MODEL D-25S12-22-S POWER UNIT OPERATION, MAINTENANCE, AND REPAIR MANUAL

MODEL D-25S12-22-S POWER UNIT OPERATION, MAINTENANCE, AND REPAIR MANUAL

Introduction 1805 2 nd AVENUE NORTH * MOORHEAD, MN, USA 56560-2310 PHONE (218) 236-0223 * FAX (218) 233-5281 E-MAIL ADDRESS; info@portaco.com * INTERNET ADDRESS: www.portaco.com The D25S12-22-S Auxiliary Power Unit (APU) is a light weight, portable hydraulic and 24 Volt DC electrical power source. It s main purpose is to provide auxiliary hydraulic power tor steering, electrical power for lights and brake modulation for towing a disabled Off-Highway Truck. Maintenance recommendations 2 Installation and Operation of APU for Charging A 24 Volt Battery..2 Installation and Operation of the APU for Unloading the Body of an Off-Highway Truck.3 Installation and Operation of the APU as Supplemental Power for Towing a Disabled Truck..4 Schematics...8 Parts Information..9 Oil Recommendations.15 Assembly, Start Up and Operation The APU is shipped without a battery. A 12 Volt Battery is required for starting the diesel engine and operating the electrical pump controls. A Group 24 Battery is used on the APU. D-25S12-22-S Auxiliary Power Unit Other uses are to provide hydraulic power for unloading a disabled loaded truck, to make towing easier and can be used as a portable 35 Amp-24 Volt DC battery charger. The D-25S12-22-S APU must be used with the additional Attachment Groups. The Attachment Groups contain all the necessary hydraulic fittings, hoses, and electrical cables to connect to the Off- Highway Truck. The APU is equipped with: -a 18.7 kw (25 Hp) diesel engine -a 35 amp, 24 Volt DC alternator -a 45.3 lpm (12 gpm) 172.5 Bar (2500 psi) hydraulic pump. NOTE: The hydraulic pump must be connected to the truck s hydraulic system before engaging the pump engage switch. Content Assembly, Start up and Operation.1 Make sure to install the battery cover after the battery is connected and secured. This will prevent dirt and oil from getting on the battery and causing a malfunction. The APU features a Lambardini diesel engine and is shipped with a Lambardini operator s manual. See the engine manual for operating and maintenance information concerning the engine. The engine is equipped with its own 12 Volt DC charging system and will maintain the charge on the 12 Volt battery in the APU. Starting and Operating 1. Check the oil and diesel fuel levels. Add if necessary. 2. Make sure pump engage switch and disconnect switch located on the instrument panel are both in the OFF position. 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.

Installation and Operation of the APU for Charging a 24 Volt Battery 3. Start the engine. The APU can be used as a portable battery charger for 24 Volt batteries or as an alternative power source for a disable vehicle equipped with a 24 Volt system. 4. When the engine is ready to use, pull the throttle out all the way to run the engine at maximum speed of 2600 rpm. NOTICE: To prevent damage to the hydraulic pump; do not adjust the engine speed above 2600 rpm. 5. To stop the engine, return the throttle to the idle position and pull the knob on the engine stop cable until the engine stops. Be sure to turn the engine run switch OFF after the engine has stopped. Maintenance recommendations The parts illustration and parts list can be used to help identify and service the components of the PortaCo, Inc D- 25S12-22-S Auxiliary Power Unit. The hydraulic pump has been modified to meet the requirements of this power unit. If the pump is to be serviced or replaced locally, contact PortaCo for details concerning the modification. PortaCo Inc. should be used when complete service of the power unit is required. Lombardini Engine Engine maintenance and repair instructions are included in the Lombardini Owners Manual. Parts and service for the engine should be obtained from an authorized Lombardini engine distributor. APU 24 Volt Cable Connection and Instrument Panel. 1. Position the APU near the battery or vehicle. Start the engine and bring it up to speed (2600 rpm). 2. Connect the Plug Assembly (Emergency Start System), to the vehicle or battery. 3. Turn the disconnect switch on the APU instrument panel to the ON

