Durapac PDM3054-Rail User manual

ABSOLUTE EQUIPMENT PTY LTD –2/186 Granite Street, GEEBUNG QLD 4034 –Australia
[e-mail] –Phone: [phone] –Fax: [phone]
Maximum Operating Pressure –700 bar
Instruction Manual
Double Acting Diesel Driven Railway Power
Unit - Model –PDM3054-RAIL

Instruction Manual
PDM3054-RAIL –DA Diesel PU - V1.0 www.durapac.com Page 2 of 12
This is a safety alert symbol. It is used to alert you to potential personal injury hazards.
Obey all safety messages that follow this symbol to avoid injury or death
1.0 Product Information
DURAPAC –Double Acting Diesel Driven Railway Power Units are engineered to meet Industrial
Standards for Performance and Safety. The PDM3054-RAIL model is suitable for heavy duty
applications in the field and can deliver a minimum flow of 2.5 Lpm at 700 bar pressure. It is
specifically designed to operate rail tensors and weld shears commonly used in the railway industry.
It features a selector valve to choose which tool to operate and individual directional control valves
for each tool. The power unit has a 50 L usable oil capacity coupled with the reliability of a 3.4 kW
Hatz® diesel motor.
Note –PDM3054-RAIL power units can be custom designed to suit many applications. Variations in
function, pressure and flow can be achieved.
Selector valve for weld shear outlet / tensor outlet
12 V battery with isolation switch
5 litre fuel tank with filter
Recoil start for manual backup
Throttle control lever for manual adjustment
Fuel and oil filter accessible for ease of service
Air cooled diesel 3.4 kW engine with variable speed control
12 V electric start/stop control panel
63 mm panel mounted 0 - 1,000 bar pressure gauge
Shutdown protection on high temperature and low oil pressure
Side exit exhaust silencer with mesh guard
Please see the enclosed HATZ Diesel Instruction Book to obtain further information, safety warnings
and alerts that relate specifically to the HATZ diesel engine.
Special skill, knowledge and training may be required for a specific task and the product may not be
suitable for all jobs. The user must ultimately make the decision regarding suitability of the product
for any given task and assume the responsibility of safety for all in the work area. Contact a Durapac
representative if you are unsure of your power units’ suitability for a particular application.
2.0 Receiving Instructions
It is recommended prior to use that an inspection be done by qualified personnel and that any
missing or damaged parts, decals, warning/safety labels or signs are replaced with Durapac
authorised replacement parts only. Any power unit that appears to be damaged in any way, is worn,
leaking or operates abnormally should be removed from service immediately until such time as
repairs can be made. Any power unit that has been or suspected to have been subject to a shock
load should be removed from service immediately until inspected by a Durapac authorised service
centre. Owners and operators of this equipment should be aware that the use and subsequent
repair of this equipment may require specialised training and knowledge.

Instruction Manual
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3.0 Safety
Save these instructions. For your safety, read and understand the information contained within. The
owner and operator should have an understanding of this product and safe operating procedures
before attempting to use this product. Instructions and safety information should be conveyed in the
operator's native language before use of this product is authorised. Make certain that the operator
thoroughly understands the inherent dangers associated with the use and misuse of the product. If
any doubt exists as to the safe and proper use of this product as outlined in this factory authorised
manual, remove from service immediately.
DANGER:
To avoid personal injury keep hands and feet away from work area during operation
Do NOT handle pressurised hoses. Escaping oil under pressure can penetrate the skin
causing serious injury. If oil is injected under the skin, see a doctor immediately
Stay clear of loads supported by hydraulics. A cylinder, when used as a load lifting
device, should never be used as a load holding device. After the load has been raised
or lowered, it must always be supported mechanically
WARNING:
The system operating pressure must not exceed the pressure rating of the lowest
rated component in the system. Install pressure gauges in the system to monitor
operating pressure. It is your window to what is happening in the system
Always wear appropriate personal protective equipment (PPE) when operating
hydraulic equipment. The operator must take precaution against injury due to failure
of the tool or work piece(s)
Do NOT hold or stand directly in line with any hydraulic connections while pressurising
Do NOT attempt to disconnect hydraulic connections under pressure. Release all line
pressure before disconnecting hoses
All personnel must be clear before lowering load or depressurising the system
Do NOT attempt to lift a load weighing more than the capacity of the cylinder
IMPORTANT:
If at any stage, the safety related decals become hard to read, these must be replaced
Minimum age of the operator must be 18 years. The operator must have read and
understood all instructions, safety issues, cautions and warnings before starting to
operate the equipment. The operator is responsible for this activity towards other
persons
Do NOT lift hydraulic equipment by the hoses or couplers. Use the carrying handle or
other means of safe transport
Hydraulic equipment must only be serviced by a qualified hydraulic technician. For
repair service, contact the Durapac authorised service centre in your area. To protect
your warranty, use only high quality hydraulic oil

