LUCAS 84072930085 User manual

Operating instructions
Rerailing Equipment
Edition 08.2009
84072930085 GB
Hydraulic units
(Translation of the original operating instructions)

2
Content Page
1. Hazard classes 4
2. Product safety 5
3. Proper use 8
4. Labelling of the units 8
5. Functional description 9
5.1 General 9
5.2 Motor variants 10
5.3 Pumps 10
5.4 Frames 11
5.5 Connection to the control unit 11
5.6 Connection options 11
5.7 Optional accessories 11
6. Connection of the hoses 12
6.1 Connection of quick-connect couplings 12
6.2 Direct connection 13
7. Set-up and start-up 13
7.1 Installation 13
7.2 Start-up 14
8. Operation 15
8.1 Starting the motors 15
8.2 Stopping the motors 16
9. Dismantling the equipment / deactivation following operation 17
10. Maintenance and service 18
10.1 Recommended inspection intervals 18
10.2 Hydraulic units with combustion engine 19
10.3 Hydraulic units with electric motor 19
11. Repairs 20
11.1 General 20
11.2 Preventive service 21
11.3 Repairs 25
11.4 Installation and repair of optional accessories 28

3
12. Troubleshooting 31
13. Technical data 34
13.1 Hydraulic power pack 34
 13.2 Recommendedhydraulicuid 37
13.3 Hoses 37
13.4 Operating temperature and storage temperature ranges 37
14. Notes 38

4
Wear helmet with face protection
Wear safety gloves
Wear safety shoes
Proper recycling
Observe principles of environmental protection
Read and observe operating instructions
We distinguish between various categories of safety instructions. The table below gives you
an overview of the assignment of symbols (pictograms) and key words to the specic hazard
and possible consequences.
Hazard classes1.
Pictogram Damage / injury
to Key word Denition Consequences
human
DANGER! Immediate danger Death or major
injury
WARNING!
Potentially
dangerous
situation
Potential death or
major injury
CAUTION! Less dangerous
situation
Minor or slight
injury
device
CAUTION!
Danger of damage
to device /
environment
Damage to the
equipment,
damage to the
environment,
damage to
surrounding
materials
- REMARK
Advice for
application and
other important /
useful information
and advice
No injury /
damage to
persons /
environment /
equipment

5
Product safety2.
LUKAS products are developed and manufactured in order to guarantee the best performance
and quality when used properly.
Operator safety is the most important aspect of the product design. Moreover, the operating
instructions are intended to ensure LUKAS products are used safely.
The generally applicable legal and other binding regulations pertaining to the prevention of
accidents and protection of the environment apply and are to be complied with in addition to
the operating instructions.
The equipment may only be operated by persons with appropriate training in the safety
aspects of such equipment – otherwise, there is a danger of injury occurring.
We would like to point out to all users that they should read the operating instructions carefully
before using the equipment and comply with the instructions there without restriction.
We further recommend that a qualied instructor train you in the use of the product.
WARNING / CAUTION!
The operating instructions for the hoses, the accessories and the connected
hydraulic equipment must also be observed.
Even if you have already received instructions on how to use the equipment, you should still
read through the following safety instructions once again.
WARNING / CAUTION!
Ensure that the accessories and connected equipment used are suitable for
the maximum operating pressure.
Please ensure that no body
parts or clothing get stuck
between the visibly moving
parts.
The department responsible
is to be informed immediately
of any changes (including to
the operating behaviour). If
necessary, the equipment is to
be shut down immediately and
secured.
Wear protective clothing, safety
helmet with visor, safety shoes
and protective gloves.
Inspect the equipment before
and after use for visible defects
or damage.
It is prohibited to work under
load if this load is lifted
exclusively by hydraulic
equipment. If this work is
absolutely imperative, additional
mechanical supports must be
used.
Inspect all lines, hoses and
screwed connections for leaks
and externally visible damage.
If necessary, repair immediately.
Squirting hydraulic liquids can
result in injuries and res.

