Lukas PC 650 User Manual

1450000085 ENHydraulic power units GC/PC 650(Translation of the original instruction manual)Instruction manual Rerailing equipmentEdition 08.2014

103. Proper useYou can obtain accessories and replacement parts for the hydraulic power unit from your authorised LUKAS dealer!WARNING / CAUTION / ATT

11-4. Assembly markingGC650 E2POWERMotor variants and coding for hydraulic power unitsType groupwith electric starterValve variants: 2POWER = Simultan

12 5.2 Layout of the units123456789101213141515 1 Hydraulic fl uid tank 2 Petrol tank 3 Petrol engine with hydraulic pump 4 Connection block with

13 5.3 Motor variants WARNING / CAUTION / ATTENTION! For all motor variants, also comply with the separate operating instructions of each motor manu

14 5.4 Valve variantsThe valves are always rigidly mounted in a connection block. This block is directly integrated in the hydraulic power unit. The h

15LUKAS 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 conn

166. Connecting the hoses / devicesATTENTION!When connecting the hose lines, always ensure that the connection components are not dirty. If necessary,

177. Erection and start-up 7.1 Set-up 7.2 Start-upWARNING / CAUTION / ATTENTION!Because of possible spark formation, combustion engine units and elect

188. OperationATTENTION!The control levels on the hydraulic power units should always be switched to the neutral position prior to starting the motor

19 8.2 Stopping the engineWARNING / CAUTION!Never touch the hot engine parts: this could result in severe burns. 8.2.1 Petrol enginesThe engine on t

2 Content Page1. Danger classifi cations 52. Product safety 63. Proper use 104. Assembly marking 115. Functional description 11 5.1 General

20 8.4 Controlling the valves 8.4.1 Control valve "Two fl ow mode" (2POWER)ATTENTION!The control levels on the hydraulic power units shoul

21 8.4.2 Control valve "Four fl ow mode" (4POWER)There are four levers mounted on the connection block of this valve.Each of the four smal

22After completing the work and before stopping the unit, place all connected units to the base setting (storage setting). You can then stop, or switc

2310. TestsThe hydraulic power units are subject to very high levels of stress. A visual inspection must therefore be carried out after every use and

24Visual InspectionHydraulic power units• check that all hydraulic connections are still tight• general tightness, no leaks (sweated oils do not hav

25 10.3 Hydraulic units with electric motorVisual InspectionHydraulic power units• Check that all hydraulic connections are still tight• General ti

2611. Maintenance and repair 11.1 General informationLUKAS hydraulic power units type GC and PC 650 have a complex structure and therefore require on

27 11.2 Service work on the hydraulic unit11.2.1 Care instructionsThe exterior of the device must be cleaned from time to time (not the electrical co

28ABC4. Fit the components "A" and "C" back in place in reverse order.5. Pour the new hydraulic fl uid through the fi ller neck in

2911.2.4 Changing decalsAll damaged and/or illegible decals (safety notices, type plate etc.) must be replaced.Procedure:1. Remove damaged and/or ille

312. Troubleshooting 3413. Technical data 40 13.1 GC 650-2POWER 41 13.2 GC 650-4POWER 42 13.3 GC 650E-2POWER 43 13.4 GC 650E-4POWER 44 13.5 PC

30Air fi lter insert11.3.1 Replacing and cleaning the air fi lterKeeping the air fi lter in good condition is extremely important.Penetrating dirt leads

3111.3.2 Replacing, cleaning and setting the sparking plugProcedure:1. Remove the right side panel on the hydraulic power unit by releasing the fi xin

3211.3.4 External charging or replacing the starter batteryProcedure:1. Remove the left side panel "A" on the hydraulic power unit by relea

333. If you want to charge the battery using an external charger you need to connect it now. (Observe the operating instructions for the charger being

3412. TroubleshootingIn the case of defects which directly affect the motor / engine, please consult the separate operating instructions of the motor

35Fault Check Cause SolutionCombustion engine will not startCheck fuel level in tankFuel tank empty Top up with fuelElectric starter present?Electric

36Fault Check Cause SolutionThe engine is running, but the connected equipment does not move upon activation of the valve.Check hose Hose assembly not

37Fault Check Cause SolutionConnected equipment does not reach its end positionCheck hydraulic fl uid volume in hydraulic tankInsuffi cient fl uid in the

38Fault Check Cause SolutionFluid coming out of hydraulic fl uid tankConnected unit not in rest position yet and fl uid coming out of fi ller cap?Returni

39Fault Check Cause SolutionIt is frequently not possible to couple hose assembliesHydraulic fl uid not adapted to the application situationHydraulic fl

4

4013. Technical dataNOTE:The following tables contain only the most important Technical Data. Additional data concerning your unit can be obtained fro

41 1) HD = High pressure 2) ND = Low pressure 3) 1MPa = 10 bar13.1 GC 650-2POWERDevice type GC 650-2POWER Units RemarksItem number 70-10-10Dimensi

42 1) HD = High pressure 2) ND = Low pressure 3) 1MPa = 10 bar13.2 GC 650-4POWERDevice type GC 650-4POWER Units RemarksItem number 70-10-20Dimensi

43 1) HD = High pressure 2) ND = Low pressure 3) 1MPa = 10 bar13.3 GC 650E-2POWERDevice type GC 650E-2POWER Units RemarksItem number 70-10-15Dimen

44 1) HD = High pressure 2) ND = Low pressure 3) 1MPa = 10 bar13.4 GC 650E-4POWERDevice type GC 650-4POWER Units RemarksItem number 70-10-25Dimens

4513.5 PC 650-2POWER 1) HD = High pressure 2) ND = Low pressure 3) 1MPa = 10 barDevice type PC 650-2POWER Units RemarksItem number 70-10-30Dimensi

4613.6 PC 650-4POWER 1) HD = High pressure 2) ND = Low pressure 3) 1MPa = 10 barDevice type PC 650-4POWER Units RemarksItem number 70-10-40Dimensi

47 13.7 Noise emissions of the power units 13.8 Sparking plug 13.10 FuelSparking plug type: BR6HS (NGK)Fuel: Lead-free petrol ROZ 91 to ROZ 98

48 13.12 Hydraulic fl uid recommendation 13.13 Operating and storage temperature rangeMineral oil DIN ISO 6743-4 for LUKAS hydraulic equipment and othe

4914. EC Declarations of conformity

5 Wear a helmet with a face guard Wear protective gloves Wear safety shoes Proper recycling Protect the environment Read and follow the operati

50 15. Notes

51

LUKAS Hydraulik GmbHA unit of the IDEX CorporationWeinstrasse 39, D-91058 Erlangen, GermanyTel.: (+49) 0 91 31 / 698 - 0Fax.: (+49) 0 91 31 / 698 -

62. Product safetyLUKAS products are developed and manufactured to ensure the best performance and quality when used as intended.The safety of the ope

7In the event of malfunctions, immediately deactivate the device and secure it. Repair the fault immediately.Do not carry out any changes (additions o

8Keep combustion engines and their fuels away from sources of ignition since otherwise there will be a danger of explosion.All damaged electrical comp

9The generally applicable, legal and other binding national and international regulations pertaining to the prevention of accidents and protection of