MODEL D-100D1540-G9-O POWER UNIT OPERATION, MAINTENANCE, AND REPAIR MANUAL

Transcription

1 MODEL D-00D50-G9-O POWER UNIT OPERATION, MAINTENANCE, AND REPAIR MANUAL 805 nd AVENUE NORTH * MOORHEAD, MN, USA PHONE (8) * FAX (8) ADDRESS; info@portaco.com * INTERNET ADDRESS:

2 TABLE OF CONTENTS.0 Introduction. General Information. Features.3 Options. Safety Summary.5 General Safety Precautions.6 Warning and Caution Statements.7 Training Requirements.3 Engine Oil Change. Engine Fuel Filter Change.5 Engine Coolant Service.6 Hydraulic System Service.7 Fuel Reservoir Service.8 Drip Pan Draining.9 Trouble Shooting.0 Technical Specifications.0 Installation Instructions. Unpacking Instructions. Engine Preparation.3 Hydraulic Power Unit Preparation. Testing.5 Hose Requirements.6 Tool Connecting Procedures.7 Hose Disconnecting Procedures.8 Work Area Safety Precautions 3.0 Operating Instructions 3. Description of Power Unit 3. Controls and Graphics 3.3 Before Start Up 3. Positioning the Power Unit 3.5 Power Unit Operation 3.6 Changing Flow Rate 3.7 Changing Pressure Relief Setting 3.8 Cold Weather Operation 3.9 Storage Preparation.0 Maintenance Instructions. Routine Servicing and Inspection Schedule. Assembly View and Parts List

3 .0 INTRODUCTION. General Information This manual presents installation, operation, and maintenance information for the D-00D50-G9-O PortaCo, Inc. Hydraulic Power Unit. This hydraulic power unit has open two open center circuits which provide variable flows up to 5gpm/ 57 Ltr on one circuit and up to 0gpm/5 Ltr on a second, at 500 psi/ 7.5 Bar. Both circuits can be operated at the same time. Each circuit is equipped with a set of gauges for monitoring the hydraulic system. CAUTION; Use only open center tools or control systems with this power unit. Failure to do so could result in damage to the power unit or tools and control systems. All engine controls and hydraulic system controls are located in a common control panel, allowing all functions to be operated from one location. Four lifting points allow the unit to be lifted by crane for placement and maintain a level position at all times. Large doors open to allow access for unit maintenance. The power unit fuel tank and oil tank are located inside the enclosure for protection from the elements.. Features The main features of the D-00D50- G9-O PortaCo series power unit are as follows: Width 9. cm 36 in Height 65. cm 65 in Weight Dry 558 kg 336 lbs Weight Wet 878 kg 0 lbs The power unit features a John Deere (05TF85/HF85) diesel engine and is shipped with a John Deere operator s manual. See the engine manual for operating and maintenance information concerning the engine. The engine is equipped with its own Volt DC charging system and will maintain the charge on the Volt battery in the power unit. The engine is also equipped with a block heater to assist in starting at low temperatures. The power unit is protected with Water temperature, oil pressure, and low fluid level shutdowns to prevent engine damage or hydraulic system damage. Two hydraulic circuits are monitored by separate flow and pressure gauges for each circuit. Each circuit has its own high pressure filter to assure clean oil. One return filter at the tank also removes contaminants which maybe introduced from tools or systems connected to the power unit. Remote drain locations for fuel tank, hydraulic tank, engine oil, and drip pan are located at each end of the enclosure. Exhaust system is wrapped to prevent exposure of hot surfaces to the operators. The enclosure is designed to lower the sound level and to prevent rain or water spray from entering the interior of the enclosure. Length 89.5 cm in 3

4 The fuel tank and hydraulic tank, including their filler tubes and caps, are located inside of the enclosure to protect them from the elements..3 Options There are no options at this time. Consult PortaCo, Inc. at for any special requirements.. Safety Summary Power unit operators and maintenance personnel must always comply with the safety precautions given in this manual 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..5 General Safety Precautions The PortaCo Inc. D-00D50-G9-O Hydraulic Power Unit is 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..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..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

5 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. Check the water level and add fluid as instructed in the engine operators manual. Radiator access cover is located on roof of enclosure. (Figure.B).0 INSTALLATION INSTRUCTIONS C. Unpacking Instructions C OIL FILLER 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.. Engine Preparation CAUTION: READ AND UNDERSTAND ENGINE MANUAL WHICH IS PROVIDED IN ADDITION TO THE PORTACO MANUAL BEFORE STARTING THE POWER UNIT. Figure.A DIPSTICK Access cover Radiator Cap CAUTION: ALWAYS CHECK ENGINE OIL AND COOLANT LEVELS BEFORE STARTING POWER UNIT. Make sure engine oil is at the FULL mark on the dipstick. (Figure.A) 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. Figure.B.3 Hydraulic Power Unit Preparation Check the fuel reservoir gauge (Figure 3.A) and add fuel as required. (Figure.3A) Check the hydraulic oil reservoir and add fluid as required to maintain a level near the top of the tank sight gauge. (Figure.3B) Inspect the hoses and fitting for leaks or damage. Replace leaking or damaged components before operating. 5