6
In the event of malfunctions,
immediately shut down the
equipment and secure it. The
malfunction is to be repaired
immediately.
Do not carry out any changes
(additions or conversions) to the
equipment without obtaining the
prior approval of LUKAS.
Comply with all the instructions
regarding safety and danger
on the equipment and in the
operating instructions.
All the instructions regarding
safety and danger on the
equipment are to be kept
complete and in a legible
condition.
Please ensure that all safety
covers are present on the
equipment and that they are in
proper and adequate condition.
Any method of operation which
impairs safety and/or stability of
the equipment is prohibited.
Safety devices may never be
deactivated.
The maximum operating
pressure set on the equipment
must not be changed.
Before the equipment is
switched on / started up, and
during its operation, it must
be ensured that nobody is
endangered by the operation of
the equipment.
Comply with all specied
dates or dates specied in the
operating instructions pertaining
to regular checks / inspections
of the equipment.
When working close to live
components and cables,
suitable measures must be
taken to avoid current transfers
or high-voltage transfers to the
equipment.
Only original LUKAS
accessories and spare parts
may be used for repairs.
During all work and transport
operations involving the
equipment, take care not to trip
and become caught in hose and
cable loops.
The build-up of static charge
with the potential consequence
of spark formation is to be
avoided when handling the
equipment.
When working with combustion
engine pumps, never touch
the motor and exhaust system,
since there is a risk of burning.
Motor pumps may not be used
in explosion hazard areas.
Combustion engines are not
permitted to be operated in
enclosed spaces as there
is a risk of poisoning and/or
asphyxiation.
If the fuel of a combustion
engine is spilled, this must be
cleaned up before the engine is
started.
Filling up during operation of
the combustion engine is strictly
prohibited.

7
Keep combustion engines and
their fuel away from ignition
sources, as otherwise there is
the danger of an explosion.
All damaged electrical
components e.g. scorched
cables, etc. are to be replaced
immediately.
To avoid the risk of re, ensure
adequate ventilation during
combustion engine operation
and maintain a minimum safety
distance of 1 m (39.4 in.)
from walls and other shielding
installations.
Damage to electrical
components must be repaired
only by a trained and qualied
electrician in compliance with
all applicable national and
international safety rules and
regulations.
To avoid fuel spillage, make
sure that the combustion
engine pumps are standing
on as level and horizontal a
surface as possible.
When setting up the units, it
must be ensured that they are
not impaired by the inuences
of extreme temperatures.
The equipment is lled with
hydraulic uid. These hydraulic
uids can be harmful to your
health if swallowed or if their
vapours inhaled. Direct contact
with the skin is to be avoided
for the same reason. Please
also note that hydraulic uids
can also have a negative effect
on biological systems.
When working with or storing
the equipment, ensure that the
function and the safety of the
equipment are not impaired by
the effects of extreme external
temperatures and that the
equipment is not damaged in
any way. Please note that the
equipment can also heat up
over a long period of use.
Ensure adequate lighting when
you are working.
Before transporting the
equipment, always ensure that
the accessories are positioned
in such a way that they cannot
cause an accident.
Always keep these operating
instructions within reach where
the equipment is used.
Ensure the proper disposal of
all removed parts, leftover oil,
hydraulic uid and packaging
materials.

8
The generally applicable, legal and other binding national and international regulations
pertaining to the prevention of accidents and protection of the environment apply and are to
be implemented in addition to the operating instructions.
WARNING / DANGER / CAUTION!
The equipment is to be used exclusively for the purpose stated in the operating
instructions (see chapter "Proper use"). Any form of use beyond this is not considered
proper use. The manufacturer / supplier is not liable for any damages resulting from improper
use. The user bears sole responsibility for such use.
Observance of the operating instructions and compliance with the inspection and maintenance
conditions are covered by the denition of proper use.
Never work when you are overtired or intoxicated.
Proper use3.
Accessories and spare parts for the rerailing equipment are available from your authorised
LUKAS dealer.
WARNING / DANGER / CAUTION!
Always observe the safety notes of these operating instructions with regard to
place of installation and type of installation. The units must not be used in all
atmospheres, since there could be a danger of explosion.
LUKAS hydraulic units are designed specically for supplying hydraulic uid to rerailing
equipment manufactured by LUKAS in order that this equipment can be used to upright and
rerail railway vehicles.
While it is possible for the units to supply pressure/uid to other makes of rerailing equipment,
this shall require the technical inspection and approval of LUKAS.
Labelling of the units4.
Motor variants:
PC = Electric motor
GC = Petrol engine
DC = Diesel engine
PC
Motor variants
6
Type group
-

