MODEL

D-25S12-22-S

POWER UNIT

OPERATION,

MAINTENANCE,

AND REPAIR MANUAL

1805 2nd

AVENUE NORTH * MOORHEAD, MN, USA 56560-2310PHONE (218) 236-0223 * FAX (218) 233-5281

E-MAIL ADDRESS; info@portaco.com * INTERNET ADDRESS: www.portaco.com

Introduction

The D25S12-22-S Auxiliary Power Unit(APU) is a light weight, portable hydraulicand 24 Volt DC electrical power source. It’smain purpose is to provide auxiliaryhydraulic power tor steering, electrical powerfor lights and brake modulation for towing adisabled Off-Highway Truck.

D-25S12-22-S Auxiliary Power Unit

Other uses are to provide hydraulic powerfor unloading a disabled loaded truck, tomake towing easier and can be used as aportable 35 Amp-24 Volt DC battery charger.

The D-25S12-22-S APU must be used withthe additional Attachment Groups. TheAttachment Groups contain all thenecessary hydraulic fittings, hoses, andelectrical 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 beconnected to the truck’s hydraulic systembefore engaging the pump engage switch.

Content

Assembly, Start up and Operation………………….1

Maintenance recommendations……………………2

Installation and Operation of APU for ChargingA 24 Volt Battery……………………………………..2

Installation and Operation of the APU forUnloading the Body of an Off-Highway Truck…….3

Installation and Operation of the APU as SupplementalPower 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 12Volt Battery is required for starting the dieselengine and operating the electrical pumpcontrols. A Group 24 Battery is used on theAPU.

Make sure to install the battery cover afterthe battery is connected and secured. Thiswill prevent dirt and oil from getting on thebattery and causing a malfunction.

The APU features a Lambardini dieselengine and is shipped with a Lambardinioperator’s manual. See the engine manualfor operating and maintenance informationconcerning the engine.

The engine is equipped with its own 12 VoltDC charging system and will maintain thecharge 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 anddisconnect switch located on theinstrument panel are both in theOFF position.

WARNING: Exhaust fumes can causepersonal injury or death. In an enclosedare, vent the exhaust to the outside. Startand operate the engine in a wellventilated area only.

3. Start the engine.

4. When the engine is ready to use,pull the throttle out all the way to runthe engine at maximum speed of2600 rpm.

NOTICE: To prevent damage to thehydraulic pump; do not adjust the enginespeed above 2600 rpm.

5. To stop the engine, return thethrottle to the idle position and pullthe knob on the engine stop cableuntil the engine stops. Be sure toturn the engine run switch OFF afterthe engine has stopped.

Maintenance recommendations

The parts illustration and parts list canbe used to help identify and service thecomponents of the PortaCo, Inc D-25S12-22-S Auxiliary Power Unit.

The hydraulic pump has been modifiedto meet the requirements of this powerunit. If the pump is to be serviced orreplaced locally, contact PortaCo fordetails concerning the modification.

PortaCo Inc. should be used whencomplete service of the power unit isrequired.

Lombardini Engine

Engine maintenance and repairinstructions are included in theLombardini Owners Manual. Parts andservice for the engine should beobtained from an authorized Lombardiniengine distributor.

Installation and Operation of the APUfor Charging a 24 Volt Battery

The APU can be used as a portablebattery charger for 24 Volt batteries oras an alternative power source for adisable vehicle equipped with a 24 Voltsystem.

APU 24 Volt Cable Connection andInstrument Panel.

1. Position the APU near the battery orvehicle. Start the engine and bring itup to speed (2600 rpm).

2. Connect the Plug Assembly(Emergency Start System), to thevehicle or battery.

3. Turn the disconnect switch on theAPU instrument panel to the ONposition. The ammeter on the APU

instrument panel will show thecharging rate of the APU.

4. The 35 amp circuit breaker on theAPU will protect against damagefrom overload of the electricalservice.

NOTE: Do not move the pump engageswitch to ON when using the APU onlyas a battery charge.

Installation and Operation of the APUfor Unloading the Body of an Off-Highway Truck

The APU can be used as the hydraulicpower source to unload the body of theOff-Highway Truck. The installation andoperation for this application follows.