6 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. Fuel Fill Cap circuit to be tested. The valve s flow rating must exceed the rated flow of the circuit being tested and have are minimum pressure rating of 5000 PSI/35 Bar. The valve should have hose whips attached with the appropriate hydraulic quick connect couplers to connect to the hydraulic circuit being tested and rated for a working pressure of 3500 PSI/ Bar. Hoses for the 5 GPM/57 Ltr circuit must be ¾ ID or larger and ID or larger for the 0 GPM/5 Ltr circuit. Make sure the flow direction matches the restrictor valve being used. b. Set the restrictor valve to the open position. Figure.3A Hydraulic Tank Filler c. Set the hydraulic circuits to OFF. d. Start the engine and allow the hydraulic fluid to warm to about 00 F/38 C. e. Set the engine speed to maximum RPM (00 RPM). Figure.3B. Testing Sight Gauge 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. a. Connect a manual adjustable flow restricting valve to the hydraulic f. Set the flow control to ON. g. Check the flow rate and pressure on the gauges located in the power units control panel. The return pressure reading should be under 7.3 bar (50 PSI). The flow readings should match those listed in section. General Information of this manual. h. With engine throttle set at maximum speed slowly close the restrictor valve on the tester while observing the flow and pressure gauges. i. As the hydraulic system relief valve begins to crack (open) and bypass 6

7 fluid through the valve, the flow rate will begin to drop. At this time, the pressure in the system should be between BAR ( PSI). j. If the pressure is not as specified, the hydraulic circuit relief valve must be adjusted or replaced. (See section. for procedure.) - If the flow rate drops below the specified range, the pump or control valve may be worn. - If the flow remains constant, but pressure does not increase, the relief valve may be defective. Open restrictor valve to relieve pressure, reduce engine RPM to idle, and set hydraulic circuit to off, test valve can now be disconnected. Test only one circuit at a time to assure accurate flows and pressures for the circuit being tested..5 Hose Requirements The power unit should be moved close to the job site. It is not often necessary or advisable to use long hoses. All hoses must have an oil resistant inner surface and an abrasion resistant outer surface. Each hose must have male pipe ends for most applications. Longer hoses can be used when necessary, but can affect the operation of the engine due to resistance in the hose. the supply and return ports, the pressure required to push the fluid through the system and back to the tank will be higher. This will reduce tool power. *Important Oil should always flow from the male coupler through the female coupler. HOSE TYPES Hydraulic hose types authorized for use by PortaCo, Inc. are as follows:. Labeled and certified non-conductive. Wire braided (conductive) 3. Fabric braided (not certified or labeled nonconductive) Hose : Listed above is the only hose authorized for use near electrical conductors. Hoses and 3: Listed above are conductive and must never be used near electrical conductors. HOSE PRESSURE RATING The rated working pressure of the hydraulic hose must be at least 07 bar (3000 PSI.) If small diameter or long hoses are used, or if restrictive fittings are connected to 7

8 .6 Hose 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 FITTINGS WITH HANDS. PIN-HOLE LEAKS CAN PENETRATE THE SKIN. 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. NOTE: Clean ends of couplers before connecting to prevent system contamination. Connect the hose set to the circuit which meets the flow requirements of the tool being used. Connect the return hose to the female coupler at the control panel first. The operator will need to move the locking ring on the female coupler back to allow the hose to be connected to the male coupler. Connect the pressure hose to the male coupler at the control panel last. The fluid should flow from the male coupler though the female coupler. CAUTION: THE PRESSURE AND RETURN HOSE FOR A TOOL OR COMPONENT BEING POWERED MUST BE CONNECTED TO THE SAME CIRCUIT. DO NOT CONNECT THE PRESSURE HOSE TO ONE CIRCUIT AND THE RETURN HOSE TO THE OTHER CIRCUIT. DAMAGE TO THE HYDRAULIC SYSTEMS MAY ACCURE IF IMPROPERLY CONNECTED. If a case drain connection is required to operate the tool, connect to the female coupler labeled CASE DRAIN on the control panel. See section 3. for coupler locations and hydraulic system labeling..7 Hose Disconnecting Procedure Slow the engine to an idle, and shut the hydraulic circuits OFF. Disconnect the pressure hose first to prevent pressure from being trapped in the hoses. Move the locking collar back on the female coupler to break the connection. Disconnect the return hose last. Disconnect the case drain hose if it was used with the circuit being disconnected. Wipe up any spills from disconnecting the couples immediately to keep the power unit and work sight clean. NOTE: The pressure increase in uncoupled hoses left in the sun may make them difficult to connect. When 8

9 possible after use, connect the free ends of the operating hoses together..8 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 meter (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 00 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. of this manual. WORK AREA SAFETY NOTES: 9