9
The main components (see example illustration) of a LUKAS hydraulic unit are:
Functional description5.
5.1 General
CAUTION!
Where multiple implements are operated with the same hydraulic unit, it must be
ensured that the usable volume of hydraulic uid in the uid reservoir is greater
than the maximum possible operating uid volume required for all connected
implements combined.
If no external control unit (e.g. control desk) is to be connected, it is possible to order a LUKAS
hydraulic unit with the valves or valve blocks directly attached.
If you are considering these optional valves or valve blocks, you should consult your
authorised LUKAS dealer or LUKAS directly before you combine your rerailing equipment
components. Only then can you be sure that the individual, combinable LUKAS components
(unit, implements, etc.) of your system arrangement will continue to function correctly, and
that risks to persons and equipment are eliminated.
Operation without an attached or external control unit is NOT
permitted.
1 Fluid reservoir
2 Motor
3 Pump
4 Frame
5 Connecting block
As a general principle on all LUKAS hydraulic units, a hydraulic pump is operated with a
motor (combustion engine or electric motor) that feeds the uid from the reservoir and builds
up the pressure. The uid distribution is then controlled by valves directly attached to the
equipment or by external control units (e.g. control desks).
The mounted frame serves as a simple protective cage and as a mounting base for
accessories that can be tted. The hydraulic unit can also be carried by the frame or using
carrying handles mounted on it.
6 Valve block
7 Carry handles
8 Fluid drain plug
9 Filler cap
10 Optional hose reel attachment
1
2
3
7
8
9
10
1
2
3
4
56
7
9
10
7
7
7
7
8

10
5.2 Motor variants
WARNING / DANGER / CAUTION!
For all motor variants, also comply with the separate operating instructions of
each motor manufacturer.
5.2.1 Electrical
These hydraulic units are equipped with an electric motor. The electric motor is driven by
electricity from the mains supply or by electricity produced by generators. In the case of
operation with generators, make sure that voltage uctuations do not occur, as these have a
direct inuence on the pumping capacity and stability of the hydraulic unit.
For the supported operating voltage and current frequency, please refer to the “Technical
data” chapter in the instruction manual for your unit.
5.2.2 Gasoline / petrol
These hydraulic units are equipped with a combustion engine driven by the fuel "gasoline /
petrol".
(For specic details, please consult the separate operating instructions of the engine
manufacturer.)
5.2.3 Diesel
These hydraulic units are equipped with a combustion engine driven by the fuel "diesel".
(For specic details, please consult the separate operating instructions of the engine
manufacturer.)
5.3 Pumps
Depending on the model, LUKAS hydraulic units contain a single-ow or multi-ow pump.
Single-ow pump 1 pump capacity
Double-ow pump 2 pump capacities
Triple-ow pump 3 pump capacities
etc.
The pumps used are always equipped with two pressure levels for each pump capacity, one
low-pressure and one high-pressure level.
Low-pressure level (ND) = up to 16 MPa*
High-pressure level (HD)= up to max. 53 MPa*
The changeover from low pressure to high pressure is carried out automatically in the
pump.
The maximum operating pressure is limited by a pressure limiting valve.
For information on how to adjust this valve to work with your hydraulic unit model, please
refer to the “Technical data” chapter.
*( 1 MPa = 10 bar)