position. The ammeter on the APU instrument panel will show the charging rate of the APU. 4. The 35 amp circuit breaker on the APU will protect against damage from overload of the electrical service. NOTE: Do not move the pump engage switch to ON when using the APU only as a battery charge. Installation and Operation of the APU for Unloading the Body of an Off- Highway Truck The APU can be used as the hydraulic power source to unload the body of the Off-Highway Truck. The installation and operation for this application follows. 2. Connect the APU to the body hoist cylinder that is equipped with the quick disconnect fittings. 3. Connect one Hose Assembly between hoist cylinder upper fitting (!) and upper right inlet fitting (2) on the APU. Schematic of Hose Connections for Unloading the Body of a Truck. (A) Hoist cylinder. (B) Pump manifold outlet ports, D-25S12-22-S APU. (C) Inlet ports. (D) Truck hydraulic tank. (E) Connector as. (F) Hose as. (G) Outlet ports. (H) Hose as. 1. Locate the APU at the right side of the disabled truck. Position it midway between the front and rear wheels, and about 1.8m (6 ft) away from the wheels on the outside. 4. Connect the other Hose Assembly between hoist cylinder lower fitting (3) and lower left outlet fitting (4) on the APU. 5. Connect the APU to the truck hydraulic tank as shown. 6. Remove the drain plug from the bottom of the tank. No hydraulic fluid will come out of this port until a fitting is installed. 7. Install a Connector Assembly (5) into the port.

15. The large blue light on the APU will be on anytime the hydraulic pump is operating. 16. After unloading is complete and the pump engage switch is moved to OFF, the body can be lowered by the operator in the cab. 8. Connect Hose Assembly (6) between connector assembly (5) and the lower right inlet fitting on the APU. 9. Start and warm up the diesel engine on the APU according to the procedure given earlier in this instruction. 10. Two people are required to unload a disabled truck, one in the cab and one to operate the APU. The operator in the cab should lace the body hoist control lever in the HOLD (number 2) position. NOTE: The truck controls are now ready to unload the body using the APU. 11. To unload the body, move the pump engage switch on the APU to the ON position. 12. The unloading can be stopped anytime by moving the pump engage switch to the OFF position. The truck body will hold in that position. The pump engage switch may again be moved to ON to continue unloading. 13. When the body reaches the maximum position required to dump the load, it should be stopped by moving the pump engage switch to OFF. 14. Do not leave the pump engaged switch ON when the body hoist cylinders are at their maximum position. 17. This is accomplished by moving to and holding the hoist control lever in the cab in the FLOAT (Number 3) position until the body is fully lowered. Or, by moving the hoist control lever to the LOWER (Number 4) position. (The lever will return to FLOAT when the body is fully lowered). -If the body is in an over-center position and will not lower, it can be pumped backed with the APU. 18. To pump an over-center body down, relieve the pressure by placing the APU pump engage switch in the OFF position and the hoist control lever in the FLOAT (Number 3) position. 19. Remove both hoses from the body hoist cylinder and connect the pressure hose from the APU outlet (lower left on APU) to the return (upper) port on the body hoist cylinder. 20. Put the pump engage switch in the ON position and have the operator (located in the cab) lower the body as he would from an over-center position. 21. Move the APU pump engage switch to the OFF position. 22. When the unloading operation is complete, shut off the APU and disconnect all hydraulic lines from between the truck and the APU. 23. Remove the Connector Assembly. Replace all plugs and dust covers.

the APU into position on the platform. 2. Hoist the APU, approximately 227 kg (500 lb), onto the platform and position it in the right front corner of the truck. 3. Carefully remove the filler cap from the steering tank to release the pressure. Replace the cap after the pressure is released. Installation and Operation of the APU as Supplemental Power for Towing a Disabled Truck The APU can be used to provide auxiliary hydraulic power for steering and 24 Volt DC for electrical power for the brake release pump and lights on an Off-Highway Truck that has been disabled due to engine failure. APU connection to assist towing of a disabled truck. 4. Check the quick disconnect fitting at the lower edge of the hydraulic steering tank. If it does not match the quick disconnect on the Hose Assembly (1), replace the tank fitting with the Steering Tank Conversion Group included in the Attachment Group. 5. These fittings can be replaced without draining the hydraulic tank. (About one liter [one quart] of oil is lost if the exchange is done quickly). Schematic of hydraulic connection with the vehicle steering system. (A) Gauge As. (B) Hose As. (C) Brake line manifold. (D) Rear axle. (E) Plug AS. (F) Steering hydraulic tank. (G) Conversion Gp. (H) Hose As. (I) Pump manifold, D-25S12-22-S APU. (J) Outlet ports. (K) Hose As. (L) Steering manifold. (M) Alternate hose connection. (N) Pump manifold inlet ports. 6. Connect hose assembly (1) between quick disconnect nipple (2) and inlet quick disconnect fitting (3) on the APU. 7. Install the Plug Assembly in inlet fitting (4) to prevent pump cavitations. The installation and operation for this application follows. 1. Remove the handrail from the platform above the ladder on the right side at the front of the truck. This will allow clearance for lifting