10 3.0 Operating Instructions 3. Description of Power Unit The PortaCo D-00D50-G9-O series Hydraulic Power Unit has been designed as an open center hydraulic system for the purpose of supplying hydraulic fluid to operate chain winching systems and can be used with a control system to operate hydraulic tools. This power has two hydraulic circuits, the first produces 5 GPM/57 LPM at 500 psi/ 7.5 bar and the second produces 0 GPM/5 LPM at 500 psi/7.5 bar. The standard engine is a John Deere rated at 99 hp. See section. features of this manual for specifications. See the technical manuals supplied by the engine manufacture included with this power unit for detailed technical specifications. PortaCo power units should not be operated at ambient operating temperatures, outside the recommended temperature range of -8 C to 3 C. (- 0 F to 0 F). 3. Controls and Graphics WARNING: FAILURE TO FOLLOW THE PROCEDURES LISTED IN THIS MANUAL, ON DECALS LOCATED ON THE POWER UNIT OR THE ENGINE S OWNER S MANUAL COULD RESULT IN PERSONAL INJURY OR EQUIPMENT DAMAGE. Refer to the engine owner s manual for explanation of controls and symbols located on the engine. The following controls and gauges are located on the control panel at the end of the power unit. The hydraulic connections and hydraulic system monitoring gauges are also located in the same panel. -Water Temperature Gauge (arrow A Figure 3.A) -Engine Oil Gauge (arrow B Figure 3.A) -Volt Meter (arrow C Figure 3.A) -Fuel Gauge (arrow D Figure 3.A) -Hour Meter (arrow E Figure 3.A) -Tachometer (arrow F Figure 3.A) -Power Switch (arrow G Figure 3.A) -Starter Button (arrow H Figure 3.A) -Throttle (arrow I Figure 3.A) -Pressure Gauge 5 GPM Circuit (arrow J Figure 3.A) -Return Pressure Gauge 5 GPM Circuit (arrow K Figure 3.A) -Flow Gauge 5 GPM Circuit (arrow L Figure 3.A) -Pressure Gauge 0 GPM Circuit (arrow M Figure 3.A) -Return Pressure Gauge 0 GPM Circuit (arrow N Figure 3.A) -Flow Gauge 0 GPM Circuit (arrow O Figure 3.A) -Pressure Coupler 5 GPM Circuit (arrow P Circuit) -Return Coupler 5GPM Circuit (arrow Q Figure 3.A) -Case Drain Coupler 5 GPM or 0 GPM Circuit (arrow R Figure 3.A) -Pressure Coupler 0 GPM Circuit (arrow S Figure 3.A) -Return Coupler 0 GPM Circuit (arrow T Figure 3.A) -On-Off Switch 5GPM Circuit (arrow U Figure 3.A) -On-Off Switch 0 GPM Circuit (arrow V Figure 3.) 0

11 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. -Serial number decal has the model number and serial number for this power unit. When ordering parts please have both numbers ready to assure the correct replacement parts are ordered. (arrow a Figure 3.A) -Decal Power/Start highlights the location of the ignition system controls. (arrow b Figure 3.A) in with the palm of your hand to slow engine to idle quickly and turn the power OFF to shut down system completely.(arrow c Figure 3.A) -Hydraulic system control decal labels the controls for each hydraulic circuit. I labels the gauges, proper hose connection ports and ON-OFF switch.(arrow d Figure 3.A) -Procedures decal instructs the operator on the proper start up procedure, shut down procedure, and emergency stop procedure. (arrow e Figure 3.A) -Throttle decal highlights the location of the engine throttle. The red button in the center is for emergency shut down. Push F J K M N A a b G B H U V C I c P S D L Q O E e d R T Figure 3.A

12 H F G Figure 3.B -Operating procedure decal instructs the operator on the proper procedure for connecting and disconnecting hoses. It also contains the following warnings: WARNING: DO NOT EXCEED MAXIMUM WORKING PRESSURE OF 500 PSI OR 80 F OIL TEMPERATURE WARNING: DO NOT OPERATE THIS UNIT BEFORE READING AND UNDERSTANDING THE OPERATORS MANUAL AND ENGINE MANUAL PROVIDED. (arrow f Figure 3.B) -Warning decal (arrow g Figure 3.B) WARNING: HEARING PROTECTION REQUIRED (WITHIN 5 FEET) CONTENTS UNDER PRESSURE DO NOT EXCEED MAXIMUM OPERATING PRESSURE.

13 -Warning decal (arrow h Figure 3.B) WARNING: HEARING PROTECTION REQUIRED (WITHIN 5 FEET) ROTATING MACHINERY CONTENTS UNDER PRESSURE -The fuel drain decal labels the plug used to drain the fuel reservoir. (Figure 3.E arrow B) -The diesel fuel decal is located on the fuel reservoir to instruct the operator on the difference between the reservoirs in the cabinet. B Figure 3.E A -The engine drain decal identifies the drain port for the engine oil. (Figure 3.F) -The drain pan decal identifies the drain for the interior of the power unit. (Figure 3.G) -The hydraulic decal is located on the hydraulic reservoir to aid the operator in distinguishing the difference between the reservoirs. Figure 3.F -The hydraulic drain decal labels the plug used to drain the hydraulic reservoir. (Figure 3.E arrow A) Figure 3.G 3

14 3.3 Before Start Up CAUTION: Refer to the engine manual for proper procedures when checking, filing, cleaning, or replace any engine components and fluids. The power unit features a John Deere diesel engine and is shipped with a John Deere operator s manual. See the engine manual for operating and maintenance information concerning the engine. Check engine oil level. (Figure.A) Check coolant level in radiator. (Figure.B) Check fuel filters for water or debris. See engine manual for proper servicing of filters. (Figure.A arrow C) Check the hydraulic oil reservoir level. The fluid level should be near the top of the sight gauge located on the side of the tank. (Figure.3B) Do not use hoses, couplers, or fittings which are damaged, replace immediately. See section.8 of this manual for additional safety procedures. 3. Positioning the Power Unit The power unit can be positioned by using a crane. The power unit has lifting eyes so it can be loaded easily or positioned at the work sight with a crane. (Fig 3.A) The power unit also can be positioned using a fork lift with a rated lifting capacity which exceeds the total weight for a fluid filled system, see section. for specifications. Fork lift openings are located on each side of the enclosure. (Figure 3.A) Check that the fuel level is at an adequate level before starting engine. The fuel level gauge is located in the control panel. (Figure 3.A arrow D) Check the power unit for leaks or damaged hoses. Replace or repair as required before operating. WARNING: NEVER INSPECT PRESSUREIZED HOSES, COUPLERS, OR FITTINGS WITH HANDS OR AT CLOSE DISTANCES. PRESSURIZE FLUID CAN PUNCTURE THE SKIN AND INJECT OIL INTO THE BODY RESULTING IN DEATH. Figure 3.A Place the PortaCo hydraulic Power Unit on a level surface with no greater than a 0 degree slope to prevent fuel spillage and power unit movement WARNING: PLACING THE PORTACO HYDRAULIC POWER UNIT ON EXCESSIVE SLOPES OR UNSTABLE PLATFORMS COULD

