PortaCo G-18S10-54-W User manual

OPERATION MANUAL
HYDRAULIC POWER UNIT G-18S10-54-W

HYDRAULIC POWER UNIT G-18S10-54-W OPERATION MANUAL
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HYDRAULIC POWER UNIT G-18S10-54-W OPERATION MANUAL
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Change overview
Auditing
Date
Comment, including chapter
Changed by
01
02
03
04-25-2018
04-30-2018
07-09-2018
Creation
Table 8.1 maintenance, DOC # 6253-OOP,4.2 Table length,
4.3 max pressure, 8.2 table changed sealings to seals.
Updated Title, Tables
Sven Kummer
Jesse Bunn
Garrett Lee

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1About this manual................................................................................................................................................. 7
2General ................................................................................................................................................................. 8
2.1 General information ................................................................................................................ 8
2.2 Designated use......................................................................................................................... 9
2.3 Environment requirements ..................................................................................................... 9
2.3.1Operating requirements............................................................................................................ 9
2.3.2Emissions ................................................................................................................................... 9
3Safety...................................................................................................................................................................10
3.1 Basics...................................................................................................................................... 10
Table 1: Signal words and symbols .............................................................................................................. 10
3.2 Important safety information ................................................................................................ 11
3.3 Danger zone........................................................................................................................... 14
3.4 Qualification of the operating and maintenance personnel ................................................. 14
3.5 Emergency information / safety devices ............................................................................... 14
4Design and function .............................................................................................................................................15
4.1 Design .................................................................................................................................... 15
4.2 Specifications ......................................................................................................................... 16
Table 2: Specifications ................................................................................................................................. 16
4.2.1Hydraulic fluid.......................................................................................................................... 16
Table 3: Hydraulic fluid ................................................................................................................................ 16
Table 4: Types of hydraulic fluid .................................................................................................................. 16
4.2.2Fuel and oil .............................................................................................................................. 17
Table 5: Types of oil ..................................................................................................................................... 17
4.2.3Supply, interfaces and connections......................................................................................... 17
4.3 Function ................................................................................................................................. 17
4.4 Boundaries and interfaces ..................................................................................................... 17
5Transport, assembly and dismantling...................................................................................................................18
6Commissioning and operation..............................................................................................................................19
6.1 General information for start-up........................................................................................... 19
6.2 Operation............................................................................................................................... 19

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6.2.1Start-up.................................................................................................................................... 20
6.2.2Shutdown................................................................................................................................. 20
7Maintenance ........................................................................................................................................................21
7.1 Recommended maintenance plan......................................................................................... 22
Table 6: Maintenance plan .......................................................................................................................... 22
7.2 Testing the hydraulic system ................................................................................................. 23
7.3 Remove condensation ........................................................................................................... 23
7.4 Change/Refill of engine oil..................................................................................................... 24
7.5 Change/Refill of hydraulic fluid ............................................................................................. 25
7.6 Refill fuel ................................................................................................................................ 26
8Maintenance and repairs .....................................................................................................................................27
8.1 General information for maintenance and repairs................................................................ 27
8.2 Troubleshooting and repairs.................................................................................................. 27
Table 7: Troubleshooting ............................................................................................................................. 27
9Shutdown and re-commissioning .........................................................................................................................28
10 Storage.................................................................................................................................................................28
11 Dismantling and disposal .....................................................................................................................................28

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Publisher: PortaCo Inc.
1805 2nd Ave N, Moorhead, MN 56560
Phone [phone], Fax [phone]
[email protected], www.portaco.com/
Date of publication: 04-25-2018
Documentation version: 1.0
Document number: 6253-OOP_rev1.0

