Hydraulic power unit P 630 SG Operating instructions for rescue
Contents
1. Inthe event of malfunctions immediately deactivate the device and secure it Repair the fault immediately Observe all safety and danger information on the device and in the operating instructions Please ensure that all safety covers are present on the equipment and that they are in proper and adequate condition Safety devices must never be disabled Make sure before switching on starting up the device and during its operation that this will put no one in danger When working close to live components and cables suitable measures must be taken to avoid current transfers or high voltage transfers to the equipment The build up of static charge and therefore possible sparking must be avoided when handling the device Motorised pumps must not be operated in areas at risk of explosion Do not carry out any changes additions or conversions to thei equipment without obtaining the approval of LUKAS beforehand All safety and danger information on the device must always be complete and ina legible condition Any mode of operation which compromises the safety and or stability of the device is forbidden The maximum operating pressure set on the equipment must not be changed Observe all intervals for recurring tests and or inspections that are prescribed or stated in the operating instructions Only original LUKAS accessories and spare parts are to be used for repairs When working with thi2. LUKAS Operating instructions for rescue equipment CE gt Hydraulic power unit P 630 SG 175070085 EN Edition 11 2013 Translation of the original operating instructions a A O N 9 Content Danger classifications Product safety Proper use Power unit designation Functional description 5 1 General information 5 2 Installation of the power unit 5 3 Motor 5 4 Valves 5 5 Pumps 5 6 Frame with side sections 5 7 Connection to the rescue equipment Connecting the hoses devices 6 1 Coupling the mono couplings Erection and start up 7 1 Set up 7 2 Start up Operation 8 1 Starting the engine 8 2 Turning the engine off 8 3 Refuelling 8 4 Controlling the valves Dismantling the equipment deactivation following operation 10 Tests 10 1 Recommended test intervals 10 2 Visual and function check 11 Maintenance and repair 11 1 General information 11 2 Service work on the hydraulic unit 11 3 Additional service work 12 Fault analysis Page Content 13 Technical data 13 1 Power unit 13 2 Noise emissions 13 3 Sparking plug 13 4 Sparking plug spanner 13 5 Fuel 13 6 Engine oil 13 7 Hydraulic fluid recommendation 13 8 Operating and storage temperature range 14 EC Declaration of Conformity 15 Notes 1 Danger classifications We differentiate between various different categories of safety instructions The table shown below shows you an overview of t
3. e Check the sparking plug clean if necessary set the electrode gap of the sparking plug You must conduct the following service measures every 200 operating hours e Replace the sparking plug e Replace air filter The following service work should be executed by an authorised dealer LUKAS directly or the engine manufacturer You must conduct the following service measures every 300 operating hours e Replace the sparking plug and the filter element e Clean and adjust the carburettor valve clearance valve seat and cylinder head You must conduct the following service measures every 1000 operating hours or every 2 years e Check the starter e Inspect the engine for damage e Check the fuel line and replace if necessary 29 11 3 1 Replacing and cleaning the air filter NOTE Keeping the air filter in good condition is extremely important Penetrating dirt leads to damage and wear in the engine in case of incorrect installation incorrect damage or unsuitable filter inserts Always keep the air filter insert clean Procedure If present remove the rear side panel of the hydraulic power unit in that the fixing clip and the side panel are removed 1 2 3 4 9 Unscrew both bolts from the air filter cover and remove the cover Remove the foam air filter insert from the cover Take the paper air filter insert from the air filter housing Check both air filter inserts and replace if damaged The paper air fi
4. 4 Measure the electrode gap on the sparking plug with a wire feeler gauge Correct the electrode gap if required by carefully bending the side electrode Target electrode gap 0 6 0 7 mm 0 024 0 028 in 5 Carefully screw in the sparking plug by hand in order to avoid stripping the thread 6 Tighten the sparking plug after mounting with a 5 8 inch sparking plug spanner in order to compress the washer 7 Anew sparking plug should be tightened by an additional 1 2 turn after fitting in order to compress the washer 8 A used sparking plug should be tightened by an additional 1 8 to 1 4 turn after fitting in order to compress the washer 9 Place the sparking plug connector on the sparking plug NOTE A loose sparking plug can overheat and damage the engine A sparking plug that is too tight can damage the thread in the cylinder head Side electrode 0 6 0 7 mm 0 024 0 028 in Sparking plug con nector Gasket Sparking plu spanner g 11 3 3 Replacing the engine oil and the engine oil filter For the procedure for replacing the engine oil and engine oil filter please refer to the separate operating instructions of the engine manufacturer 31 11 3 4 Mono couplings The mono couplings must be replaced if there is external damage the locking does not function hydraulic fluid continues to leak in the coupled uncoupled state WARNING CAUTION Never repair couplings they must be replaced