Schematic of Hose Connections for Unloadingthe Body of a Truck. (A) Hoist cylinder. (B)Pump manifold outlet ports, D-25S12-22-SAPU. (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 ofthe disabled truck. Position itmidway between the front and rearwheels, and about 1.8m (6 ft) awayfrom the wheels on the outside.

2. Connect the APU to the body hoistcylinder that is equipped with thequick disconnect fittings.

3. Connect one Hose Assemblybetween hoist cylinder upper fitting(!) and upper right inlet fitting (2) onthe APU.

4. Connect the other Hose Assemblybetween hoist cylinder lower fitting(3) and lower left outlet fitting (4) onthe APU.

5. Connect the APU to the truckhydraulic tank as shown.

6. Remove the drain plug from thebottom of the tank. No hydraulicfluid will come out of this port until afitting is installed.

7. Install a Connector Assembly (5)into the port.

8. Connect Hose Assembly (6)between connector assembly (5)and the lower right inlet fitting on theAPU.

9. Start and warm up the diesel engineon the APU according to the

procedure given earlier in thisinstruction.

10. Two people are required to unload adisabled truck, one in the cab andone to operate the APU. Theoperator in the cab should lace thebody hoist control lever in the HOLD(number 2) position.

NOTE: The truck controls are now ready tounload the body using the APU.

11. To unload the body, move thepump engage switch on the APU tothe ON position.

12. The unloading can be stoppedanytime by moving the pumpengage switch to the OFF position.The truck body will hold in thatposition. The pump engage switchmay again be moved to ON tocontinue unloading.

13. When the body reaches themaximum position required to dumpthe load, it should be stopped bymoving the pump engage switch toOFF.

14. Do not leave the pump engagedswitch ON when the body hoistcylinders are at their maximumposition.

15. The large blue light on the APU willbe on anytime the hydraulic pump isoperating.

16. After unloading is complete and thepump engage switch is moved toOFF, the body can be lowered bythe operator in the cab.

17. This is accomplished by moving toand holding the hoist control lever inthe cab in the FLOAT (Number 3)position until the body is fullylowered. Or, by moving the hoistcontrol lever to the LOWER(Number 4) position. (The lever willreturn to FLOAT when the body isfully lowered).

-If the body is in an over-center position andwill not lower, it can be pumped backed withthe APU.

18. To pump an over-center body down,relieve the pressure by placing theAPU pump engage switch in theOFF position and the hoist controllever in the FLOAT (Number 3)position.

19. Remove both hoses from the bodyhoist cylinder and connect thepressure hose from the APU outlet(lower left on APU) to the return(upper) port on the body hoistcylinder.

20. Put the pump engage switch in theON position and have the operator(located in the cab) lower the bodyas he would from an over-centerposition.

21. Move the APU pump engage switchto the OFF position.

22. When the unloading operation iscomplete, shut off the APU anddisconnect all hydraulic lines frombetween the truck and the APU.

23. Remove the Connector Assembly.Replace all plugs and dust covers.

Installation and Operation of the APU asSupplemental Power for Towing aDisabled Truck

The APU can be used to provide auxiliaryhydraulic power for steering and 24 Volt DCfor electrical power for the brake releasepump and lights on an Off-Highway Truckthat has been disabled due to engine failure.

Schematic of hydraulic connection with the vehiclesteering 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) Pumpmanifold, D-25S12-22-S APU. (J) Outlet ports. (K)Hose As. (L) Steering manifold. (M) Alternate hoseconnection. (N) Pump manifold inlet ports.

The installation and operation for thisapplication follows.

1. Remove the handrail from theplatform above the ladder on theright side at the front of the truck.This will allow clearance for liftingthe APU into position on theplatform.

2. Hoist the APU, approximately 227kg (500 lb), onto the platform andposition it in the right front corner ofthe truck.

3. Carefully remove the filler cap fromthe steering tank to release thepressure. Replace the cap after thepressure is released.

APU connection to assist towing of a disabledtruck.