11
WARNING / DANGER / CAUTION!
In the interests of safety, the pressure set at this pressure limiting valve must not
be adjusted (without direct approval of LUKAS).
5.4 Frames
All hydraulic units for the rerailing equipment are supplied with a frame. The frame enables
optional accessories to be attached directly to it. In addition, the frame makes the unit easier
to transport, thanks in particular to the integral carry handles.
5.5 Connection to the control unit
5.6 Connection options
The unit is connected to the control unit by means of hoses or pairs of hoses. These
are available in various lengths, coloured bend protections and with various connection
options.
The individual hose lines in a hose pair are distinguishable by their different colour, which
helps to prevent confusing the supply line for the return line.
(Forspecicdetails,pleaseconsulttheLUKASrangeofaccessoriesorcontactyour
LUKASdealer).
On the hydraulic unit, the supply and return lines are connected to a connecting block or
valve block.
The standard range is designed to support only direct hose connections or quick-disconnect
couplings.
5.7 Optional accessories
5.7.1 Hose reels
Some hydraulic unit frames allow hose reels to be tted. The use of attachment reels makes
it possible to route the optimum length of hose for a specic application and to keep the
amount of hose needed in the work area to a minimum.
The hose reels are connected to the pump assembly mechanically and hydraulically. The
hydraulic connection is achieved either by hose lines or by pipework.
(Tondoutwhethersuitableattachmentreelsareavailableforyourunit,pleaseconsultyour
authorisedLUKASdealerorLUKASdirectly.)
5.7.2 Drain valves
Some hydraulic units can be equipped with a drain valve instead of the connecting block.
The advantage of the drain valve is that, when it is opened (handwheel turned clockwise to
the stop), the hydraulic unit is switched to depressurised circulation. It is only when the valve
is closed (handwheel turned anti-clockwise to the stop) that the connected control unit and
the associated implements are made ready for operation.
It is possible to have the connecting block replaced by a drain valve at a later time.
The hose lines or pipework are connected to the drain valve in the same way they are
connected to the connecting block
(Todiscussthepurchaseofadrainvalve,pleasecontactyourauthorisedLUKASdealeror
LUKASdirectly.)

12
CAUTION!
When connecting the hose assemblies, always ensure that the connection
components are not soiled; clean beforehand if necessary.
WARNING / DANGER / CAUTION!
Before connecting equipment, make sure that all the components
used are suitable for the maximum operating pressure of the
hydraulic unit. In cases of doubt, you must consult LUKAS
directly before connecting the equipment.
Connection of the hoses6.
REMARK:
Before you attempt to connect or disconnect hose lines to or from the hydraulic
unit, including hose lines with quick-disconnect couplings, always make sure
that the pump assembly is switched off. Electric pumps must be disconnected
from the power supply.
The equipment is connected to the hydraulic pump via quick-disconnect coupling halves (male
and female).
Before coupling, remove the dust protection caps, then pull back and hold the locking sleeve
of the female coupling (position X). Fit the socket and plug together and release the locking
sleeve. Then turn the locking sleeve to position Y. The connection has now been made and
locked. Disconnection is made in the reverse order.
WARNING / DANGER / CAUTION!
Some quick-disconnect couplings have special functions. Therefore it is not
permitted to screw them off the hoses or to swap them.
X
To protect against dust, the accompanying dust protection caps must be replaced.
REMARK:
Coupling of the devices is only possible when the hoses are depressurised.
6.1 Connection of quick-connect couplings
CAUTION!
Always couple the return hose rst and then the supply hose.
On disconnecting, you should always disconnect the supply line rst and then
the return pipe.

13
6.2 Direct connection
The hydraulic hoses are screw-connected to the connecting block of the hydraulic unit. The
connecting block must contain the necessary connection nipples. The hoses are fastened
to these connection nipples directly by union nuts. To do this, you need to remove the
dust protection caps or screw plugs and the steel balls underneath before connecting the
hydraulic hose and securing the hose to the connection nipple by tightening the union nut.
The specied tightening torque of 35 Nm must be observed. At the connecting block, the
return line is labelled “T” and the supply line is labelled “P”.
REMARK:
To be able to screw the hoses onto the connecting block directly, you must
check rst whether the corresponding connection nipples are tted inside the
connecting block.
CAUTION!
Always connect the return hose rst and then the supply hose.
Set-up and start-up7.
7.1 Installation
WARNING / DANGER / CAUTION!
Combustion engine units and most electrical units must not be used in a
potentially explosive situation (danger of the formation of sparks). Units with
combustion engines must not be used in enclosed spaces, as there is a danger
of poisoning and/or asphyxiation.
The unit is to be set up in a suitable location (safe location / at surface / sufcient distance
from vehicles, loads, sources of ignition, etc.).
LUKAS units work perfectly at an angle of up to 30°. However, in order to guarantee maximum
safety and uid withdrawal, they should be operated in as horizontal a position as possible.