Instruction Manual
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CAUTION:
KEEP HYDRAULIC EQUIPMENT AWAY FROM FLAMES AND HEAT. Hydraulic fluid can
ignite and burn. Excessive heat will soften packings and seals, resulting in fluid leaks.
Heat also weakens hose materials and packings. For optimum performance do not
expose equipment to temperatures of 65°C (150°F) or higher. Protect all equipment
from weld spatter
No alteration should be made to this device
3.1 Hydraulic Power Units
Do use a gauge or other load measuring instrument to verify load
Do NOT exceed the rated capacity of the power unit or any equipment in the system.
Burst hazard exists if connection pressure exceeds rated pressure
Do NOT operate the system with bent or damaged couplers or damaged threads
Do NOT subject the power unit and its components to shock loads
Use only Durapac approved accessories and components
Do NOT connect to an application which can return more oil to the reservoir than the
power unit reservoir can hold
Do NOT connect power unit to a hydraulic system that is powered by another pump
3.2 Hydraulic Hoses & Fluid Transmission Lines
Avoid short runs of straight line tubing. Straight line runs do not provide for expansion
and contraction due to pressure and/or temperature changes
Reduce stress in tube lines. Long tubing runs should be supported by brackets or clips.
Before operating the power unit, tighten all hose connections with proper tools. Do
not over tighten. Connections should be tightened securely and leak-free. Over
tightening can cause premature thread failure or high pressure fittings to burst
Should a hydraulic hose ever rupture, burst or need to be disconnected, immediately
shut off the power unit and release all pressure. Never attempt to grasp a leaking
pressurised hose with your hands. The force of escaping hydraulic fluid can inflict
injury
Do NOT subject the hose to potential hazard such as fire, sharp objects, extreme heat
or cold or heavy impact
Do NOT allow the hose to kink, twist, curl, crush, cut or bend so tightly that the fluid
flow within the hose is blocked or reduced. Periodically inspect the hose for wear
Hose material and coupler seals must be compatible with the hydraulic fluid used.
Hoses also must not come in contact with corrosive materials such as battery acid,
creosote-impregnated objects and wet paint. Never paint a coupler or hose
Please also refer to the HATZ Diesel Instruction Book for safety warnings and alerts that relate
specifically to the HATZ diesel engine.