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1About this manual
This document is the original operation manual for the Hydraulic Power Unit G-18-S10-58-W of PortaCo Inc., 1805 2nd Ave N,
Moorhead, MN 56560.
The Hydraulic Power Unit is a portable hydraulic unit for powering hydraulic tools.
The Hydraulic Power Unit is considered to be a complete machine according to the machinery directive 2006/42/EG.
The operation manual is intended to enable the operator to safely operate the system as intended and warn them of foreseeable
misuse. The manual is intended for the operating company´s specialized staff. In addition to the operation manual, the spare part
catalogue and the maintenance manual of the manufacturers of the individual components are to be observed.
WARNING
Operating errors using the device, e.g. by instruction errors, may lead to personal injury or damage to the
device.
-The instruction for use must be accessible to operators and maintenance personnel at all times!
-A copy of the technical documentation including the instruction for use must be kept in a suitable and
accessible place.
The explanation of the hazard pictograms is contained in chapter safety.
This document is to be treated as confidential. No portion of the document may be disseminated to another party or reproduced
without written permission from PortaCo Inc. All rights reserved.

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2General
This chapter contains basic information about the machine and is intended to provide an initial overview.
2.1 General information
Hydraulic tools can be powered with PortaCo Inc.´s Hydraulic Power Unit. The hydraulic unit is powered by a combustion engine
and is thus portable. The Hydraulic Power Unit is equipped with two wheels and a transport handle for safe transport.
Furthermore, there is a pedestal across from the wheels for parking the hydraulic unit.
Fuel and auxiliary materials for operating the combustion engine are not included in PortaCo Inc.´s scope of service.
Additional design information is shown and described in chapter 4.
Regarding ergonomics, the stresses and strains resulting from the device are typical for a device in the construction industry.
Because the Hydraulic Power Unit is considered to be a complete machine according to the machinery directive 2006/42/EG, an
identification plate (type plate) is attached.
Figure 1: Identification plate

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2.2 Designated use
Hydraulic tools can be powered by the PortaCo Inc. Hydraulic Power Unit. Hydraulic power units may only be used with tools which
allow for return flow of the hydraulic fluid to the hydraulic unit. The tools must be equipped with a pressure limiter which also
allows for return of the hydraulic fluid to the hydraulic unit. The hydraulic unit is not suited for operation of lifting gear.
Deployment in tunnels also constitutes misuse and is not permitted.
To use the Hydraulic Power Unit as intended, all persons who work with the device must observe the guidelines contained in the
instruction manual.
2.3 Environment requirements
2.3.1 Operating requirements
The machine is designed for use on construction sites outdoors. It can be used at temperatures between
-20 °C to 45 °C / -4° F to 113° F. The temperature of the hydraulic fluid should be at least 10 °C / 50° F.
The statutory minimum distance must be observed around power lines and conductor rails. When working in tunnels, the country-
specific safety regulations must be observed.
2.3.2 Emissions
In technically perfect condition, the A-weighted emission sound power level at the work place is
99 dB(A). Hearing protectors is required.
During operation, exhaust gases are released by the combustion engine, and for this reason deployment in tunnels is not
permitted. Other emissions do not occur during regular device operation.
In the event of damage, hydraulic fluid may leak. In this case, the leak must be eliminated and the fluid which has escaped must be
absorbed with the binding agent intended for this purpose and disposed of professionally.

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3Safety
3.1 Basics
The machine corresponds to the generally recognized standards of technology and practice. Nevertheless, knowledge of the
residual risks as well as general knowledge of the device are required to ensure safe and accident-free work.
The safety information is understood to be in addition to the existing accident prevention regulations and laws. The information is
intended to warn operating personnel about foreseeable misuse. Existing safety prevention measures and laws must be followed at
all costs!
The instruction for use must be read and understood by all persons who work on the device. Introduction to the device is to be
documented in writing.
CAUTION
Hazards from the operational environment of the device can lead to injuries of persons.
-No alterations to the device may be made which lead to a change in function.
-All hazards from the environment or from unforeseeable operating conditions of the device cannot be
captured and depicted within this manual.
Modifications to the machine must be made by the distributing company. In this case this instruction for use
and the system documentation of the machine also be adapted.
The chapter on safety regulations serves to:
-explain the depiction of the safety regulations and symbols
-inform users about dangers, residual risks and measures for reducing risks
-specify the minimum requirements of the operating personnel
Symbol
Meaning
DANGER
DANGER indicates a hazard with a high degree of risk, which when it is not avoided results in death or
serious injury.
WARNING
WARNING indicates a hazard with a medium degree of risk, which when it is not avoided may result in
death or serious injury.
CAUTION
CAUTION indicates a hazard with a low degree of risk, which when it is not avoided may result in minor
or moderate injury.
NOTICE
NOTE, non-compliance may result in environmental or material damage
Attention risk of injury!
General note for helpful tips and additions.
Read the safety information before using the machine. Non-compliance may result in injuries and
damage to property.
Table 1: Signal words and symbols