5. a The previously Rectification see different unit and connected unit is operating instructions check whether defective of the connected unit it works when actuated Check the switch Pressure relief on position of the the unit is still active valve lever on the circulation at static pump block of the pressure hydraulic unit Check the switching positions of the valve lever s and if necessary reset as far as the final position Defective pump unit Have repaired by authorised dealer or directly by LUKAS Air in hydraulic system Vent the hydraulic system Plug in coupling Replace plug in female defective coupling female Mono coupling female Replace mono coupling defective female 35 Fat Check Cause Solution Connected rescue device does not reach its final position Connected rescue device does not reach its specific performance data During function test A pressure gauge rescue equipment and the hydraulic power unit does not indicate the maximum operating pressure of the equipment Check hydraulic fluid volume in hydraulic tank Check the details of the rescue installed between the device Insufficient fluid in the hydraulic tank Usable hydraulic fluid volume of the unit is insufficient Maximum permitted operating pressure of the pump is not reached Pump block defective Connected unit defective The operating pressure of the connect
6. are also used despite the robust design to protect the power unit from external influences such as for example dirt or damage 5 7 Connection to the rescue equipment Connection to the rescue equipment is via extension hose pairs or via hose reels They are supplied in various lengths For specific details please consult the LUKAS range of accessories or contact your LUKAS dealer 15 6 Connecting the hoses devices ATTENTION When connecting the hose assemblies units always ensure that the connection components are not dirty Clean prior to use if necessary WARNING CAUTION Before connecting the 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 6 1 Coupling the mono couplings The hose lines units are connected via quick disconnect coupling halves female and male to the hydraulic pump or hose reel in such a way that they cannot be swapped over Dust protection caps if Mono coupling halve female Mono coupling halve male JN 16 Remove the dust caps before coupling together Then push the male and female parts together and turn the locking sleeve on the female coupling in the direction 1 until the locking sleeve clicks in place The connection has been made and locked Decoupling is accomplished by turning
7. for your device and the data in the following tables The values may also differ because of reading inaccuracies and or tolerances in the measuring equipment used NOTE The following tables contain only the technical data required for standard acceptance Additional data concerning your unit can be obtained from LUKAS on request The limitation of the max fill quantity of the hydraulic tank results from the operability at an incline prescribed in the standards 13 1 Power Unit 13 1 1 Basic dimensions of the power unit mm inch Power unit P 630 SG 445 17 54 360 14 17 495 19 49 39 13 1 2 Technical data P 630 SG Article number 81 53 20 Motor type 4 stroke petrol engine 2 kW 2 Engine power rating HP 3 0 i min Engine speed 3000 3800 rpm Feed rate simultaneous min HD gal US min 2x 0 15 2x 0 18 Feed rate turbo l min 1x1 1 1x1 35 Feed rate simultaneous l min ND gal US min 2x0 63 2x0 79 Feed rate turbo l min 1x4 7 1x5 8 ND gal US min 1x 1 24 1x 1 53 Max operating pressure MPa 70 HD psi 10000 Max operating pressure MPa 14 ND psi 2000 Max fill volume I 22 hydraulic fluid gal US 0 58 Max fill volume I 0 77 Petrol gal US 0 17 kg 23 9 Weight with petrol and hydraulic fluid lbs 56 7 Valve variants Simultaneous operation Max unit connection facilities EEE TE 0 HD High pressure 2 ND Low pr
8. ION Attention must be paid to ensuring that no operating fluids can escape from units with combustion engines during repair work 11 2 Service work on the hydraulic unit 11 2 1 Care instructions The exterior of the device must be cleaned from time to time not the electrical contacts and the metallic surfaces not the electrical contacts must be treated with a suitable agent to protect against corrosion In case of doubt contact your authorised LUKAS dealer or LUKAS directly 11 2 2 Function and load test If there is any doubt regarding the safety or reliability of the equipment a function and stress test must also be performed LUKAS offers appropriate testing equipment for this 11 2 3 Replacing the hydraulic fluid After approx 200 deployments but after three years at the latest replace the hydraulic fluid The fluid should be replaced after it has warmed up The engine must be switched off The used hydraulic fluid must be disposed of properly 2 Replacing the hydraulic fluid procedure 1 Place the power unit on a slightly elevated base so that the drain plug for the hydraulic fluid can be easily reached 2 Place a suitable collection container under the A drain plug 3 Open the B filler cap remove the A drain plug and let the hydraulic fluid run into the provided collection container 4 Screw the A drain plug in again tightening torque max 5 Nm 5 Pour the new hydraulic fluid
9. KAS hydraulic power units the hydraulic pump is operated with a motor The pump conveys the fluid from the hydraulic oil tank and builds up the pressure in the tool Fluid is distributed to the connected equipment through control valves The P 630 SG is a power unit with frame and with a petrol engine and simultaneous operation 5 2 Installation of the power unit meer 7 5 1 Petrol tank 2 Hydraulic fluid tank 3 Engine with hydraulic pump 4 Connecting block with control valves 5 Speed adjusting lever 6 Carrying handle 7 Cable pull starter 8 Valve control lever 9 TURBO control lever 10 Mono coupling female 11 Fuel tank cap 12 Filler cap hydraulic fluid 13 Frame 14 Rubber buffer 15 Side panel 23 14 15 16 Air filter 17 Choke 18 Fuel tap 19 ON OFF switch engine switch Engine oil filler cap dipstick Fill level indicator 12 5 3 Motor WARNING CAUTION AN See also the separate operating instructions of each engine manufacturer accompanying the delivery 5 3 1 Petrol engine These hydraulic units are equipped with a combustion engine driven by the fuel petrol The power units are equipped with a cable pull starter with which the engine is started For specific details please consult the separate operating instructions of the engine manufacturer HONDA motors have a main switch that must be activated to switch the power unit on and off The speed adjusting lever on these power units has two switch position