15 CAUSE THE UNIT TO ROLL OR TIP DAMAGING THE POWER UNIT OR ENDANGERING WORKERS. Locate hydraulic power unit in well lit area with a minimum ambient light intensity of 00 lux weather indoors or outdoors, particularly at night. Keep the power unit at least meter (3.3ft) away from buildings, obstructions, and flammable objects. Do not aim engine exhaust at materials that could catch fire. 3.5 Power Unit Operation Observe all safety precautions found through out this manual and the included engine manual. ) Connect the hoses to the power unit; see section.6 Hose Connecting Procedure. ) Set both hydraulic circuit switches to the OFF position. Set throttle to idle. WARNING: Exhaust fumes can cause personal injury or death. In an enclosed are, vent the exhaust to the outside. Start and operate the engine in a well ventilated area only. 3) Switch the power switch to ON, and push the START button. Hold the button in until the engine starts (limit to 30 seconds at a time) and release the button. ). Increase engine speed to between 000 and 00 RPM. Turn the switch ON for the hydraulic circuit being used. NOTICE: To prevent damage to the hydraulic pump; do not adjust the engine speed above 00 rpm. 5) Pull the throttle out all the way to run the engine at maximum speed of 00 rpm 6) Perform the duties required. 7) Slow the engine to between 000 and 00 RPM and shut the hydraulic circuits OFF. Allow the engine to run for minutes at this RPM. 8) To stop the engine, return the throttle to the idle position, and shut the power switch in the OFF position. 9) Disconnect the hoses; see section.7 Hose Disconnecting Procedure. 3.6 Changing Flow Rate The flow rates can be varied for the hydraulic circuits by adjusting the engine RPM. Monitor the circuit being used and adjust the engine RPM until the flow gauge matches the flow required. Each hydraulic circuit has its own flow gauge, figure 3.A arrow L, for the 5 GPM circuit and figure 3.A arrow O, for the 0 GPM circuit. 3.7 Changing Pressure Relief Setting The hydraulic pressure can be changed by adjusting the pressure relief valve located on the control manifold behind the control panel. (Figure 3.7A) 5

16 enclosed are, vent the exhaust to the outside. Start and operate the engine in a well ventilated area only. ) Switch the power switch to ON, and push the START button. Hold the button in until the engine starts (limit to 30 seconds at a time) and release the button. Figure 3.7A Adjusting the relief valve requires a wrench to loosen the jam nut, and an allen wrench to adjust the stud. Turning clockwise (IN) will increase pressure. Turning counterclockwise (OUT) will decrease the pressure. PortaCo recommends that the valve be left at the factory setting unless lowering the pressure is absolutely necessary. WARNING: DO NOT ADJUST THE SYSTEM PRESSURE ABOVE 500 PSI. SYSTEM FAILURE OR POTENTIAL PERSON INJURY IS POSSIBLE IF THE MAXIMUM PRESSURE OF 500 PSI IS EXCEEDED. To set the relief pressure: ) Disconnect all hose sets from the control panel couplers. Follow Hose Disconnect Procedure in section.7. ) Loosen the jam nut on the relief valve to be adjusted. 3) Set both hydraulic circuit switches to the OFF position. Set throttle to idle. 5). Increase engine speed to 00 RPM. Turn the switch ON for the hydraulic circuit being used. The flow will be going over the relief valve at the current setting and will register on the gauge at the control panel for the circuit which is on. 6) Have an assistant monitor the pressure gauge for the system being adjusted. Turn the stud on the relief valve counterclockwise (OUT) to lower the pressure or clockwise (IN) to raise the pressure setting, DO NOT EXCEED 500 PSI. 7) When the required pressure registers on the pressure gauge at the control panel stop adjusting the valve. Turn the hydraulic circuit OFF and slow the engine to an idle. Hold the stud in place with the allen wrench and tighten the lock nut. 3.8 Cold Weather Operation Hydraulic fluids are thicker in cold weather; therefore, run the engine at low idle long enough to bring the fluid temperature up to minimum of 0 C/50 F or until the hydraulic tank feels warm. Refer to the engine manual for cold weather operating recommendations. WARNING: Exhaust fumes can cause personal injury or death. In an 6

17 The engine is equipped with a 0 volt plug in block heater. Plug the block heater in for one hour before starting the engine. 3.9 Storage Preparation To prepare the engine for transportation or storage refer to the engine owner's manual. Remove the ground cable from the battery. Store the PortaCo hydraulic power unit on a smooth level surface. The power unit should be stored in a cool, dry environment which is not subjected to rapid temperature changes. 7