Use this only as an emergency measure, as it transfers hydraulic fluid from the steering tank to the main hydraulic tank. The relief valve above the quick disconnect fitting and the gauge at the APU can be used to adjust the pressure to 4150 kpa (600 psi). This is an adequate setting for the trucks. Steering system hydraulic manifold below operator s compartment with APU pressure hose connected. 8. Connect on end of Hose Assembly (5) to outlet quick disconnect fitting (6) on the APU. Connect the other end of hose assembly (5) to quick disconnect fitting (7) on steering manifold (8). Manifold (8) is located under the front of the truck on the frame between the front wheels. APU 24 Volt cable connection to the truck batteries. 11. Connect the Plug Assembly to the truck battery and plug it into the electrical outlet on the APU. 12. Start and warm up the diesel engine on the APU according to the procedure given in this instruction. 13. Turn the disconnect switch on the APU to ON to connect the APU to the truck electrical system. Parking brake manifold connection for the 1U8330 Hose Assembly at the rear of the truck. 9. Connect Hose Assembly (9) to the quick disconnect fitting located on the top of the rear axle housing. 10. Install a Gauge Assembly on the other end of the hose assembly (9). Position the gauge, in the cab of the truck, so that the operator can monitor it during towing. NOTE: If the brake release pump on the truck does not work, remove the Gauge Assembly and connect the Hose Assembly on the small outlet (upper left) of the APU. This will provide the 4150 kpa (600psi) necessary to release the secondary brake. 14. Turn the pump engage switch to the ON position. The blue light on the APU will come on indicating pressure is provided to the system. NOTE: If the blue light goes off anytime while towing, stop the vehicle immediately and determine the reason for the loss of pressure. 15. Wait a few minutes for the steering pressure gauge (on the APU instrument panel) to build up pressure. When the pressure is above 12402 kpa (1800 psi), test the steering of the truck. If the steering appears to be normal the truck is ready to tow. 16. Connect the towing vehicle.

17. Release the parking brake. If the pressure on the gauge installed earlier does not read over 3100 kpa (450 psi), engage the brake retract switch in the truck cab of a few seconds to pump up the pressure. 18. Check while towing and recharge with the brake retract switch when necessary. 19. If the APU hydraulic system is used to provide oil pressure to release the parking brakes, the trucks secondary brake lever can still be applied to engage the brakes for an emergency stop. 20. The vehicle can now be towed using the service air brakes to control the speed. See Towing Section of Operation and Maintenance Guide for towing instructions. 21. If the air system malfunctions, the truck can still be stopped using the secondary brake lever. 22. After towing is completer, reverse the hookup procedures to disconnect the APU. 23. The Steering Tank Conversion Group should remain on the truck for future use. Replace the fittings that were used (taken form the Attachment Group).

HYDRAULIC SCHEMATIC: WIRING SCHEMATIC:

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. D-25S12-22-S Parts List ITEM NO. PART NO. DESCRIPTION QTY 1 1023-OOP HOSE FC212 08 08MP 30 1 2 3 1040-OOP BOLT #10 32 x ¾ RD Head ST. 2