10. all packaging materials and removed items properly LUKAS Hydraulik GmbH A Unit of IDEX Corporation Weinstra e 39 D 91058 Erlangen Tel 49 0 91 31 698 0 Fax 49 0 91 31 698 394 e mail lukas info idexcorp com www lukas com MADE IN GERMANY Subject to changes P630SG_manual_175070085_en indd Copyright 2013 LUKAS Hydraulik GmbH
11. ant fluid 1 Open the petrol tap 2 Setthe ON OFF switch to the ON position 3 Move the lever from switching position A to switching position B choke when starting cold 4 Pull the cable starter 5 When the motor is running switch the lever back to position A For the detailed procedure for starting the combustion engine please see the separate operating instructions of the engine manufacturer 20 8 2 Turning the engine off 1 Setthe ON OFF switch to the OFF position 2 When the engine has come to a standstill close the fuel tap For more details on switching off the engine please refer to the separate operating instructions of the engine manufacturer CAUTION A Never touch hot engine parts this could result in severe burns 8 3 Refuelling The engine must be switched off for refuelling Procedure 1 Open the fuel tank cap 2 Fill the tank with fuel until the fill level is just below the filler opening WARNING CAUTION A Be sure not to spill fuel In particular hot engine parts must not come into contact with fuel danger of fire otherwise If fuel is spilled it must be cleaned up immediately with a suitable absorbent cloth In doing so be careful not to burn yourself on one of the hot engine parts The used cloth must then be cleaned or disposed of according to the relevant provisions and guidelines 3 Close the fuel tank again with the fuel tank cap 21 8 4 Controlling the
12. by genuine LUKAS parts Procedure for coupling to valve block First empty the hydraulic tank as described in the chapter Replacing the hydraulic fluid Remove screwed fittings on the coupling Remove couplings and underlying seals Position the new coupling together with the seals onto the valve block Re attach the couplings with the bolts and tighten to a torque of M 40 Nm The hydraulic fluid tank must be refilled and the power unit vented O9 O0POD Procedure for coupling to hose pairs 1 First empty the hydraulic tank as described in the chapter Replacing the hydraulic fluid 2 Pull the cover back from the couplings 32 ATTENTION Ensure that connection T1 T2 on the pump block is always connected to connection T on the mono coupling 4 Position the new coupling and tighten the union nuts on the hose assemblies to a torque of M 40 Nm and push the cover of the couplings back 5 The hydraulic fluid tank must be refilled and the power unit vented 11 3 5 Quick disconnect couplings The quick disconnect couplings must be replaced if there is external damage the locking does not function hydraulic fluid continues to leak in the coupled uncoupled state During assembly tighten the union nuts on the hose line to a torque of M 35 Nm WARNING CAUTION Never repair couplings they must be replaced by genuine LUKAS parts Procedure 1 Loosen the u
13. ctly by LUKAS Hydraulic fluid milky Water condensation in Replace the hydraulic and cloudy the system fluid immediately Hoses cannot be Pressure too high e g Switch valve block to coupled caused by ambient circulation at static temperature too high pressure Coupling defective Coupling must be replaced immediately 3 It is frequently not Hydraulic fluid not Hydraulic fluid must be possible to couple adapted to the replaced see chapter hose assemblies application situation Recommended hydraulic fluids Coupling defective Coupling must be replaced immediately Leak in the couplings Coupling defective Coupling must be replaced immediately Leakage at the drive Shaft seal defective Repair by an shaft of the hydraulic authorised dealer by pump personnel specially trained by LUKAS or by LUKAS itself NOTE In case of faults which affect the combustion engine please also observe the instructions in the separate operating instructions of the engine manufacturer Contact an authorised LUKAS dealer or the LUKAS Customer Service Department directly if the malfunctions cannot be rectified The address for the LUKAS Customer Service department is LUKAS Hydraulik GmbH A Unit of IDEX Corporation Weinstra e 39 D 91058 Erlangen Tel 49 09131 698 348 Fax 49 09131 698 353 38 13 Technical data Because all values are subject to tolerances there may be small differences between the data
14. e The user bears sole responsibility for such use Proper use includes observance of the operating instructions and compliance with the inspection and maintenance conditions A Never work in a fatigued or intoxicated state A WARNING CAUTION If you still injure yourself on the hydraulic unit clean the wound immediately and D consult a doctor to have it attended to If you get hydraulic fluid in your eye rinse it immediately several times with clear clean water and consult a doctor Also if you swallow hydraulic fluid you should consult a doctor 3 Proper use LUKAS hydraulic units are specially designed to supply LUKAS rescue equipment with hydraulic fluid so that this equipment can be used to rescue victims of road rail or air traffic accidents as well as from buildings Their use for supplying pressure fluid to rescue equipment of other manufacturers is possible yet requires the technical inspection and approval by LUKAS in each individual case The equipment is not designed to operate without hoses or equipment operating time without hoses or equipment lt 15 minutes WARNING CAUTION The safety instructions in this operating instruction manual concerning the site of O erection and type of erection must always be observed LUKAS P 630 units are not explosion protected When using the equipment in explosion risk areas you must make sure that operation of the unit does not trigger an explosion The responsibilit