18 .0 Maintenance Instructions Observe service intervals listed in this manual and the engine manual included with the hydraulic power unit. Use the hour meter located at the control panel as a guide performing all previous maintenance operations in addition to the ones specified. Keep a record of hurly intervals and services performed. IMPORTANT: recommended service intervals are for normal operating conditions. Service MORE OFTEN if power unit is operated under adverse conditions. Neglecting maintenance can result in failures of permanent damage to the power unit. Use correct fuels, coolants, lubricants, and hydraulic fluids, listed in this manual and the John Deere engine manual included. IMPORTANT: use only fuels, lubricants, and coolants meeting specifications outlined in the Fuels, Lubricants, and Coolant section when servicing the engine.. Service Chart Lubrication and Maintenance Service Interval See the engine manual for additional engine maintenance requirements. Item Daily 50 hour/ 3 month 500 hrs/ month Service Required Check Engine Oil and Coolant Level Check Fuel Filter/Water Bowl Check Air Cleaner Visual Walk Around Inspection (check for leaks, worn belts, damaged hoses, loose components) Check Hydraulic Fluid Level Check hydraulic Filter Gauges Check for and Remove Condensation from Hydraulic Reservoir Change Hydraulic Oil and Return Filter Service Battery Change Engine Oil and Replace Oil Filter (b,c) Replace Fuel Filter Elements X X X X X X X X X X X X X X Check Coolant System Pump Coupling X Every Years (a) Check, replace as required. Hose Assemblies (Internal) Test Hydraulic Flows and Pressures. Every Years (a) Check, Replace as required Every Years (a) Check, Service as required a) These items should be serviced by a qualified Hydraulics Technician. b) During engine break-in, change the oil and filter for the first tie before 00 hours of operation. c) Service intervals depend on sulfur content of the diesel fuel, oil pan capacity, and the oil and filter used, which means that intervals may be REDUCED. (See DIESEL ENGINE OIL AND FILTER SERVICE INTERVALS in Fuels, Lubricants, and Coolant Section of the Engine Manual. 8

19 . Assembly View and Parts List CAUTION: USE ONLY GENUINE PORTACO INC PARTS OR EQUIVALENT. THE USE OF REPLACEMENT PARTS WHICH ARE NOT OF EQUIVALENT QUALITY MAY DAMAGE THE HYDRAULIC POWER UNIT. WARNING: UNAUTHORIZED MODIFICATIONS TO THE POWER UNIT MAY IMPAIR THE FUNCTION AND/OR SAFETY AND IMPAIR MACHINE LIFE. USE ONLY APPROVED SERVICE PARTS OR ACCESSORIES G9-OOP-0 G9-OOP-03 G9-OOP-0 93-OOP 063-OOP G9-3W-OOW G9-D-OOW 36-OOP 363-OOP G9-5D-OOW 356-OOP 35-OOP 85-OOP 8-OOP 80-OOP 658- OOP G9-OOP-05 5-OOP 33-OOP 7-0P 7-0P 7-OOP 6-OOP 3-OOP 79-OOP G9-OOP OOP 76-OOP 366-OOP 358-OOP 896-OOP 0-OOP G9-OOP-07 G9-5D- Engine Splined mt. plate Plate pump mt. Bolt 3/8 x ¾ Washer 3/8 lock Frame base End panel control Bolt 3/8 x ¾ ss Bolt 3/8 x ss Panel Gauge Washer Lock 3/8 Nut 3/8 ss Gauge hour meter Gauge fuel Gauge Amp Gauge oil pressure Gauge water temp Gauge Tach starter push button solenoid Valve Plug Valve relief Fitting nipple Fitting 90 degree Fitting 8npt-jic Manifold ¼ x ¾ BHAS ss Nut ¼ ss Lock washer ¼ ss Fitting 90 degree Adapter or-8npt Flow gauge 0/gpm mount flow gauge

20 OOP G9-OOP-08 G9-OOP-09 G9-5D- G9-OOP-00 G9-OOP-0 G9-OOP-0 G9-OOP-03 G9-OOP-0 G9-OOP-05 G9-OOP OOP 07-OOP 53-OOP G9-OOP OOP G9-OOP-08 G9-OOP OOP G9-OOP OOP G9-OOP-03 3-OOP G9-W-OOW 08-OOP G9-OOP OOP 85-OOP -OOP 856-OOP 077-OOP 076-OOP G9-W-OOW G9-OOP OOP G9-OOD-OO G9-W-0W -OOP G9-OOP-03 G9-OOP-035 G9-OOP OOP 935-OOP 8-OOP G9-OOP-037 G9-OOP-038 fitting 90-or-jic valve complete 0 gpm flow gauge 50gpm mount fl.gauge 0gpm fitting -6or-6jic 90d. fitting ad.. 6or-6nptf fitting ad. 6 or-6mpt fitting ad. 6npt-6jic fitting ad. - fitting Fitting 6orb -6 hose Fitting 90 degree Adapter Fitting bead Fitting Fitting bushing Gauge 5,000psi Gauge 600psi Fitting - straight Tee- 0 Fitting 90 bead - Fitting 90 bead 0- Fitting - str Tank fuel Fitting pipe cap Bushing degr short degr - Murphy switch Screw Fuel sender Tank oil Sight gauge Magnet Gasket access cover Cover access oil tank Fitting 90 bead 8-8 Ebow 90 degr - Fitting suction 5 gpm Filter return. Fitting 8npt -hose Fitting 8npt - hose degr -8 short Hose - x Hose clamp - ss