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3.2 Important safety information
Read this chapter and observe the safety information before using.
The safety regulations are to be observed by all persons who work on the device. The regulations and instructions for accident
prevention valid at the place of operation are to be observed. Instruction of the operating and maintenance personnel in system
safety is to be documented.
Please pay particular attention to this chapter to avoid accidents!
PortaCo Inc. is not liable for injury to persons or property which result from misuse of the machine.
DANGER
The bursting of hydraulic components and uncontrolled whipping of the hydraulic hoses is possible.
-Only use the machine within the prescribed limits.
-Before disconnecting the hydraulic couplings, make sure that the pressure is relieved.
-The machine must be maintained at regular intervals, the intervals are specified by the operator's risk
assessment.
DANGER
Contact with live parts results in the worker sustaining a lethal electric shock.
-In the case of railway tracks with live rails, the bus bar must be shorted or switched off by the control
room of the transport company.
-Check that no voltage is present in the rail system continuously!
-The battery shall be changed by instructed personnel only.
DANGER
Due to cavitation procedures and diesel effect, unforeseeable operating states may occur in the system
which may cause injury.
-Piping may not be damaged or modified.
-Ensure that the hydraulic oil filling level is correct (filling level display)

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DANGER
The operator inhales aerosol of hydraulic oil.
-Only use the device within the prescribed limits.
-The device must be maintained at regular intervals, the intervals are specified by the operator's risk
assessment.
-In the event of leaks switch the device to a safe state.
DANGER
If an employee is hit by a train or car, severe or fatal injuries may result.
-Pay attention to your own safety!
-Wear work clothing with reflectors and a safety vest!
-The foreman must ensure that the line being worked on has been closed.
-Place a track marshal with a horn on the opposite track.
WARNING
The machine is heavy. There is a potential for serious injury during transport.
-Always park the device securely on the pedestal.
-Ensure that the air pressure in the tires is sufficient.
-Wear safety shoes
-Use the lifting lugs intended for this purpose during transport.
-Do not stand under suspended loads.
WARNING
Improper maintenance or maintenance not carried out on time may result in damage to the machine or
injury to persons.
-Maintenance intervals are to be determined by the operator within the scope of their risk assessment.
-Observe the maintenance intervals and maintenance instructions of the manufacturer and existing
directives.
-Components may only be replaced with identical spare parts. It is imperative that the specifications of
the component manufacturer be followed when mounting the component.
WARNING
Spilled hydraulic oil can lead to an increased risk of fire and environmental pollution.
-Remove spilled hydraulic oil with the prescribed absorbent material.

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WARNING
Inspired gases may lead to irreversible health problems.
-Keep adequate distance from the exhaust system
-Do not operate the unit in a tunnel
-The machine must be shut down if there are defects in the exhaust system.
WARNING
In case of poor weather conditions (rain, snow) there is a risk of injury due to poor visibility or slippery
standing surfaces.
-Stop work if standing surfaces are slippery.
-Stop work if visibility is poor.
WARNING
Operating errors using the device, e.g. by instruction errors, may lead to personal injury or damage to the
device.
-The instruction for use must be accessible to operators and maintenance personnel at all times!
-A copy of the technical documentation including the instruction for use must be kept in a suitable and
accessible place.
CAUTION
The hydraulic oil heats up during operation. Leaking hydraulic oil can easily burn the operator.
-Wear safety clothing.
CAUTION
Components of the combustion engine heat up as a result of operation. The operator can be easily burned
by hot surfaces.
-Wear safety clothing
CAUTION
Noise emissions occur during operation of the hydraulic unit.
-Wear ear protection.
-Switch of the system if unusual noises occur.