4. Check the quick disconnect fitting atthe lower edge of the hydraulicsteering tank. If it does not matchthe quick disconnect on the HoseAssembly (1), replace the tank fittingwith the Steering Tank ConversionGroup included in the AttachmentGroup.

5. These fittings can be replacedwithout draining the hydraulic tank.(About one liter [one quart] of oil islost if the exchange is done quickly).

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 inletfitting (4) to prevent pumpcavitations.

Steering system hydraulic manifold belowoperator’s compartment with APU pressure hoseconnected.

8. Connect on end of Hose Assembly(5) to outlet quick disconnect fitting(6) on the APU. Connect the otherend of hose assembly (5) to quick

disconnect fitting (7) on steeringmanifold (8). Manifold (8) is locatedunder the front of the truck on theframe between the front wheels.

Parking brake manifold connection for the 1U8330Hose Assembly at the rear of the truck.

9. Connect Hose Assembly (9) to thequick disconnect fitting located onthe top of the rear axle housing.

10. Install a Gauge Assembly on theother end of the hose assembly (9).Position the gauge, in the cab of thetruck, so that the operator canmonitor it during towing.

NOTE: If the brake release pump on thetruck does not work, remove the GaugeAssembly and connect the Hose Assemblyon the small outlet (upper left) of the APU.This will provide the 4150 kPa (600psi)necessary to release the secondary brake.

Use this only as an emergency measure, asit transfers hydraulic fluid from the steeringtank to the main hydraulic tank. The reliefvalve above the quick disconnect fitting andthe gauge at the APU can be used to adjustthe pressure to 4150 kPa (600 psi). This isan adequate setting for the trucks.

APU 24 Volt cable connection to thetruck batteries.

11. Connect the Plug Assembly to thetruck battery and plug it into theelectrical outlet on the APU.

12. Start and warm up the diesel engineon the APU according to theprocedure given in this instruction.

13. Turn the disconnect switch on theAPU to ON to connect the APU tothe truck electrical system.

14. Turn the pump engage switch to theON position. The blue light on theAPU will come on indicatingpressure is provided to the system.

NOTE: If the blue light goes off anytimewhile towing, stop the vehicle immediatelyand determine the reason for the loss ofpressure.

15. Wait a few minutes for the steeringpressure gauge (on the APUinstrument panel) to build uppressure. When the pressure isabove 12402 kPa (1800 psi), testthe steering of the truck. If thesteering appears to be normal thetruck is ready to tow.

16. Connect the towing vehicle.

17. Release the parking brake. If thepressure on the gauge installedearlier does not read over 3100 kPa(450 psi), engage the brake retractswitch in the truck cab of a fewseconds to pump up the pressure.

18. Check while towing and rechargewith the brake retract switch whennecessary.

19. If the APU hydraulic system is usedto provide oil pressure to release theparking brakes, the truckssecondary brake lever can still beapplied to engage the brakes for anemergency stop.

20. The vehicle can now be towed usingthe service air brakes to control thespeed. See Towing Section of

Operation and Maintenance Guidefor towing instructions.

21. If the air system malfunctions, thetruck can still be stopped using thesecondary brake lever.

22. After towing is completer, reversethe hookup procedures todisconnect the APU.

23. The Steering Tank ConversionGroup should remain on the truckfor future use. Replace the fittingsthat were used (taken form theAttachment 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 1030-OOP FITTING 2089 – 8 – 8S 1

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

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 1

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 Max38 C 27-42 C.S. 100 F 130-200 SSU60 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 MinimumDemulsibility (ASTM D-1401) 30 Minutes MaximumFlash Point (ASTM D-92) 340 F/171 C MinimumRust Inhibition (ASTM D-665 A & B) PassOxidation (ASTM D943) 1000 Hours MinimumPump West Test (ASTM D2882) 60 mg Maximum

Recommend Hydraulic Fluids

Type Hydraulic fluidChevron “Clarity” AW ISO 32Exxon “Univis” J 32Mobil D.T.E. 13 MGulf “Harmony” AW-HVI-150-32Shell “Tellus T” 32Texaco “Rando” HDZ 32Union “Unax” AW-WR-32Amsoil AWH ISO 32Sunvis Low Pour H/032-product code 193000