5 1044-OOP BOLT 1/4nc HH PL 3 6 1061-OOP NUT 3/8nc HH PL 28 7 1062-OOP NUT 1/4nc HH PL 8 8 1063-OOP LOCK WASHER 3/8 47 9 1064-OOP LOCK WASHER ¼ 9 10 5404-OOP -8 NPT HEX COUPLING 1 11 5405-OOP NPT NIPPLE -8 X 3.00 1 12 1072-OOP FITTING ELBOW 90-8 FEMALE 1 13 1094-OOP NUT 5/16nc HH PL 2 14 1099-OOP WASHER ¼ FLAT PLATED 3 16 1122-OOP FITTING, BRASS STEM 1 17 1144-OOP PLUG ¼ PIPE PLUG HEX 2 18 1175-OOP LOCK WASHER 5/16 2 19 1176-OOP WASHER 5/16 FLAT PLATED 38 21 1204-OOP CABLE BATTERY#6 GAUGE 25LG. 1 22 1206-OOP Bolt 1/4nc x 8 HH PL #2 2 24 1269-OOP CAP FUEL #G 23 1 25 1289-OOP CABLE THROTTLE VCGT3100X 1 26 1324-OOP BOLT 3/8nc x 1 HH PL #5 7 28 1348-OOP BOLT 1/2nc x 1 ½ HH PL #5 1 29 1349-OOP LOCK WASHER ½ 6 30 1350-OOP WASHER ½ FLAT PLATED 1 31 1351-OOP NUT 1/2nc HH PL 8 33 1404-OOP FITTING #2216-8-12S 1 36 1464-OOP BOLT 10-1.5 x 30 6 37 2830-OOP BOLT 1/4nc x 1/2SH CAP SCRE 3 38 1505-OOP FITTING #23540-12-12 1 39 1536-OOD PULLEY SEE PRINT 1 41 1544-OOP` SHIM #N-132 1/32 X ½ AS NEEDED 43 1547-OOD PUMP AR 103033 1 44 1550-OOP ALTERNATOR #6N9294 1 24 V.D.C. 45 1551-OOP PULLEY 1 46 1553-OOP BOLT ½nc x 6 HH PL #5 1 47 1555-OOW FRAME SEE PRINT 1 48 1556-OOP FOOT #50930 4 49 1557-OOP CABLE 3/8 x 3/8 x 8 GRND STR 1

50 1559-OOP MOUNT 4 51 1561-OOW TANK, FUEL SEE PRINT 1 52 1562-OOP HOSE #FC211 ¼-1/8mpr- 8 1 53 1563-OOP CLAMP #900729-1.500 1 54 1565-OOW BOX, BATTERY 1 55 1566-OOW HOLDDOWN, BATTERY 1 56 1567-OOP WIRING COMPLETE 1 57 1569-OOW DASH PANEL SEE PRINT 1 58 1570-OOP LIGHT #56020 BLUE 1 59 1571-OOP EYE, LIFTING #6V2156 1 60 1572-OOP GUARD SEE PRINT 1 61 1573-OOP METER, HOUR 1 62 1574-OOP GAUGE 1 63 1575-OOP SWITCH 1 64 1576-OOP FUSE HOLDER 1 65 1577-OOP LIGHT 1 66 1578-OOD GRAPHIC SET 1 67 1579-OOP METER, AMP 1 68 1580-OOP PLUG #2G1830 CAT 1 69 1581-OOP CAP 1 70 1583-OOP BREAKER 1 71 1584-OOP SWITCH 1 72 1585-OOP BOLT 1/2nf x 1 ½ 1 76 1591-OOP COUPLER 2 77 1592-OOP CAP 2 78 1598-OOP STUD ½ nc x 2 PL 4 79 1600-OOP HOSE ¼, 1/8 mpr ¼ mpr x 19 1 80 1601-OOP FITTING #2048-4-45 1 83 1610-OOP BELT #6837 (GATES) 1 84 1612-OOP NUT ½ nc HH SELF LOCKING 5 86 1776-OOP HOSE, SUCTION ¾ x 3 ¾ 1 87 1777-OOP BOLT ½ nc x 2 ¾ 4 88 1781-OOP ACCUMULATOR #1U5295 1 89 1782-OOP FITTING #2021-4-4 1 90 1784-OOP FITTING #202702-5-5 1 91 1786-OOP HOSE #4 37 FS x 18.5 1 92 1788-OOP FITTING #2024-4-4 2