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3.3 Danger zone
Exhaust gases are released during operation of the Hydraulic Power Unit. Do not stand near the exhaust.
3.4 Qualification of the operating and maintenance personnel
The intended circle of users for the machine includes the operators and maintenance personnel.
Anyone who carries out work on the device must be familiar with the functions and dangers of the machine. Introduction to the
machine is to be documented in writing.
All operators as well as employees that regularly enter the area of the machine should at least be instructed on the following
topics:
-Basic device functions (operators)
-instruction for use (operators)
-Conduct in work area (all)
-Location of safety devices (operators)
-Personal protective equipment (all)
Furthermore, operators should possess the necessary physical and mental capacities which are required to operate and service the
machine.
The operating personnel must wear personal protective equipment according to the job at hand and dangers of the environment.
The operational procedures as well as the professional association guidelines and safety data sheets are to be observed.
3.5 Emergency information / safety devices
The specification of the Working Conditions Act must be observed when working with the machine. Persons who work with the
machine are required to use their personal protective equipment as intended. In this case that means:
-work gloves
-safety shoes S3
-hearing protection

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4Design and function
4.1 Design
Figure 2: Hydraulic Power Unit 1
Figure 3: Hydraulic Power Unit 2
1
Drive motor
8
Filler neck gasoline
2
Refill opening motor oil
9
Filler neck hydraulic fluid
3
Dipstick motor oil
10
Ignition switch
4
Transport rolls
11
Display operating hours
5
Transport handle
12
Flow regulator hydraulic fluid
6
Locking mechanism for transport handle
13
Choke and gas
7
Pedestal
14
Connection hydraulic (flow and return flow)

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4.2 Specifications
Criteria
Value
Width
737 mm / 29 inch
Length
990 mm / 39 inch
Height
813 mm / 32 inch
Height
100 kg / 220 lb
Hydraulic pressure
max. 140 bar / 2,150 psi
Hydraulic flow
max. 40 lpm / 10 gpm
Engine speed
3,600 rpm
Table 2: Specifications
4.2.1 Hydraulic fluid
The hydraulic fluid should meet the following requirements.
Criteria
Value
Viscosity (at 10 °C)
95 cSt
Viscosity (at 38 °C)
27-42 cSt
Viscosity (at 60 °C)
16,5 cSt
Pour point
-23 °C / -10° F
Viscosity index (ASTM-D2220)
min. 140
Flash point (ASTM-D92)
min. 171 °C/ 340° F
Pump wear test (ASTM-D2882)
max. 60 mg
Demulsibility (ASTM-D1401)
max. 30 minutes
Table 3: Hydraulic fluid
The following hydraulic fluids or equivalent are suitable for use.
Manufacturer
Type
Chevron
Clarity AW ISO 32
Mobil
Univis J32
Gulf
Harmony AW-HVI-150-32
Shell
Tellus T32
Table 4: Types of hydraulic fluid

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4.2.2 Fuel and oil
Use only gasoline with an octane rating of at least 87, an ethanol percentage of up to 10 % is permissible.
Selection of the correct oil must be carried out according to the conditions on-site: oils in the following table may be used.
Temperature range
Oil
5 °C / 41° F and higher
SAE 30
4 °C / 39° F and lower
5W-30
-18°C to 38 °C / -0.4° F to 100° F
10W-30
38 °C / 100° F and lower
5W-30 (synthetic)
Table 5: Types of oil
4.2.3 Supply, interfaces and connections
The machine is used to power hydraulic tools. Quick couplings are available for connecting the tools (3/8 " flat face).
Filling with fuel for the combustion engine and with hydraulic fluid is carried out on the control panel of the Hydraulic Power Unit.
Oil filling for the combustion engine is carried out on the engine itself.
The quick couplings and filling openings are shown in chapter design.
4.3 Function
Hydraulic energy for operating hydraulic tools is provided by PortaCo Inc.´s Hydraulic Power Unit. The hydraulic unit supplies a flow
of 40 lpm / 10 gpm at 140 bar / 2,000 psi. The pressure in the system is limited to max. 150 bar / 2,150 psi.
4.4 Boundaries and interfaces
The Hydraulic Power Unit consists of the parts shown in the chapter design. The battery limit is the connection to the hydraulic
tools. Fuel and auxiliary materials are not included in PortaCo Inc.´s scope of service. Other parts which are not directly part of the
machine are also excluded.