Instruction Manual
PDM3054-RAIL –DA Diesel PU - V1.0 www.durapac.com Page 5 of 12
FAILURE TO HEED THESE WARNINGS MAY RESULT IN PERSONAL INJURY AS WELL AS PROPERTY DAMAGE.
4.0 Installation
IMPORTANT:
This power unit is for use with a double-acting cylinder ONLY! Ensure that both A and B
ports are properly connected to a double acting application
Always secure threaded port connections with high grade, non-hardening pipe thread
sealant. Teflon tape can be used if only one layer of tape is used and it is applied
carefully, two threads back, to prevent the tape from being introduced into hydraulic
system, which could cause jamming of precision-fit parts
4.1 Familiarise yourself with the specifications and illustrations in this owner’s manual.
Know your power unit, its limitations and how it operates before attempting to use.
Refer to specification chart below or if in doubt, contact a Durapac representative.
4.2 Ensure that there is adequate oil in the reservoir to perform the required function.
Ideally the gauge should not read less than 1/3. If this is the case see section 6.1
Adding Hydraulic Fluid.
4.3 Hydraulic connections –check all system fittings and connections to be sure they are
tight and leak free.
4.4 Completely fill the fuel tank with diesel following the instructions in the HATZ Diesel
Instruction Book. The bleeding of the fuel system is automatic.
4.5 Remove air from the system –Air can accumulate in the hydraulic system during the
initial setup or after prolonged use, causing the cylinder to respond slowly or in an
unstable manner. Should removal of air from power unit be required, please follow the
steps in 6.2 –Bleeding Air from the System in the Maintenance Section.
5.0 Operation
IMPORTANT:
Do NOT operate the power unit in closed or badly ventilated rooms
Never set the relief valve to a higher pressure than the maximum rated pressure of the
power unit. Higher settings may result in equipment damage and/or personal injury
Do NOT remove the relief valve
The power unit has a high pressure safety valve set to 700 bar. The operator should
ensure the tool being operated is adequately rated
Always monitor pressure, load or position using suitable equipment. Pressure may be
monitored by means of an optional manifold and gauge. Correct application position
PDM3054-RAIL 3.4 2,200 2.5 50 190
rpm
Usable Oil
Capacity (L)
Dry
Weight
(kg)
Model
Number
Kw
Flow Rate Lpm
@ 700 bar

Instruction Manual
PDM3054-RAIL –DA Diesel PU - V1.0 www.durapac.com Page 6 of 12
can only be determined by the operator of the equipment
Do NOT operate a power unit that is disconnected from the application. If operated in
this condition, the hose and connections will become pressurised. This increases the
chance of a burst hazard. Damage may also occur to the power unit and its
components
5.1 Before Using the Power Unit
5.1.1 Check all system fittings and connections to be sure they are tight and leak free.
5.1.2 Check hydraulic oil level in reservoir. See section 6.1 Adding Hydraulic Fluid, if
required.
5.1.3 Check the engine oil level. Refill as per the HATZ Diesel Instruction Book, if
required.
5.1.4 Check fuel level. Refill as per the HATZ Diesel Instruction Book, if required.
5.1.5 Auxiliary equipment should be placed in neutral.
5.2 Before Starting the Engine
5.2.1 Set the speed control lever to the STOP position.
5.2.2 Ensure the hydraulic selector valve and tool directional valves (Figure 1) are in
the centre position
Figure 1 –Selector Valve & Outlets
5.2.3 Move the speed control lever to ½ START or all the way to the START position,
as desired or necessary.
Note - Starting at a lower speed will minimise exhaust smoke.

Instruction Manual
PDM3054-RAIL –DA Diesel PU - V1.0 www.durapac.com Page 7 of 12
Figure 2 –Starting the Engine
5.3 Starting the Engine
5.3.1 Insert the key fully and turn to position
“I”(Figure 2). Battery charge telltale (2)
and the oil pressure warning (3) must
light up.
5.3.2 Turn start key to position “II”.
5.3.3 As soon as the engine is running,
release the start key. It will
automatically return to position “I” and
will remain in this position during
operation.
Battery charge telltale and oil pressure warning will go out immediately
after starting
Indicator light (1) will be on when the engine is in operation
The engine temperature display (4) will light up if the temperature at the cylinder
head becomes too high. If this occurs, switch off the engine and identify the cause
of the problem (refer to the HATZ Instruction Book for further details)
Always turn the start key back to position 0 before restarting the engine. The
repeat lock in the ignition lock prevents the starter motor from engaging and
possibly being damaged while the engine is still running
The preheating light (5) will light up at temperatures below 0oC. Do not start the
engine when the light is on
5.4 Stopping the Engine
5.4.1 Move the speed adjustment lever back to the STOP position. The engine will cut
out.
5.4.2 Turn the key to position 0 (Figure 2) and remove. All indicator lights will go out.
Note –Failure to return the starter key to position 0 may result in the battery
being totally discharged.
Please refer to the HATZ Diesel Instruction Book for further operational details, safety
warnings and alerts that relate specifically to the HATZ diesel engine.
5.5 Tool Operation
5.5.1 Ensure both tool directional control valves are in the centre position.
5.5.2 Move the selector valve to the desired position to power either the tensor or
weld shear.
5.5.3 The operator can now control the advance and retract function of the chosen
tool by operating the tool directional control valve.