14
7.2 Start-up
Please proceed as follows:
1. First of all, check the hydraulic uid level of the unit.
Depending on the unit model, the uid level is indicated
by a uid sight glass (maximum = centre of sight glass;
rell required if uid level no longer visible in the sight
glass) or a dipstick (usually attached to a ller screw). If
necessary, you should top up the uid to the maximum
level.
2. Now connect the external control unit, if this is not already permanently connected to the
hydraulic unit.
3. For hydraulic units with an electric motor, you should now connect the plug to the power
supply.
4. Then vent the hydraulic unit. Make sure that the control unit is switched to depressurised
circulation. If you cannot be absolutely sure that this is the case, take appropriate measures
to enforce depressurised circulation, e.g. by connecting the supply and pressure lines
together (observe the separate operating instructions for the control unit concerned).
The actual venting is carried out in the units in a different manner, depending on the drive
motor:
a) Gasoline / petrol engine:
- Remove plug connector from the spark plug.
- Slowly turn the starter rope several times.
For a motor with electric starter, activate the starter several times.
- Then replace the plug connector.
b) Diesel engine:
- Slowly turn the starter rope several times in such a way that the engine
does not start.
c) Electric motor (power and accumulator operation):
- Switch on the motor and switch it off again after approximately 10 seconds.
Repeat this procedure several times. (Before switching back on,
the motor must be at a standstill.)
This procedure means that the pump can slowly extract and be well vented. The hydraulic
uid reservoir is equipped with automatic venting, which means no further venting
measures are required.
5. Check the level of the uid in the reservoir once more. If necessary, top up the uid.
6. Return the control unit to operational condition, i.e. reconnect the control unit correctly.
MAXIMUM
MINIMUM
MAXIMUMMINIMUM

15
Operation8.
CAUTION!
Before the motor is started, the hydraulic unit and the control unit must be
switched to depressurised circulation (for the hydraulic unit, this means
connecting the supply and return lines together, for example). Only in this way is
it possible to start the unit without a hydraulic load.
8.1.1Gasoline / petrol and diesel engines
Before starting the combustion engines, check that the fuel tank is full and that the engine oil
level is within the permitted tolerances. If necessary, top up the relevant uid.
Procedure for starting Briggs & Stratton engines:
1. Open gasoline / petrol tap
2. Move the lever from switch position A to switch
position C
3. Pull the starter rope or activate the E starter
Procedure for starting Intek engines:
1. Open gasoline / petrol tap
2. Move top lever from switching position E to switching
position F
3. Move bottom lever (choke) from switching position G
to switching position H
4. Pull the starter rope or activate the E starter
5. When the motor is running, switch bottom lever back
to switching position G.
Procedure for starting Honda engines:
1. Open gasoline / petrol tap
2. Switch the ON/OFF switch to ON.
3. Move lever from switching position J to switching
position K (choke)
4. Pull starter rope
5. When the motor is running, switch lever back to
switching position J
Lever at top
Lever at bottom
ABC
EF
G H
K
J
8.1 Starting the motors
Please consult the separate operating instructions of the motor manufacturer for the precise
procedure for starting the combustion engine.