21 G9-OOP-039 G9-OOP-00 G9-OOP-0 G9-OOP-0 G9-OOP-03 G9-OOP-0 G9-OOD-003 G9-OOP-05 G9-7D G9-6W-OOW G9-OOP-06 G9-OOP-07 G9-OOP-08 G9-OOP-09 G9-OOP-00 G9-OOP-050 G9-OOP-05 G9-OOP-05 G9-OOP-053 G9-OOP-05 G9-OOP-055 G9-OOP-056 G9-OOP OOP 9-OOP 08-OOP G9-OOP-058 G9-OOP-059 G9-OOP-060 G9-OOP-06 G9-OOP-06 G9-OOP-063 G9-OOP-06 G9-OOP-065 G9-OOP-066 G9-OOP-067 G9-OOP OOP G9-OOP OOP 08-OOP G9-OOP OOP 805-OOP G9-OOP-07 G9-OOP-07 Motor mount Cooler Bolt ½ x ½ ss Washer ½ flat ss Washer lock ½ ss Nut ½ ss Pad Bushing -3- Grill Mount cooler Filter hp 0gpm Fitting 90 filter Fitting straight or6-6jic Bolt 3/8 x GR 8 RAIN CAP Pump BF8830GS Bolt 5/8 x ss Washer lock ss Fitting 6or- or Fitting p. port 0gpm Filter 5gpm hp Filter suction 5 gpm Fitting 8npt plug hex Bushing -8-6 Fitting Barb -6 Hose ¾ x 6 Fitting 5 -ob- hose Hose clamp ss Hose.5 suction 8.5 Hose suction 30 long Hose clamp -/ ss PIPE NIPPLE -0 Fitting -or -jic str GAUGE FILTER RETURN GAUGE FILTER 5 GPM Flambu type drain valve Hose clamp Hose ½ x 36 Fitting -8nptf -8 hose Plug -8npt head Hose ½ x 9 ½ Throttle cable STRAINER 5 GPM STRAINER 0 GPM Hose 3/8 Dot fuel x

22 OOP G9-OOP-073 G9-OOP-07 G9-OOP-075 G9-OOP-076 G9-OOP-077 G9-OOP-078 G9-OOP-079 G9-OOP-080 G9-OOP-08 G9-OOP-08 G9-OOP-083 G9-OOP-08 G9-OOP-085 G9-OOP-086 G9-OOP-087 G9-OOP OOP G9-OOP-089 G9-OOP-090 G9-OOP OOP 358-OOP 366-OOP G9-OOP OOP 330-OOP G9-OOP-00 G9-OOP-093 G9-OOP-003 G9-OOP-00 G9-OOP-007 G9-OOP-09 G9-OOP-095 G9-OOP-096 G9-OOP-097 G9-OOP OOP G9-OOP OOP G9-OOP-099 G9-8D-OOW G9-OOD-00 G9-OOD-005 G9-9D G9-OOD-006 Hose clamp Coupler case drain Coupler male 5 gpm Coupler female 5 gpm Coupler male 0 gpm Coupler 0 fem.- 0g Hose x return Hose 6 x 6 Hose clamp 6 ss Hose ½ x 3 Hose clamp Fitting tee fitting tee fitting npt - hose 90 fitting npt - hose 5 fitting bushing fitting 6npt -6 hose fitting 6npt - hose 90 3/8 fuel line 7 ¼ fuel line 50 Battery box Bolt ¼ x ½ ss Washer ¼ lock ss Nut ¼ ss Battery Exide 60 Switch on/off Weather boat switch CLAMP EXHAUST 3/8 hose x BONNET AIR INTAKE CLAMP BONNET Battery cable red Hose ½ x 90 Hose ½ x 75 Clamp Hose ½ Hose 63x 3/6 dot f. line Hose 7x3/6 dot f. line Nytie Battery cable black Grounding strap Fitting nptf -jic panel top Air duct top Bracket hose mount Lifting eye Bracket throttle

23 OOP 350-OOP 76-OOP G9-OOP OOP G9-OOP-00 G9-OOP-0 G9-OOP-0 G9-OOP-03 G9-OOP-0 G9-OOP OOP G9-OOP-06 G9-D- OOW G9-0D- OOW G9-D OOW G9-0D OW G9-OOP-06 G9-OOP-07 G9-OOP-08 G9-OOP-09 G9-OOP-0 G9-OOP- G9-OOP- G9-OOP-3 G9-OOP- G9-OOP OOP 57-OOP G9-OOP-5 G9-OOP-6 G9-OOP-7 G9-OOD OOP 358-OOP G9-OOP-8 G9-OOP-00 G9-OOP-009 G9-OOP-00 G9-OOP-0 Cable clamp Stop throttle cable Bolt ¼ x BHSC ss TRANSITION TUBE Relay Hose -fjic-fjic x 8 Hose -fjic-fjic 0 Hose 6-6fjic-6fjic 56 Hose 6-6fjic-6fjic 6 Hose 6-6fjic-6fjic Hose -fjic-fjic 36 Fitting 90 -jic-fjic Muffler horizontal Door left front Door left rear Door right front Door right rear Latch slam Bolt #8-3 x.75 ss Washer #8 flat ss Washer lock #8 Nut #8-3 ss CABLE /6 SS Ring key chain style Latch door left Latch door right FITTING BARB Cap fuel tank Cap hydraulic tank Exhaust pipe 90 turn up Clamp exhaust Clamp exhaust Radiator access cover Bolt ¼ x ¾ ss Washer lock ¼ ss Weather seal SEAL TANK BOLT ENGINE MNT WASHER LOCK WASHER FLAT G9-OOP-9 G9-OOP-0 G9-OOP- G9-7D-D G9-7D-D TURBO BLANKET Muffler wrap Exhaust tube wrap Deflector Stand off 3