Instruction Manual
PDM3054-RAIL –DA Diesel PU - V1.0 www.durapac.com Page 8 of 12
CAUTION: The rail tensor circuit is fitted with a pilot operated check valve system to
hold hydraulic pressure positively when shifting from advance or retract to the
centre position. To prevent pressure build up and difficult hose removal ensure the
rail tensor cylinder is not pressurised in the fully advanced or retracted position.
Prior to shutting down the engine, advance the cylinder a few millimetres to
remove pressure from the hydraulic hoses.
5.6 Relief Valve Adjustment
All power units contain a factory set relief valve to prevent over-pressurisation of the
system. A deck mounted adjustable pressure relief valve is also included and can be set
to lower working pressures.
6.0 Maintenance
IMPORTANT:
Check oil level regularly
Use only good quality hydraulic fluid. Do NOT use brake fluid, transmission fluid,
turbine oil, motor oil, alcohol, glycerine etc. Use of anything other than good quality
hydraulic oil will void warranty and damage the power unit, hose, and application. We
recommend Durapac Hydraulic Oil or equivalent
Equipment must only be serviced by a qualified hydraulic technician. For repair service,
contact your local Durapac authorised service centre
Damage to hydraulic hoses may not be detected during visual inspections. For this
reason, Durapac recommends that hydraulic hoses be replaced on a regular basis
Tighten connections as needed. Use non-hardening pipe thread compound when
servicing connections
Dirt, sand, etc. will quickly ruin any hydraulic system. Ensure that couplings are clean and
free of foreign matter. After each use, clean couplings and attach dust caps.
Maintenance is required when wear or leakage is noticed. Periodically inspect all
components to detect any problem that may require service and maintenance.
6.1 Adding Hydraulic Fluid
WARNING: Always add oil with cylinders fully retracted (or extended, if pull cylinders) or
the system will contain more oil than the reservoir can hold
6.1.1 Depressurise and disconnect hydraulic hose from application/cylinder.
6.1.2 With the power unit in its upright, horizontal position, remove the air vent
plug located on the top plate of the reservoir.
6.1.3 Take out the filling plug.
6.1.4 Use a small funnel to fill the oil to within 20mm of the opening.
6.1.5 Bleed air from system if necessary.
6.1.6 Wipe up any spilled fluid and reinstall the air vent plug/reservoir cap.

Instruction Manual
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6.2 Bleeding Air from the System
6.2.1 Repeat Steps 6.1.1 to 6.1.4 (above) if required.
6.2.2 Invert cylinder and place at a lower level than the power unit reservoir.
6.2.3 Extend and retract the cylinder several times without putting a load on the
system. Air will be released into the power unit reservoir.
6.3 Changing Hydraulic Fluid
For best results, change fluid once a year or every 300 hours of use
6.3.1 Repeat Steps 6.1.1 to 6.1.3 (above).
6.3.2 Tilt power unit to drain out old oil into a sealable container.
6.3.3 Repeat Steps 6.1.4 to 6.1.6 (above).
6.3.4 Dispose of fluid in accordance with local regulations.
6.4 Storage
6.4.1 When not in use, depressurise and disconnect the power unit from the
application.
6.4.2 Wipe clean, thoroughly and store in clean, dry environment. Avoid
temperature extremes.
6.4.3 For transportation or long storage, replace the air vent plug with the
shipping plug.
Please also refer to the HATZ Diesel Instruction Book for maintenance tasks that relate specifically to
the HATZ diesel engine.