16
An electric starter is available from the LUKAS range of accessories for some units.
(Forspecicdetails,pleaseconsulttheLUKASrangeofaccessoriesorcontactyourLUKAS
dealer).
On these units, after checking the uid levels, proceed as follows:
1. Switch to "START ENGINE"
2. Turn the ignition key clockwise.
Charge the accumulator of the electric starter:
1. Switch to "CHARGE BATTERY"
2. Connect the supplied charger to the mounted socket.
8.1.2Electric motors
Before starting the electric motors, check that all electrical connections and cables are in
proper order. First of all, connect the power cable (for motors with power supply) to the
supply socket.
The motor is started by turning the ON/OFF switch to the ON position.
CAUTION!
Electric motors need a brief, very high starting current. When using a generator,
you should therefore check to see that it can also supply the relevant current
strength.
Formotorsratedupto1.5kW,thepowersupplymustbeprotectedbyafusewith
aminimumratingof25A(slowblow).Formotorsratedover1.5kW,theminimum
fuseratingis30A(slowblow).
Astheinformationabovemayvarydependingonindividualcircumstancesand
on the type of motor used, you should always consult your dealer or LUKAS
directly in case of doubt.
8.2 Stopping the motors
8.2.1Gasoline / petrol and diesel engines
The gasoline / petrol and diesel engines stop automatically when the fuel tank is empty.
Should they stop moving beforehand, the following procedure is required:
Procedure for stopping Briggs & Stratton engines:
1. Move the lever from switch position C to switch
position A
2. When the engine has come to a standstill, close the
fuel tap.
Procedure for stopping Intek engines:
1. Move the top lever from switching position F to
switching position E
Lever at top
Lever at bottom
EF
G H
ABC

17
2. When the engine has come to a standstill, close the
fuel tap.
Procedure for stopping Honda engines:
1. Set the ON / OFF switch to the OFF position.
2. When the engine has come to a standstill, close the
fuel tap.
Please consult the separate operating instructions of the motor manufacturer for the precise
procedure for stopping combustion engines.
WARNING / CAUTION!
Never touch the hot motor / engine parts: this could result in severe burns.
8.2.2Electric motors
The movements of the electric motors are stopped by changing the ON/OFF switch to the
OFF position. This also stops the pumping output of the connected hydraulic pump.
Once work has been completed, all connected equipment is to be reset to its base position
before the unit is shut down. You can now stop the motor of the unit / switch it off and, if using
an electric motor (without accumulator), disconnect it from the mains supply.
Quick-disconnect couplings:
If the connected hose assemblies have to be dismantled during shut-down, decouple as
described in chapter "Coupling the quick-disconnect couplings". Ensure that you replace the
dust protection caps onto the mono-coupling halves.
Clean heavy soiling caused during use of the hydraulic unit before storage.
Direct connection:
Thisconnectionshouldonlybeunscrewedwhenitisabsolutelynecessary,e.g.whenyou
havealongerstoragetime,whendecommissioning,formaintenancetasks,etc.
If the connected hose assemblies have to be dismantled during shut-down, rst of all
disconnect the pressure hose and then the return hose. Ensure that you replace the dust
protection caps onto the screw-in sleeves and onto the hoses. Clean heavy soiling caused
during use of the hydraulic unit before storage.
If the equipment is to be stored for a longer period of time, the exterior is to be cleaned
completely and the mechanical moving parts are to be lubricated. If storing a unit with
combustion engine, you should also remove the fuel from the fuel tank.
Avoid storing the hydraulic units in a damp environment.
The guidelines in the separate operating instructions for the hose lines must also be observed.
Dismantling the equipment / deactivation following9.
operation
CAUTION!
Depending on the size and the weight of the hydraulic unit, it should be transported
to the storage site by one person or several people.

18
Maintenance and service10.
The hydraulic units are subject to very high mechanical loads. For this reason, visual
inspections and function tests must be carried out at regular time intervals. These inspections
and tests enable signs of wear to be identied in good time. Prompt replacement of wear
parts can then prevent damage to the equipment. Also check regularly that all fastening
screws are tightened securely (observe tightening torques where applicable).
You must observe all applicable national and international laws, rules, regulations and
standards relating to the maintenance intervals of rerailing equipment.
CAUTION!
Clean off any dirt before checking the equipment.
WARNING / DANGER / CAUTION!
In order to carry out maintenance and repair work, tools appropriate for the job
and personal protection equipment obligatory (including protective covers).
10.1 Recommended inspection intervals
Operating time per day Function test
up to 1 hour 1 x annually
up to 8 hours 1 x per quarter
up to 24 hours 1 x per month
Inadditionto theseinspectionintervals, afunctiontest shouldbeperformedif theunitis
making suspicious noises or if there is reason to suspect that the unit has been damaged
internally.
If these noises or signs of possible damage arise more than once in a month, or if the
nominalpressure(75%ofmaximumpressure)isnotachievedduringthefunctiontestitself,
youmustcontacttheLUKASCustomerServicedepartmentimmediately.Youwillndthe
relevant contact information in the “Troubleshooting” chapter.
10.1.1 Visual inspection
10.1.2 Function test
A visual inspection must be carried out after each use and once a year regardless of use.