24 OOP G9-OOP-30 G9-OOP-3 G9-OOP-3 G9-OOP-33 G9-OOP-3 G9-OOP OOP WASHER FLAT 3/8 G9-7D G9-8D G9-D Guard grill side Guard grill side opposite Guard grill top G9-OOP- 6-OOP G9-OOP-3 G9-OOP- G9-OOP-5 G9-OOP-009 G9-OOP-6 G9-OOP-7 38-OOP G9-OOP-8 G9-OOP-9 Hose air intake Clamp hose ss Clamp hose ss size 7 Clamp hose ss size 6 Clamp hose ss Spacer 3/8 D Hose engine drain ½x0 Hose engine drain ½x6 Fitting ¼ npt -6 barb Fitting -6 barb - Fnpt Plug - radiator drain hose Clamp radiator drain hose BUSHING -8-3 BOLT U 3 3 GAUGE FILTER 0GPM SOLENOID 0 GPM SOLENOID VALVE 0 GPM RELIEF VALVE 0 GPM

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31 ELECTRICAL SCHEMATIC 3

32 HYDRAULIC SCHEMATIC.3 Engine Oil Change See engine manual for additional and more detailed instructions for engine maintenance. WARNING: SHUT OFF ENGINE BEFORE DOING ANY MAINTENANCE. TO PREVENT ACCIDENTAL START-UP, TURN THE POWER SWITCH OFF AND DISCONNECT THE NEGATIVE CABLE FROM THE BATTERY TERMINAL. Run engine approximately 5 minutes to warm up oil. Shut off engine. Drain crankcase oil from engine while warm. When draining oil place a suitable container under the drain plug and remove plug. Drain engine completely and replace plug. The engine oil drain is located outside the enclosure see figure 3.F. When replacing the engine oil filter (Figure.3A arrow A) turn element using a suitable filter wrench to remove. Discard oil filter element. Apply clean engine oil to the new filter ant the inner and outer seals and to filter threads. 3

33 Wipe both sealing surfaces of the header with a clean rag. Ensure notches in dust seal are properly installed in the slots in the housing. Replace dust seal if damaged. IMPORTANT: When installing filter element, hand tighten only. A filter wrench may be used for removal only. Be sure notches in dust seal are properly installed in the slots in the housing. D E B C A Install and tighten oil filter by hand until firmly against dust seal. DO NOT apply an extra ¾ to -/ turn after gasket contact as done with standard filters. Fill engine with oil through oil filler cap on side of engine. (Figure.3A arrow B) See engine manual for quantity of oil required. IMPORTANT: Immediately after completing any oil change, crank engine for 30 seconds without permitting engine to start. This will help insure adequate lubrication to engine components before engine starts. Start engine and check for possible leaks. Stop engine and check oil level after 0 minutes. Oil level reading should be within crosshatch marks on dipstick (Figure.3 arrow C). DO NOT OVER FILL. NOTE: Dispose of all consumable items (filters, oils.etc.) in a manner that is compatible with the environment. PortaCo, Inc. suggests you take such items in a sealed container to your local collection sight for reclamation. DO NOT throw these items in the trash or pour them on the ground. Figure.3A. Engine Fuel Filter Change The engine is equipped with a primary fuel filter (Figure.3A arrow D) and a final fuel filter (Figure.3 arrow E). The primary filter has a water drain valve. This bowl should be checked daily and any water should be drained off before starting the engine. See the engine manual for proper procedure. CAUTION: Escaping fluid under pressure can penetrate the skin causing serious injury. Relieve pressure before disconnecting fuel or other lines. Tighten all connections before applying pressure. Keep hands and body away from pinholes and nozzles which eject fluids under high pressure. Use a piece of cardboard or paper to search for leaks. Do not use your hand. If any fluid is injected into the skin, it must be surgically removed within a few hours by a doctor familiar with this type injury or gangrene may result. Doctors unfamiliar with this 33

34 type of injury may call the Deere & Company Medical Department in Moline, Illinois, or other knowledgeable medical source. An in line canister style filter is located near the top of the reservoir. Monitor the gauge and replace the filter when the arrow is in the red. Figure.6A Read the John Deere Engine manual (05TF85/HF85) provided for proper filter replacement procedures..5 Engine Coolant Service Maintaining the correct coolant conditioner concentration and freeze point is essential in you cooling system to protect against rust, liner pitting and corrosion, and freeze-ups due to incorrect coolant dilution. Test the coolant solution at 500 hours or months of operation and service the system as required. For detail instructions on coolant system service and maintenance see the John Deere Engine Manual. The radiator is drain through a hose with a plug located in the enclosure. The hose allows the fluids to be drain outside the enclosure preventing spills in the enclosure. Figure.6A Two high pressure filters clean the oil before it reaches the control manifolds. Both the 5 GPM (Figure.6B arrow A) and 0 GPM (Figure.6B arrow B) filters feature gauges to alert the operator when they need to be replaced. Replace filters when indicators are in the red. A The radiator fill cap can be accessed from the top of the enclosure by removing an access cover..6 Hydraulic System Servicing B C C The hydraulic system is kept clean by three inline filters with feature sight gauges that indicate when the filters need changing. Each suction line from the reservoir also has strainers located in the reservoir which can be removed and cleaned or replace by removing the access cover on top of the reservoir. Figure.6B When changing the filters, place a container large enough to contain any spills or divert any spills out of the enclosure to keep it clean. 3