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5Transport, assembly and dismantling
The machine must be disconnected from the hydraulic tools for transport. The hydraulic unit must be switched off and
depressurized for this purpose. Then the couplings on the hydraulic hoses can be detached. Allow the hydraulic unit to cool before
transport. Disconnect the ground terminal from the starter battery. Finally, the machine can be transported fully assembled
without any disassembly.
The Hydraulic Power Unit is equipped with a transport handle and two wheels. The hydraulic unit can be pushed to the operation
site using these.
1. Flip the transport handle up and lock it in the upper position.
2. Lift the Hydraulic Power Unit slightly and push the hydraulic unit.
3. Flip the transport handle down after transport.
The Hydraulic Power Unit is also equipped with transport lugs. The hydraulic unit can be transported with a crane suited for the
weight. Do not stand under the hydraulic unit during transport.
Ensure that the ground does not slope more than 20°. Set the Hydraulic Power Unit up at least 1 meter from buildings or other
flammable materials.

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6Commissioning and operation
6.1 General information for start-up
DANGER
Incorrect operation of the machine or disregard of safety instructions may lead to endangerment of
persons or damage to the machine.
-Familiarize yourself with the complete instruction for use before beginning work on the machine. Pay
particular attention to chapter 3!
NOTICE
A thorough, visual inspection of the machine is to be carried out by the operator before start-up.
Start-up of the machine may only be carried out by qualified specialist personnel. The start-up engineer must be acquainted with
the machine. Requirements for start-up are:
-the Hydraulic Power Unit have been tested and is ready for operation
-safety devices have been tested and are ready for operation
-all detachable connections have been checked and tightened if necessary
6.2 Operation
A visual inspection is to be carried out before beginning work. In the event of damage, no work may be carried out. Install hydraulic
hoses away from walking and transport routes. Ensure that hydraulic hoses are not installed over sharp edges. Make sure that the
environment is well lit; set up additional work lights if necessary.

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6.2.1 Start-up
1. Clean the quick couplings.
2. Connect the hydraulic hoses
Ensure that the hydraulic hoses are connected to the tool.
Ensure that the flow and return flow of the hydraulic unit are connected to the proper quick coupling.
Figure 4 & 5: Connecting the hydraulic hoses
3. Set the flow regulator for the hydraulic fluid to the "OFF" position
4. Push the gas lever towards "fast"
5. Push the choke to "on"
6. Turn the ignition until the engine starts.
7. Slowly return the choke to "off" so that the engine continues to run and wait approximately 3 to 5 minutes.
8. Set the gas lever all the way to "fast".
9. Turn the flow regulator for the hydraulic fluid to the "on" position.
If the temperature of the hydraulic fluid is below 10 °C / 50° F, then let the hydraulic unit idle to warm up.
Operation of the tools is carried out directly on the tool.
6.2.2 Shutdown
1. Set the flow regulator for the hydraulic fluid to the "OFF" position
2. Set the gas lever to "slow" until the engine idles and wait 2 to 3 minutes.
3. Turn the ignition to stop the engine.
4. Disconnect the hydraulic hoses from the Hydraulic Power Unit. Then the hydraulic hoses can be detached from the tool.
Allow the hydraulic unit to cool down before transport.
In case of emergency, the hydraulic unit can be stopped by turning the ignition without following the procedure described.