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Visual inspection
Hydraulic units
• Check that all hydraulic connections are tightened
• General tightness, no leakage (the hot oils do not have any inuence on the function)
• Is there damage to the motor, connecting block or housing?
• Frame present, undamaged and securely assembled?
• Are type plate, all activation plates, signs, identication marks and warning labels are
present and legible?
• Are all covers (e.g. protective roof, exhaust cover) present and undamaged?
• Are all liquid levels within the specied tolerances?
• Are the starters in proper working order and undamaged?
• Couplings must be easy to couple (where present)
• Dust protection caps must be available
• All necessary accessories (such as spark plugs, plug socket and fuel canister must be
present.
Connected hoses
(also observe the separate operating instructions for the hydraulic hoses)
• Visual check for visible damage
• Check for leaks.
Function test
• No suspicious noises
• Checks at nominal pressure (75% of maximum pressure).
(Recommendation: Carryouttheloadtestwithafullyassembledrerailingsystem.LUKAS
also offers a range of appropriate test equipment.)
10.2 Hydraulic units with combustion engine
10.3 Hydraulic units with electric motor
Visual inspection
Hydraulic units
• Check that all hydraulic connections are tightened
• General tightness, no leakage (the hot oils do not have any inuence on the function)
• Is there damage to the motor, connecting block or housing?
• Frame present, undamaged and securely assembled?
• Are type plate, all activation plates, signs, identication marks and warning labels are
present and legible?
• Are all covers (e.g. protective roof, fan cover) present and undamaged?
• Are all liquid levels within the specied tolerances?
• ON/OFF switch in proper working order, undamaged
• Couplings must be easy to couple (where present)
• Dust protection caps must be available
• All electrical attachments (such as cables and plugs) must be present and undamaged
Connected hoses
(also observe the separate operating instructions for the hydraulic hoses)
• Visual check for visible damage
• Check for leaks.

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CAUTION!
Since LUKAS hydraulic units are designed for top performance, only those
components in the spare parts lists of the relevant unit may be replaced.
Further components in the unit may only be replaced if:
- You have participated in appropriate LUKAS service training,
- You have the explicit permission of the LUKAS customer service (on request,
check for granting permission. Check is necessary in each individual case.)
REMARK:
Do not carry out any repairs without the relevant LUKAS spare parts list, since
this contains the necessary torques for screws and / or important additional
information.
CAUTION!
Attention must be paid to ensuring that no fuel can escape from units with
combustion engines during repair work.
Repairs11.
11.1 General
Servicing may only be carried out by the manufacturer or personnel trained by the
manufacturer and by authorised LUKAS dealers.
Only LUKAS spare parts may be used to replace all components (see spare parts list) since
special tools, assembly instructions, safety aspects, inspections might have to complied with
(see also chapter "Maintenance and service”).
During all installation work, pay particular attention to the cleanliness of all components
as contaminants could cause damage to the hydraulic unit.
WARNING / DANGER / CAUTION!
Protective clothing must be worn when repairs are being carried out, since
parts of the units can also be pressurised in an idle state.
REMARK:
Before you use couplings from a different company, you must contact LUKAS or
an authorised dealer.
Function test
• No suspicious noises
• Checks at nominal pressure (75% of maximum pressure)
(Recommendation: Carryouttheloadtestwithafullyassembledrerailingsystem.LUKAS
also offers a range of appropriate test equipment.)