35 To replace the return filter, turn the element using a suitable filter wrench. Discard the used filter. Wipe the sealing surface of the filter head with a clean cloth. Apply clean oil to the seal and turn on until the seal contacts the filter head. Turn another ¾ to full turn. The high pressure replacement element is located inside a removable housing, us a wrench to remove the housing (Figure.6B arrow C). Remove the element and discard. Install the new element and oring seal. Apply a thin coat of clean hydraulic fluid to the seal before installation. Use the wrench to tighten the housing. The hydraulic reservoir drain is labeled on the outside of the enclosure. (Figure 3.E arrow A) Place a suitable container under the drain plug and remove the plug. The plug may have to be replaced before the reservoir is drained to empty the container. Depending on the size of container, this method may have to be repeated several times. An access cover located on top of the hydraulic reservoir can be removed and the interior of the tank cleaned and drained using the same drain port. NOTE: Dispose of all consumable items (filters, oils.etc.) in a manner that is compatible with the environment. PortaCo, Inc. suggests you take such items in a sealed container to your local collection sight for reclamation. DO NOT throw these items in the trash or pour them on the ground..7 Fuel Reservoir Servicing The fuel reservoir drain is located on the outside of the enclosure and is label. (Figure 3.A arrow B) Place a suitable container under the drain plug, and remove the plug. Depending on the size of the container, it may be necessary to plug the drain and empty the container several times to empty the reservoir completely. Two large pipe ports are located on the side of the reservoir which can be used to flush the reservoir clean..8 Drip Pan Draining The bottom of the enclosure is a drip pan to catch any spilt fluids or leaks to prevent them from contaminating the environment. Clean up any spills or leaks immediately and make any repairs required. The engine and interior can be rinsed down to keep the compartment clean. A drain plug is located at the front of the enclosure (Figure 3.F arrow B). Remove the plug and drain the fluid into an appropriate container. Dispose of in a matter which is compatible with the environment. 35

36 .9 Trouble Shooting This trouble shooting sections provides information in relation to the hydraulic system and it s relationship to the engine. Read the engine manual provided (John Deere Operators Manual for PowerTech E 05TF85/HF85 and 6068HF85 OEM Diesel Engines PN#OMRG3707) for addition trouble shooting of engine problems. PROBLEM CAUSE Starter will not crank engine Engine working against the hydraulic pump pressure. Battery discharged or not properly connected. Starter defective. Engine cranks but will not start Ignition switch or solenoid switch(es) defective. Air in injectors and/or injector pump. Water in fuel. Inadequate compression. Engine runs but hydraulic circuit will not operate Flow is correct but system doesn t build pressure. REMEDY Be sure Circuit Switches are OFF. Check condition of battery, cable connections, etc. Replace as necessary. Inspect starter. Replace as necessary. Replace as necessary. Bleed injectors. Refer to engine manual. Empty water sediment trap. Bleed injectors per engine manual. Check for clogged air cleaner, valves seated, cylinder compression loss. Repair as required. Set switches to OFF. Replace if defective. Check and fill as required. Circuit switches ON or defective. Hydraulic fluid reservoir low Hoses incorrectly connected Check that the hoses are to power unit. connected correctly. Circuit switch is OFF Check that the right circuit is being turned ON. Circuit switch is defective. Test switch and replace as required. Solenoid ON-OFF valve Test solenoid valve and is malfunctioning. replace as required. Relief valve set too low. Check the relief valve setting. See section 3.8 of this manual. Relief valve set too low. Check the relief valve setting. See section 3.8 of this manual. 36

37 Contamination in relief valve. Malfunctioning relief valve. Remove relief valve. Insert punch in end of valve and push in to dislodge obstruction. Inner spool should slide in and out easily when pushed in. Replace valve as required. Service Replacements Parts Description Filter Hydraulic Oil Return 0 micron twist on Filter Hydraulic Oil element 5 GPM high pressure. Filter Hydraulic Oil element 0 GPM high pressure. Strainer Suction in-tank 5 GPM port Part Number G9P-5608-OOP Source PortaCo Inc. G9P-6503-OOP PortaCo Inc. G9P-659-OOP PortaCo Inc. 805-OOP PortaCo Inc. Strainer Suction in-tank 0 GPM port Engine Oil Filter Engine Primary Fuel Filter Engine Final Fuel Filter Engine Air Filter Engine Air Filter Gasket Hydraulic Tank Clean Out Cover Dust Cover male quick coupler Dust Cover female quick coupler Dust Cover ¾ male quick coupler Dust Cover ¾ female quick coupler Dust Cover ½ female quick coupler G9-SEC OOP G9RE OOP G9RE-5963-OOP G9RE-5878-OOP G9P OOP G9P OOP G9- -OOP G OOP G OOP G OOP G OOP G OOP PortaCo Inc. PortaCo Inc. PortaCo Inc. PortaCo Inc. PortaCo Inc. PortaCo Inc. PortaCo Inc. PortaCo Inc. PortaCo Inc. PortaCo Inc. PortaCo Inc. PortaCo Inc. 37

38 .0 Technical Specifications Hydraulic Power Unit Weight Dry Wet Engine Dry Weight (John Deere) Max Pressure Max Flow Circuit Circuit Relief Valve Setting Engine RPM Max. Hydraulic Reservoir Capacity Fuel Reservoir Capacity 558 kg (336 lbs) 878 kg (0 lbs) 9 kg (083 lbs.) 7.5 BAR (500 PSI) 5 GPM / 57 Liter 0 GPM / 5 Liter 8.8 BAR (650 PSI) 00 RPM 6 Liters (65 gallons) 7 Liters (39 gallons) Recommend Hydraulic Fluids -Houghton 9 Hydraulic Fluid -Texaco Rando ISO 6 oil -Other high quality Hydraulic Oils meeting the specifications for ISO 6 hydraulic fluid. 38

39 SERVICE AND REPAIR NOTES 39