Instruction Manual
PDM3054-RAIL –DA Diesel PU - V1.0 www.durapac.com Page 10 of 12
7.0 Troubleshooting
Problem
Cause
Solution
Noisy operation
Air trapped in system
Check all points where air may
leak into the system
Refer to 6.2 –Bleeding Air from
the System
Power unit reservoir too full
Drain fluid to correct level
Low fluid level in power unit
reservoir
Refer to 6.1 –Adding Hydraulic
Fluid
Fill and bleed the system
Power unit oil is over-
heating
Oil viscosity is too high
Refer to 6.3 –Changing
Hydraulic Fluid
Refill with a good quality
hydraulic oil
High pressure leakage on upper
pressure plate
Tighten plug
Low fluid level in power unit
reservoir
Refer to 6.1 –Adding Hydraulic
Fluid
Fill and bleed the system
Power unit runs but will
not pump oil
Power unit is not primed
Run power unit a few minutes
tipping from side to side
Externally adjustable relief valve
is not correctly set
Reset the relief valve to
appropriate level
Damaged o-ring
Send to a Durapac authorised
service centre for repair
Defective control valve
Send to a Durapac authorised
service centre for repair
Power unit does not
reach rated capacity
Low fluid level in reservoir
Secure load by other means.
Depressurise power unit and
hose, remove application, then
fill and bleed the system
Leaking system components
Repair or replace as necessary
Poor performance
Fluid level in power unit is low
Secure load by other means.
Depressurise power unit and
hose, remove application, then
fill and bleed the system
Application does not
extend, move or respond
to pressurised fluid
Overload condition
Remedy overload condition
Loose couplers
Tighten couplers
Faulty couplers
Replace couplers
Malfunctioning power unit
Contact a Durapac authorised
service centre for repair
Application does not
fully extend (cylinder or
spreader)
Reservoir overfilled
Secure load by other means.
Depressurise power unit and
hose, remove application, then
drain fluid to proper level
Low fluid level in power unit
reservoir
Secure load by other means.
Depressurise power unit and
hose, remove application, then
fill and bleed the system

Instruction Manual
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Problem
Cause
Solution
Load above capacity of system
Use correct equipment
Application responds
slower than normal
Loose connection or coupler
Tighten couplers
Restricted hydraulic line or fitting
Clean and replace if damaged
Power unit not operating
correctly
Check the power unit’s
operating instructions
Check the HATZ Diesel
Instruction Manual
Repair or replace as necessary
Low fluid level in power unit
reservoir
Secure load by other means.
Depressurise power unit and
hose, remove application, then
fill and bleed the system
Application responds to
pressurised fluid, but
system does not
maintain pressure
Leaky connection
Clean, reseal with thread
sealant, and tighten
connection
Leaking cylinder seals
Replace worn seals. Look for
excessive contamination or
wear. Replace contaminated
fluid
Power unit or valve not operating
correctly
Contact a Durapac authorised
service centre for repair
Overload condition
Remedy overload condition
Application does not
return fluid to power
unit (i.e. cylinder will not
retract)
Closed release valve
Secure load by other means.
Open release valve
Loose couplers
Secure load by other means.
Tighten couplers
Blocked hydraulic lines
Secure load by other means.
Clean and flush lines
Weak or broken retraction
springs
Secure load by other means.
Contact a Durapac authorised
service centre for repair
Internally damaged cylinder
Secure load by other means.
Contact a Durapac authorised
service centre for repair
Power unit reservoir too full
Secure load by other means.
Depressurise power unit and
hose, remove application, then
drain fluid to proper level
Please also refer to the HATZ Diesel Instruction Book for maintenance tasks that relate specifically to
the HATZ diesel engine.

Instruction Manual
PDM3054-RAIL –DA Diesel PU - V1.0 www.durapac.com Page 12 of 12
8.0 Hydraulic Circuit