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Summary of Contents for LUCAS 84072930085
- Page 1 Operating instructions Rerailing Equipment 84072930085 GB Hydraulic units Edition 08.2009 (Translation of the original operating instructions)
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Page 2: Table Of Contents
Content Page 1. Hazard classes 2. Product safety 3. Proper use 4. Labelling of the units 5. Functional description 5.1 General 5.2 Motor variants 5.3 Pumps 5.4 Frames 5.5 Connection to the control unit 5.6 Connection options 5.7 Optional accessories 6. - Page 3 12. Troubleshooting 13. Technical data 13.1 Hydraulic power pack 13.2 Recommended hydraulic fluid 13.3 Hoses 13.4 Operating temperature and storage temperature ranges 14. Notes...
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Page 4: Hazard Classes
Hazard classes We distinguish between various categories of safety instructions. The table below gives you an overview of the assignment of symbols (pictograms) and key words to the specific hazard and possible consequences. Damage / injury Pictogram Key word Definition Consequences Death or major DANGER! -
Page 5: Product Safety
Product safety LUKAS products are developed and manufactured in order to guarantee the best performance and quality when used properly. Operator safety is the most important aspect of the product design. Moreover, the operating instructions are intended to ensure LUKAS products are used 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. - Page 6 In the event of malfunctions, Do not carry out any changes immediately shut down the (additions or conversions) to the equipment and secure it. The equipment without obtaining the malfunction is to be repaired prior approval of LUKAS. immediately. Comply with all the instructions All the instructions regarding regarding safety and danger safety and danger on the...
- Page 7 Keep combustion engines and All damaged electrical their fuel away from ignition components e.g. scorched sources, as otherwise there is cables, etc. are to be replaced the danger of an explosion. immediately. To avoid the risk of fire, ensure Damage to electrical adequate ventilation during components must be repaired combustion engine operation...
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Page 8: Proper Use
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. WA R N IN G / D A N GER / CA UTION! The equipment is to be used exclusively for the purpose stated in the operating instructions (see chapter "Proper use"). -
Page 9: Functional Description
Functional description 5.1 General The main components (see example illustration) of a LUKAS hydraulic unit are: 1 Fluid reservoir 6 Valve block 2 Motor 7 Carry handles 3 Pump 8 Fluid drain plug 4 Frame 9 Filler cap 5 Connecting block 10 Optional hose reel attachment As a general principle on all LUKAS hydraulic units, a hydraulic pump is operated with a motor (combustion engine or electric motor) that feeds the fluid from the reservoir and builds... -
Page 10: Motor Variants
5.2 Motor variants WARNING / DANGER / CAUTION! For all motor variants, also comply with the separate operating instructions of each motor manufacturer. 5.2.1 Electrical These hydraulic units are equipped with an electric motor. The electric motor is driven by electricity from the mains supply or by electricity produced by generators. -
Page 11: Frames
WARNING / DANGER / CAUTION! In the interests of safety, the pressure set at this pressure limiting valve must not be adjusted (without direct approval of LUKAS). 5.4 Frames All hydraulic units for the rerailing equipment are supplied with a frame. The frame enables optional accessories to be attached directly to it. -
Page 12: Connection Of The Hoses
Connection of the hoses CAUTION! When connecting the hose assemblies, always ensure that the connection components are not soiled; clean beforehand if necessary. REMARK: Before you attempt to connect or disconnect hose lines to or from the hydraulic unit, including hose lines with quick-disconnect couplings, always make sure that the pump assembly is switched off. -
Page 13: Direct Connection
6.2 Direct connection REMARK: To be able to screw the hoses onto the connecting block directly, you must check first whether the corresponding connection nipples are fitted inside the connecting block. The hydraulic hoses are screw-connected to the connecting block of the hydraulic unit. The connecting block must contain the necessary connection nipples. -
Page 14: Start-Up
7.2 Start-up Please proceed as follows: 1. First of all, check the hydraulic fluid level of the unit. Depending on the unit model, the fluid level is indicated by a fluid sight glass (maximum = centre of sight glass; refill required if fluid level no longer visible in the sight glass) or a dipstick (usually attached to a filler screw). -
Page 15: Operation
Operation CAUTION! Before the motor is started, the hydraulic unit and the control unit must be switched to depressurised circulation (for the hydraulic unit, this means connecting the supply and return lines together, for example). Only in this way is it possible to start the unit without a hydraulic load. -
Page 16: Stopping The Motors
An electric starter is available from the LUKAS range of accessories for some units. (For specific details, please consult the LUKAS range of accessories or contact your LUKAS dealer). On these units, after checking the fluid levels, proceed as follows: Switch to "START ENGINE" Turn the ignition key clockwise. Charge the accumulator of the electric starter: Switch to "CHARGE BATTERY"... -
Page 17: Dismantling The Equipment / Deactivation Following Operation
2. When the engine has come to a standstill, close the fuel tap. Procedure for stopping Honda engines: 1. Set the ON / OFF switch to the OFF position. 2. When the engine has come to a standstill, close the fuel tap. -
Page 18: Maintenance And Service
Maintenance and service The hydraulic units are subject to very high mechanical loads. For this reason, visual inspections and function tests must be carried out at regular time intervals. These inspections and tests enable signs of wear to be identified in good time. Prompt replacement of wear parts can then prevent damage to the equipment. -
Page 19: Hydraulic Units With Combustion Engine
10.2 Hydraulic units with combustion engine Visual inspection Hydraulic units • Check that all hydraulic connections are tightened • General tightness, no leakage (the hot oils do not have any influence on the function) • Is there damage to the motor, connecting block or housing? •... -
Page 20: Repairs
Function test • No suspicious noises • Checks 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.) Repairs 11.1 General Servicing may only be carried out by the manufacturer or personnel trained by the manufacturer and by authorised LUKAS dealers. -
Page 21: Preventive Service
11.2 Preventive service 11.2.1 Care instructions The exterior of the equipment is to be cleaned from time to time in order to protect it from external corrosion. Oil is to be applied to the metallic surfaces. 11.2.2 Replacing the hydraulic fluid - After approx. 200 deployments, but after three years at the latest, replace the hydraulic fluid - The fluid should be replaced when it is warmed up. - Page 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.