15. e cannot be achieved during the function test you need to contact LUKAS customer service immediately The contact details are given in the Chapter Fault analysis 10 2 Visual and function check Visual Inspection e Tightness of all hydraulic connections e General tightness no leakage sweated oils do not have any influence on the function e is there any detectable damage to the engine connecting blocks on the frame or the side sections e ls there any sign of damage to the hydraulics or fuel tank e Side plates present and tightened e Presence and legibility of the identification plate all actuation signs instruction signs markings and warnings e The presence and perfect condition of all covers e g exhaust deflector e All fluid levels are within the specified tolerances e Are the rotary switches and switching levers in proper working order and undamaged e Couplings must be easy to couple e Dust protection caps must be available e All required accessory parts e g sparking plug sparking plug spanner and fuel can are present e Check for leaks Functional test e Unconventional or noticeable noises heard during operation e Cable pull starter fully functional e Engine switch fully functional e Test for maximum load NOTE use the LUKAS test kit including testing instructions for the function test 29 11 Maintenance and repair 11 1 General information LUKAS hydraulic units model P 630 re
16. ed rescue device is locked internally Connected rescue device is defective Hydraulic unit defective 36 Top up hydraulic fluid to the maximum filling level Caution Before topping up the rescue equipment return to the base position Use a different rescue device with a demand quantity below the maximum usable quantity of the unit Have the pressure limiting valve reset or repaired by authorised dealer or directly by LUKAS Have repaired by authorised dealer or directly by LUKAS Rectification see operating instructions of the connected unit No repair or fault rectification required Consult the separate operating manual for the connected rescue device Have repaired by authorised dealer or directly by LUKAS Fluid coming out Connected unit Return of the hydraulic Reduce fluid level in from hydraulic fluid not in base fluid from the rescue the hydraulic tank to tank position yetand device exceeds the Minimum mark move fluid coming out of tank s maximum the unit to the base filler cap quantity when filled position and then fill back up with hydraulic fluid to the Maximum level Fluid leaks from a Leak from tank lines or Replace defective different location seals components or repair by authorised dealer or Lukas directly Leaking fluid Radial shaft seal on the Have repaired by between engine and drive shaft is defective authorised dealer or flange bearing dire
17. essure 3 MPa 10 bar 40 13 2 Noise emissions Sound pressure level Device type P 630 5G Speed 3000 1 min rpm 3800 rpm Idle run according to EN dB A Full load according to EN dB A Idle run according to NFPA dB A E Full load according to NFPA dB A Explanation of dual number noise emission values according to DIN EN 13204 2012 09 Serial number of the machine operating conditions and other characteristic properties Model P 630SG type 81 53 20 maximum working pressure 700 bar engine speed 3800 1 min rpm INDICATED DUAL NUMBER NOISE EMISSION VALUES according to EN ISO 4871 Measured A rated emission sound pressure level LpA in dB referred to 20 uPa 88 Measurement uncertainty KpA in dB Measured A rated emission sound power level if required LWA in dB referred to 1 pW 101 Measurement uncertainty KpA in dB Values determined according to EN 13204 Appendix B using basic standards EN ISO 3744 and EN ISO 11201 NOTE The sum of the measured noise emission values and the associated measure ment uncertainty that can occur during the measurement represent the upper limit of the measured values 41 13 3 Sparking plug Sparking plug type CR5HSB NGK U16FSR UB DENSO 13 4 Sparking plug spanner Universal joint sparking plug spanner with spanner size 16 mm 5 8 inch 13 5 Fuel Fuel Lead free petrol ROZ 91 to ROZ 98 42 13 6 Engine
18. gt wurden insbesondere die Normen DIN EN ISO 12100 2010 Ausgabe 2011 03 Sicherheit von Maschinen Allgemeine Gestaltungsleits tze Risikobeurteilung und Risikominderung DIN EN 13204 Ausgabe 2012 09 Ann nahe or Tr ee Rettungsdienste Sicherheits und o A reg See T O ri rende and the national statutory provisions that uhr schreien base wire ang ov re DIN EN ISO 12100 2010 2011 03 Safety of machinery General principles for design Risk assessment and risk DIN EN 13204 puttnation tate 30 2012 09 Double acting hydraulic rescue tools for fire and rescue service use Safety and performance requirements Bei einer nicht mit uns abgestimmten nderung oder Verwendung der Maschine Ausr stung verliert diese Erkl rung ihre G ltigkeit This declaration loses its validity in the case of alterations or usage of the machinery equipment not approved by LUKAS Erlangen 04 11 2013 E GE Carsten Sauerbier Thomas Littwin Bevollm chtigter Authorized Representative Konstrukteur Engineering Designer Director of Technical Innovation and Development IDEX Europe GmbH Seite Page 1 von of 1 44 15 Notes 45 46 47 WARNING CAUTION A A Before connecting the equipment make sure that O all the components used are suitable for the O maximum operating pressure of the hydraulic unit In cases of doubt you must consult LUKAS directly before connecting the equipment Please dispose of
19. he assignment of symbols pictograms and signal words to the specific danger and the possible consequences Injury to A DANGER Immediate danger u Potentially Potential death or WARNING dangerous i serious injury situation CAUTION Less dangerous Minor or slight situation injury Damage to the equipment damage to the environment damage to surroundings Danger of damage ATTENTION to property environment Handling tips and No injury damage other important to persons useful information environment and advice device EB u om i G Wear a helmet with a face guard Wear protective gloves Wear safety shoes Proper recycling Protect the environment Read and follow operating instructions 5 2 Product safety LUKAS products are developed and manufactured to ensure the best performance and quality when used as intended The safety of the operator is the most important consideration in product design Furthermore the operating instructions are intended to help in using LUKAS products 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 must only be operated by persons with appropriate training in the safety aspects of such equipment otherwise there is a danger of injury We would like to point out to all
