prepared receptacle This enables easy cleaning of the hydraulic unit 3 We recommen...

Page 22: ...22 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 E F G H ...

Page 23: ...23 Take care not to lose spacer rings N 6 Free the entire reservoir of dirt using a smooth cloth J K ...

Page 24: ...or tightening torque see spare parts list 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 Finally the unit must be vented as described in the chapter entitled Start up M L ...

Page 25: ...r any torques and additional assembly instructions 11 3 2 Quick disconnect couplings The quick disconnect couplings must be replaced in the event of external damage the locking device not working hydraulic fluid continually leaking in a coupled uncoupled state WARNING DANGER CAUTION Never repair couplings they are to be replaced by original LUKAS parts Procedure when mounted on hoses 1 Loosen the ...

Page 26: ... Position the new screw in sleeve and tighten it with a torque of MA 40 Nm 11 3 5 Replacing the engines motors Replace the engines motors if they are defective and direct repair of the valve block by a dealer or the manufacturer is no longer possible The engine motor may only be replaced with the hydraulic motor switched off Electric motors must be disconnected from the power supply Engines motors...

Page 27: ...ecuring bolts and nuts Please consult the spare parts list for the necessary torques 6 For combustion engine pumps top up the necessary liquid levels e g engine oil fuel For electric motor pumps connect the necessary electrical cables 7 Perform a function test with the hydraulic unit as described in the chapter entitled Maintenance and service 11 3 6 Labels All damaged and or illegible labels safe...

Page 28: ... hose reels with hoses The hydraulic connection of the attachment hose reels is established in the same way as for hoses connected directly to the connecting block or valve block of the hydraulic unit For instructions on how to connect the hose lines refer to the procedure described under Direct connection in the Repairs chapter Procedure for fitting an attachment hose reel 1 Place the carrier pla...

Page 29: ...sary 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 Slot union nut D onto the pipe with the thread facing towards the end of the pipe 4 Slot olive E fully onto the pipe 5 Fit the pipe with coupling sleeve into connection nipple G 6 Slide the union nut up to the connection nipple and screw it on tight...

Page 30: ...hange The work required to replace the connecting block or drain valve is performed at pump carrier plate O 2 Loosen union N securing the pipes to the connecting block or drain valve and unscrew return line M from the connecting block 3 Loosen securing screws L from the connecting block or drain valve and remove the screws along with washers K underneath 4 Now you can remove the connecting block o...

Page 31: ...acturer or directly by LUKAS Switch switched on and off too rapidly in succession switching time 5 seconds Switch on the motor and wait until the start capacitor has charged The motor will then start on its own Combustion engine will not start Fuel tank empty Top up fuel Electric starter battery flat Charge electric starter battery Fuel tap not open Open the fuel tap Starting switch is not at ON S...

Page 32: ... directly by LUKAS Defective hydraulic coupling if fitted Replace hydraulic coupling Pressure relief at control unit still active depressurised circulation Consult the separate operating instructions for the control unit Trouble Cause Solution Connected implement does not reach its end position Insufficient fluid in the hydraulic reservoir Top up hydraulic fluid to the maximum filling level Attent...

Page 33: ...ctive hydraulic coupling Hydraulic coupling needs to be replaced immediately With quick disconnect coupling system Leak in the coupling male Safety valve reacted After pressure release there is no more leakage Defective hydraulic coupling Hydraulic coupling nipple needs to be replaced immediately With quick disconnect coupling system Leak in the coupling female Defective hydraulic coupling Hydraul...

Page 34: ...x h mm 560 x 540 x 695 in 22 04 x 21 26 x 27 36 motor type electric motor 400V 50Hz motor power kW 2 2 HP 2 95 rotation speed min 1 2850 rpm max operating pressure HP 1 MPa 3 53 psi 7 687 max operating pressure LP 2 MPa 3 23 psi 3 336 flow rate HP 1 l min 2 3 gal US min 0 61 flow rate LP 2 l min 5 3 gal US min 1 40 max fill up quantity l 42 gal US 11 10 max useable quantity l 35 gal US 9 25 weight...

Page 35: ... HP 1 MPa 3 53 psi 7 687 max operating pressure LP 2 MPa 3 23 psi 3 336 flow rate HP 1 l min 2 5 gal US min 0 66 flow rate LP 2 l min 5 9 gal US min 1 56 max fill up quantity l 42 gal US 11 10 max useable quantity l 35 gal US 9 25 weight incl all max fluid fill up quantities kg 55 lbs 121 3 ambient temperature C 20 55 F 4 131 max options to connect devices 1 1 HP High pressure 2 NP Low pressure 3 ...

Page 36: ...P 1 MPa 3 53 psi 7 687 max operating pressure LP 2 MPa 3 23 psi 3 336 flow rate HP 1 l min 2 5 gal US min 0 66 flow rate LP 2 l min 5 3 gal US min 1 40 max fill up quantity l 40 gal US 10 57 max useable quantity l 32 gal US 8 45 weight incl all max fluid fill up quantities kg 81 lbs 178 6 ambient temperature C 20 55 F 4 131 max options to connect devices 1 1 HP High pressure 2 NP Low pressure 3 1 ...

Page 37: ...ctions for the hydraulic hoses Mineral oil DIN ISO 6743 4 for LUKAS hydraulic equipment and others Oil temperature range Oil code Viscosity rating Remarks A 24 30 C HL 5 VG 5 B 18 50 C HM 10 VG 10 C 8 75 C HM 22 VG 22 D 5 80 C HM 32 VG 32 E 8 70 C HF E15 VG 15 Bio oil Oil temperature range Oil code Viscosity rating Remarks A 11 2 86 F HL 5 VG 5 B 0 4 122 F HM 10 VG 10 C 17 6 167 F HM 22 VG 22 D 41...

Page 38: ...38 Notes 14 ...

Page 39: ...39 ...

Page 40: ... LUKAS Hydraulik GmbH Aggregate_BA_GB_84072930085_0809 indd Please dispose all packaging materials and dismantled parts properly Subject to revision 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 ...

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