93 1790-OOP FITTING #2068-8-8 1 94 1792-OOP PLUG 1 95 1793-OOP GAUGE 1 96 1794-OOP FITTING #2092-4-4 1 97 1795-OOD ORFICE.024 2 98 1796-OOD ORFICE.028 2 99 1797-OOP COUPLER, HOSE QUICK #H12-6 1 100 1798-OOP CAP, HOSE COUPLER #H12-6 1 101 1799-OOP COUPLER 1 103 1869-OOP ENGINE 9LD625-21 LOMB. DIES 1 104 1871-OOP BOLT 3/8 nc x 1 ¼ HH PL #5 2 105 1926-OOP CLAMP, HOSE IDEAL #5012 2 106 1932-OOP BOLT 3/8 nc x ¾ HH PL #5 25 107 1970-OOP BOLT 5/16 nc x 2 ¾ 2 108 1988-OOW BRACKET, PUMP MOUNTING 1 109 1989-OOP BOLT 3/8 nc x 2 ½ HH PL #5 3 110 1990-OOD SPACER 2 111 1991-OOW TANK, HYDRAULIC 1 113 1993-OOD PLATE, ENGINE MOUNTING 1 114 1994-OOW BRACE, HYD TANK SUPPORT 1 115 1996-OOD BRACKET, ALTERNATOR 1 116 1997-OOD SPACER 1 123 2479-OOP FITTING 1 124 2901-OOP LOCK WASHER M10 4 126 4744-OOD BRACKET ALTERNATOR MOUNT 1 127 4745-OOD GUARD CRANK 1 128 4746-OOD GUSSET PUMP MOUNT 1 129 4747-OOD MOUNT THROTTLE 1 130 4748-OOD BRACKET ALTERNATOR MOUNT 1 131 4794-OOD MANIFOLD HYDRAULIC 1 132 4795-OOP VALVE 1 133 4801-OOP FITTING 6400-4-3 1 134 4802-OOP 4 HOSE 14 4 FJ 90 1 135 4803-OOP 4 HOSE 18 ½ 4 to 5 1 136 4804-OOP FITTING 6401-8-8 1 137 1205-OOP BATTERY CABLE RED 1 138 1987-OOD COUPLER #L-110 1 7/16 x 3/8 7/8 x #9 1

139 1780-OOP VALVE PRES. REDUCING 1 140 3270-OOP BOLT ¼ x ½ lg. 2 141 2521-OOP FUSE 1 142 4841-OOP BOLT 10-32 x 1 4 143 1221-OOP BOLT ¼ x ½ Lg. 4 144 4838-OOP HOSE OIL DRAIN 18 6-6 MP- 6-6MP 1 145 2247-OOP #6 PIPE CAP 1 146 4616-OOP BOLT 5/8 x 1 ½ 4 147 3125-OOP NUT 5/8nc 4 148 3126-OOP BOLT 5/8 x 2 4 149 4840-OOP WASHER 5/8 FLAT PLATED 4 150 4839-OOP PUMP KEY 1 151 1960-OOP SPACER 2 152 1132-OOP PLUG 2 153 4837-OOP HOSE #4 4FJ 4 4MP 18 1 154 2036-OOP HOSE CLAMP 4 155 1470-OOP STOP CABLE 1 156 2301-OOP CABLE TIES 1 157 1068-OOP FITTING 2 158 4796-OOP 1 159 4797-OOP 1 160 1851-OOP STREET ELBOW 1 161 4987-OOP STRAIGHT BARB 3/16 1

Hydraulic Fluid Requirements Viscosity (Fluid Thickness) METRIC U.S.A. 10 C 95 Centistokes 50 F 450 SSU Max 38 C 27-42 C.S. 100 F 130-200 SSU 60 C 16.5 C.S., Min. 140 F 85 SSU Min. Pour Point 10 F/-23 C Minimum (for cold startup) Viscosity Index (ASTM D 2220) 140 Minimum Demulsibility (ASTM D-1401) 30 Minutes Maximum Flash Point (ASTM D-92) 340 F/171 C Minimum Rust Inhibition (ASTM D-665 A & B) Pass Oxidation (ASTM D943) 1000 Hours Minimum Pump West Test (ASTM D2882) 60 mg Maximum Recommend Hydraulic Fluids Type Hydraulic fluid Chevron Clarity AW ISO 32 Exxon Univis J 32 Mobil D.T.E. 13 M Gulf Harmony AW-HVI-150-32 Shell Tellus T 32 Texaco Rando HDZ 32 Union Unax AW-WR-32 Amsoil AWH ISO 32 Sunvis Low Pour H/032-product code 193000