20. ion of the hydraulic Have the engine motor set to the altitude of application of the hydraulic power unit by an authorised dealer engine manufacturer or LUKAS directly only if the unit is to be used frequenily at this altitude Check air filter Air filter contaminated Clean or replace the air filter Are all valves set Combustion motor Have repaired by to pressure free defective or overloaded authorised dealer rest setting due to different defect motor engine in the unit manufacturer or directly by LUKAS 34 The motor is running but the connected rescue equipment is not moving moving very slowly upon activation of the valve The connected rescue equipment does not move on activation of the valve or moves only very slowly or unevenly Check connection of hose and reconnect if necessary Check hose Hose assembly not connected properly or is damaged Switch valve to pressure load of the supply line Check the switch Valve not switched position of the to supply line valve lever on the pressurisation pump block of the Defective pump unit Have repaired by hydraulic unit authorised dealer or directly by LUKAS Rectification see operating instructions of the connected unit Connect a The previously different unit and connected unit is check whether defective it works when actuated Mono coupling female Replace mono coupling defective female Connect
21. lter insert must always be replaced at planned intervals Clean the air filter inserts if reusing them Paper air filter insert Tap out the paper air filter insert a few times on a hard surface to remove dirt or blow compressed air not more than 207 kPa 2 1 kg cm from the air filter housing side through the filter insert Never attempt to brush out dirt because it would be pressed in by the bristles Replace the paper air filter insert if it is exceedingly dirty Foam air filter insert Clean in warm soapy water rinse and allow to dry thoroughly Or clean in non flammable solvent and let dry Do not introduce any oil to the foam air filter insert Wipe away dirt from the inside of the air filter housing with a damp cloth Ensure that dirt does not penetrate the air duct leading to the carburettor Then re fit the filter Air filter housing Paper air filter insert Foam air filter insert Bolts Air filter cover 30 11 3 2 Replacing cleaning and setting the sparking plug Procedure In order to deliver good performance the sparking plug must have a correct electrode gap and be free from deposits 1 Detach the sparking plug connector and remove any dirt near the sparking plug 2 Unscrew the sparking plug using a 16 mm 5 8 inch sparking plug spanner 3 Check the sparking plug Replace the sparking plug if it is damaged extremely dirty the sealing washer is in poor condition or the electrodes are worn
22. nion nuts on the hose line and remove the coupling 2 Position the new coupling and tighten the union nut on the hose assemblies to a torque of M 35 Nm ATTENTION The return hose which is screwed onto the port T of the rescue tool must be equipped with a quick disconnect coupling male always However the supply hose line must be equipped with a quick disconnect coupling female 33 12 Fault analysis Fault Check Cause Combustion engine Check fuel level Fuel tank empty ae up fuel will not start in tank Check fuel line Fault in the fuel line Shut down immediately and have repaired by NOTE authorised dealer motor In Bea Sala engine manufacturer which directly affect or directly by LUKAS the combustion Inspect engine Cable pull starter Activate cable pull engine please switch starter also observe Motor switch not set to Set motor switch to the separate Choke Choke Instructions In the operating Hydraulic unit Ambient temperature For the solution instructions or engine not too low consult the separate of the engine suitable for operating instructions manufacturer the working of the engine environment manufacturer Use a different hydraulic fluid or operating fluid that is suitable for the relevant ambient temperature see Chapter Technical Data Not enough oxygen in Use a different more the air because of the suitable hydraulic unit altitude of application locat
23. oil 13 7 Hydraulic fluid recommendation Mineral oil DIN ISO 6743 4 for LUKAS hydraulic equipment and others Ei Oil temperature range Oil designation Viscosity rating 20 55 C HM 10 VG 10 _ Oiltemperature range Oil designation Viscosity rating 4 0 131 F HM 10 VG 10 VE recommended range of viscosity 10 200 mm s 10 200 cSt Supplied with HM 10 DIN ISO 6748 4 ATTENTION Before you use hydraulic fluids from a different manufacturer you must contact LUKAS or an authorised dealer 13 8 Operating and storage temperature range Operating temperature C Ambient temperature 5 C F device in operation Storage temperature device not in operation C F 43 14 EC Declaration of Conformity IREX LUKAS RESCUE en Suti Dinglee LUKAS Hurst Vetter 91058 Erlangen BE EEE 91 058 Erlangen Germany EG Konformit tserkl rung EC Declaration of Conformity Im Sinne der EG Maschinenrichtlinie 2006 42 EG Anhang Il A In accordance with the EC Machinery Directive 2006 42 EC Appendix Il A Hiermit erkl ren wir dass die nachfolgend bezeichneten hydraulischen Motorpumpen We hereby declare that the following hydraulic power units 815320070707 ESS e inder von uns gelieferten Ausf hrung den Bestimmungen der Maschinenrichtlinie 2006 42 EG ersetzte Richtlinie 98 37 EG und den sie umsetzenden nationalen Rechtsvorschriften entsprechen Ber cksichti