- Page 23 Take care not to lose spacer rings “N”. Free the entire reservoir of dirt using a smooth cloth.
- Page 24 When you refit the reservoir, exchange the reservoir seal and fasten the securing bolts (for tightening torque, see spare parts list). Also replace the seal ring of the drain plug and fit it as specified in the spare parts list. Add the new hydraulic fluid to the reservoir through the filling plug.
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Page 25: Repairs
11.3 Repairs When carrying out permitted repairs, please observe the relevant spare parts lists with the remarks and drawings they contain. Should there be any uncertainties regarding the repairs, please contact your authorised LUKAS dealer or LUKAS Customer Service. CAUTION! As LUKAS hydraulic units are designed for extremely heavy loads, it is prohibited to attempt any repairs other than those described in the operating instructions. - Page 26 11.3.3 Direct connection The screw-in sleeves must be replaced in the event of: - external damage - hydraulic fluid continually leaking in connected / unconnected state. Procedure: 1. Remove the screw-in sleeve from the valve block. 2. Position the new screw-in sleeve and tighten it with a torque of M = 40 Nm.
- Page 27 2. Pull the engine / motor off. Please ensure that you do not damage the engine / motor shaft mount. 3. Equip the shaft of the new engine / motor with an appropriate adjusting key (provided it is not already in place). 4.
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Page 28: Installation And Repair Of Optional Accessories
11.4 Installation and repair of optional accessories 11.4.1 Fitting attachment hose reels to the frame Attachment hose reels usually come prefitted and do not need to be removed unless the complete hose reel is to be exchanged. A retrofit kit is available and it contains all the necessary fasteners. The hose reels differ depending on which side they are to be fitted (left or right). - Page 29 11.4.3 Connection of attachment hose reels with pipework Before you connect the pipework, you must check that suitable connection nipples (GE-08) are present inside the connecting block and attachment hose reels. In case of doubt, please contact your authorised LUKAS dealer or LUKAS directly. Procedure: 1.
- Page 30 11.4.4 Replacing the connecting block or drain valve The connecting block or drain valve must be exchanged if the assembly is damaged, if continued and correct function is no longer guaranteed or if a permanent leak has developed in the assembly. It is possible to convert from a connecting block to drain valve arrangement and vice versa.
- Page 31 Troubleshooting For malfunctions directly related to combustion engines, please refer to the separate operating instructions issued by the engine manufacturer. Trouble Cause Solution Electric motor does not Power cable not connected Connect power cable start following activation of correctly the switch Electric motor defective or Shut down immediately overloaded due to another...
- Page 32 Trouble Cause Solution Motor runs but connected Hose assembly not Inspect the connection of implement does not move connected properly or is the hose assembly and, if in response to control damaged necessary, reconnect command. Defective pump unit Have repaired by authorised dealer or directly by LUKAS Defective hydraulic...
- Page 33 Trouble Cause Solution Fluid leaks from the Due to hydraulic fluid Reduce the level in the hydraulic fluid reservoir returning from the hydraulic fluid reservoir to (especially from the filler implement, the maximum the mark on the dipstick or screw) capacity of the tank is inspection glass exceeded...
- Page 34 Technical data As all values are subject to tolerances, there may be minor differences between the data achieved by your equipment and the data specified in the following table. 13.1 Hydraulic power pack 13.1.1 Basic data type PC-6 ref.no. 840729316 [mm] 560 x 540 x 695 dimensions...
- Page 35 type GC-6 ref.no. 840729317 [mm] 560 x 540 x 665 dimensions l x w x h [in.] 22.04 x 21.26 x 26.18 4-stroke motor type gasoline engine [kW] motor power [HP] 4.69 [min rotation speed 3100 [rpm.] [MPa] max. operating pressure (HP) [psi.] 7,687...
- Page 36 type DC-6 ref.no. 840729319 [mm] 550 x 480 x 742 dimensions l x w x h [in.] 21.65 x 18.90 x 29.21 4-stroke motor type diesel engine [kW] motor power [HP] [min rotation speed 2500 [rpm.] [MPa] max. operating pressure (HP) [psi.] 7,687 [MPa]...
- Page 37 13.1.2 Noise emissions (in accordance with EN ISO 3744): type PC-6 GC-6 DC-6 ref.no. 840729316 840729317 840729319 idle running [dB(A)] (measuring distance: 1m) full load [dB(A)] 93,7 (measuring distance: 1m) idle running [dB(A)] (measuring distance: 5m) full load [dB(A)] 83,5 (measuring distance: 5m) 13.2 Recommended hydraulic fluid Mineral oil DIN ISO 6743-4 for LUKAS hydraulic equipment and others...
- Page 38 Notes...
- Page 40 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. Please dispose all packaging materials and dismantled parts properly.
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