24. p NOTE The engine oil level must be inspected before the first commissioning or after longer periods of storage First fill the engine or top up the engine oil For safety reasons LUKAS power units do not contain engine oil upon delivery ATTENTION Never mix up the fuel and hydraulic fluid tanks when filling the tank this can damage the power unit 7 2 1 First commissioning Power unit without engine oil hydraulic fluid and petrol 1 Pour in the engine oil according to the instructions in the scope of delivery included with the separate manufacturer operating instructions regarding the filler opening engine oil filler cap see chapter Installation of the power unit 2 Pour hydraulic oil into the hydraulic fluid tank until the fill Max level indicator in the viewing window is between MIN MAX see illustration on the right The upper mark Min shows the absolute fill level when connecting additional equipment with increased usable volume The resulting l fill quantity is up to 3 0 I Hydraulic oil fill 3 Pour fuel petrol into the tank until the fill level is just level indicator below the filler opening If the power unit is resting on an inclined surface do not fill the tank to its maximum capacity 18 4 Now bleed the hydraulic power unit 5 Set all levers of the distributor valve to circulation at static pressure see also the chapter Valves Open and remove the tank cap so
25. prohibited All damaged electrical components e g scorched cables etc are to be replaced immediately Damage to electrical components must only be repaired by a qualified electrician in compliance with all applicable national and international safety guidelines and regulations When setting up the units you must make sure that they are not impaired by the influences of extreme temperatures When working with or storing the equipment ensure that the function and the safety of the equipment are not impaired by the effects of severe external temperatures or that the equipment is damaged in any way Please note that the equipment can also heat up over a long period of use Before transporting the equipment always ensure that the accessories are positioned in such a way that they cannot cause an accident Ensure the proper disposal of allremoved parts leftover oil hydraulic fluid and packaging materials 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 CAUTION The device is intended exclusively for the purpose stated in the operating instructions see chapter Proper Use Any other use is not in accordance with its designated use The manufacturer supplier is not liable for any damages resulting from improper us
26. quire only limited maintenance For service work special training is unnecessary however knowledge of the function of the power unit the legal safety instructions and dealing with the required tools are basic prerequisites ATTENTION Never use unnecessary force during maintenance work that could damage the components of the power unit or compromise operational safety Due to the complex installation service work on the hydraulic power unit must only be executed by the equipment manufacturer personnel trained by the equipment manufacturer or authorised LUKAS dealers WARNING CAUTION Protective clothes must be worn when maintenance and repairs are being carried out since the devices may also be pressurised when not in operation During work ensure that all components are particularly clean since dirt can damage the rescue equipment 26 ATTENTION Since LUKAS hydraulic units are designed for top performance only those components in the replacement parts lists for the relevant unit can be replaced Any other components in the unit may only be replaced if You have participated in an appropriate LUKAS service training course You have the express permission of LUKAS customer service upon request we will check for the grant of permission Examination in each individual case necessary When cleaning units and equipment note that no cleaning agent may be used that has a pH value outside the range 5 8 ATTENT
27. s Switch position 1 standard Speed 3000 1 min i and Switch position 2 Speed 3800 1 min I The setting is adjusted by moving the speed adjusting lever NOTE The engine installed in the LUKAS power units does not match every detail of the engine described in the manufacturer s separate operating instructions Nevertheless it is important that you follow all safety rules and operating maintenance and storage instructions in the separate engine instructions as absolute since they are not affected by adjustments made by LUKAS 13 5 4 Valves Both valves of the power unit in the pump block are fixed in place The pump block is fully integrated into the hydraulic power unit The hose assemblies pressure line grey and return blue must be connected to the pump block The rescue equipment is connected to the hose assemblies Model P 630 units are equipped with a SIMO connecting block The connecting block of the P 630 SG also has a TURBO function With a switching lever either both connected devices can be supplied simultaneously with hydraulic fluid or a single device can be supplied with double the volume TURBO function By supplying at double the feed rate the speed of the connected device is increased The hoses are connected with the connecting block via mono couplings 5 4 1 Control valve simultaneous operation SIMO This valve enables the connection of two pressure hoses and two return hoses It has two
28. s equipment or when transporting it ensure that you do not get caught up in the hose or cable loops and trip Do not touch the engine and exhaust system when running with combustion engine pumps because of the danger of burning Combustion engines must not be operated in enclosed spaces because of the danger of poisoning and or smothering If you spill any fuel when using combustion engines you must remove the spilled fuel completely before starting the engine Keep combustion engines and their fuels away from sources of ignition since otherwise there willbe a danger of explosion In order to prevent the danger of fire you should ensure adequate ventilation when operating combustion engines and you must keep a safety distance of at least 1m 39 4 in to walls and other screens Make sure that the combustion engines are always standing on as flat and horizontal a surface as possible to prevent fuel from leaking out The equipment is filled with hydraulic fluid This hydraulic fluid can be detrimental to health if it is swallowed or its vapour is inhaled Direct contact with the skin must be avoided for the same reason Also when handling hydraulic fluid note that it can negatively affect biological systems Make sure there is adequate lighting while working Always keep these operating instructions easily accessible at the place of operation Refuelling whilst the engine is running is strictly
29. switching options each of which controls the pressure application of the pressure hose that is marked accordingly This means that two devices can be supplied with pressure simultaneously and independently of each other Without impairing the work output it enables work with two devices simultaneously and independently of each other ATTENTION When operating several pieces of rescue equipment with one unit ensure that the usable volume of hydraulic fluid in the power unit is greater than the maximum possible operating fluid volume of all connected rescue equipment 14 5 5 Pumps The LUKAS hydraulic power units model P 630 are equipped with a SIMO connecting block The pump is rigidly connected to the connecting block Double flow pump for operating with SIMO valve The pump used always has two pressure stages per pump feed flow one low pressure and one high pressure Low pressure level LP upto 14 MPa High pressure level HP up to 70 MPa 1 MPa 10 bar The changeover from low pressure to high pressure is carried out automatically by the pump This system is secured with a pressure limiting valve Therefore the maximum permissible system pressure cannot be exceeded WARNING CAUTION For safety reasons the pressure set on this valve must not be adjusted without the approval of LUKAS directly 5 6 Frame with side sections The P 630 hydraulic power unit is mounted within a frame The frame and side panels
30. that air enters the tank 6 Open the venting plug on the pump block tilt the power unit backwards by approx 45 see illustration and wait until oil comes out from the bolt Pump block P 630 SG Venting plug 7 When oil comes out at the venting plug the air has been removed from the pump First close the venting plug and then return the power unit to the level 8 Check the fluid levels Top up if necessary 9 Now connect the extension hoses and or hose reels unless already connected to the unit and or couple the rescue equipment 19 7 2 3 Commissioning after the first filling or prior to use 1 Check the fluid level of the engine oil the hydraulic fluid and the fuel tank Top up if necessary For precise reading off of the fluid levels and for filling the hydraulic unit should be as level as possible 2 Now connect the extension hoses and or hose reels unless already connected to the unit and or couple the rescue equipment 8 Operation ATTENTION The control levels on the hydraulic power unit should always be switched to the neutral position de pressurised prior to starting the engine in order to prevent unwanted movements of connected hydraulic equipment and to start the power unit without hydraulic load 8 1 Starting the engine Before starting the combustion engine check that the fuel tank is full and that the engine oil level is within the permitted tolerances If necessary top up the relev
31. the locking sleeve in direction 0 Coupling of the hose assemblies when under pressure is also possible assuming that the connected equipment is not turned on NOTE lil We recommend connecting the coupling halves in a depressurised state when working in areas with low ambient temperature and using extension hose assemblies hose reels as otherwise the coupling may require the application of a great deal of force For dust protection the supplied dust caps must be refitted Using the dust protection caps The dust protection caps A have two external grooves B The dust protection caps must be inserted in the female coupling in such a way that the grooves can be guided over the pins C Screw in the dust protection caps to the stop to fix in the female couplings 17 7 Erection and start up 7 1 Set up WARNING CAUTION Because of possible spark formation combustion engine units and electrical equipment cannot be used in an explosion risk area 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 secure location flat surface sufficient distance from vehicles loads sources of ignition etc LUKAS units work perfectly at an angle of up to 20 However in order to guarantee maximum safety and fluid withdrawal they should be operated in as horizontal a position as possible 7 2 Start u
32. through the filler neck into the hydraulic tank and close the neck again with filler cap B 6 The unit then has to be bled again as described in the Chapter Commissioning 11 2 4 Changing decals All damaged and or illegible decals safety notices type plate etc must be replaced Procedure 1 Remove damaged and or illegible decals 2 Clean surfaces with industrial alcohol 3 Affix new decals Take care to affix the decals in the correct positions If this is no longer known you should ask your authorised LUKAS dealer or contact LUKAS directly 28 11 3 Additional service work NOTE Non observance of the maintenance plan can lead to malfunctions that are not covered by the warranty For dismantling the sparking plug use a commercially available sparking plug spanner with universal joint and spanner size of 16 mm 5 8 inch A straight rigid sparking plug spanner would damage or break off the sparking plug also observe the separate instructions from the engine manufacturer First month or after the first 20 hours first time e Replace engine oil see operating instructions of the engine manufacturer You must conduct the following service measures every 50 operating hours e Clean the air filter element e After using in a dusty environment inspect the air filter element and clean immediately if necessary You must conduct the following service measures every 100 operating hours e Replace engine oil
33. ty of the unit an additional function check is to be carried out in this connection comply with the applicable national and international regulations with regard to the maintenance intervals of rescue equipment Operating time per day In the Federal Republic of Germany regular safety inspections according to the regulations of the Gesetzlichen Unfallversicherung GUV connoted Legal accident insurance are mandatory ATTENTION Clean off any dirt before checking the equipment WARNING CAUTION To perform inspections maintenance and repairs personal safety equipment appropriate for the work is an absolute requirement when necessary also use N screens LUKAS offers a suitable test kit for the function test of the hydraulic units For specific details please consult the LUKAS range of accessories or Contact your LUKAS dealer 10 1 Recommended test intervals 10 1 1 General visual inspection A visual inspection must be carried out after every use but at least once every six months 24 10 1 2 Function check Operating time per day Functional test up to 1 hour 1x annually up to 8 hours 1x per quarter up to 24 hours 1 x per month In addition to these test intervals you need to carry out a function test if the unit makes suspicious noises there is a justified suspicion of internal damage to the unit If the noises and suspicions referred to above arise several times in a month or if maximum pressur
34. users that they should read carefully the operating instructions and the instructions contained therein before they use the equipment and that they should carefully follow such We further recommend you have a qualified trainer show you how to use the product CAUTION The operating instructions for the hoses accessories and the connected devices must also be heeded Even if you have already received instruction on how to use the equipment you should still read through the following safety instructions again CAUTION Ensure that the accessories and connected equipment are suitable for the maximum operating pressure Please ensure that no body parts or clothing get stuck between the visibly moving parts Immediately report any changes that occur including changes in operating behaviour to the appropriate persons departments If necessary the equipment is to be shut down immediately and secured Wear protective clothing safety helmet with visor safety shoes and protective gloves Working under suspended loads is not permitted where such loads are being lifted only by means of hydraulic devices If this work is unavoidable Suitable mechanical supports are also required Check the equipment for visible flaws or damage before and after use Check all lines hoses and screwed connections for leaks and externally visible damage and repair immediately Escaping hydraulic fluid can Cause injuries and fires
35. valves ATTENTION The control levels on the hydraulic power unit should always be switched to the neutral position de pressurised prior to starting the engine in order to prevent unwanted movements of connected hydraulic equipment 8 4 1 Simultaneous operation control valve SIMO P 630 SG A switching lever that controls the valves see the top illustration is located on the pump block Both mono couplings have been designed in such a way that they are automatically in the de pressurised state without connected device The control unit on the device controls the switching when the device is connected The switching lever makes it possible to switch to the TURBO function With this function one of the two connections is able to be supplied with double the feed volume by switching the lever The TURBO function is activated by turning the large lever towards the connection that is to be pressurised at the doubled pumping output NOTE All switching levers must always be completely switched on up to the end stop 22 9 Dismantling the equipment deactivation following operation Once the work has been completed all connected equipment is to be reset to its neutral position storage position before the unit is shut down You can then switch off the engine of the power unit WARNING for power units with combustion engines Check that the engine switch is set to the OFF position and remains there to pre
36. vent the unwanted starting of the power unit Mono couplings If the connected hose assemblies are to be dismantled during shut down decouple as described in chapter Coupling the mono couplings Ensure that you put the dust protection caps back onto the mono coupling halves Clean the hydraulic power unit of any stubborn dirt prior to storage If the equipment is to be stored for a longer period of time the exterior is to be cleaned completely and the mechanically mobile 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 power units in a damp environment Observe the additional regulations in the separate operating instructions for the hoses CAUTION A Depending on the size and weight of the hydraulic power unit it should be transported to the storage location by one or more persons 23 10 Tests The hydraulic power units are subject to very high levels of mechanical stress A visual inspection must therefore be carried out after every use and at least one visual inspection must be carried out every six months This reveals wear and tear in good time punctual replacement of these wearing parts prevents damage to the equipment Also check regularly that all the securing screws are tightened if applicable comply with prescribed tightening torques Every 3 years or when there might be doubts regarding the safety or reliabili
37. y for explosion prevention or for ruling out work with the P 630 rests with the operator of the device or with the person responsible at the place of use When working in areas at risk of explosion all applicable legal national and international regulations standards and safety rules for avoiding explosions must be observed without limitation The equipment should not come into contact with acids or alkalis If this is unavoidable clean the equipment immediately afterwards with a suitable cleaning agent You can obtain accessories and replacement parts for the rescue apparatus from your authorised LUKAS dealer ATTENTION When selecting the units to connect to the unit bear in mind that the maximum possible useable volume of hydraulic fluid is limited The sum of the max required operating volume hydraulic fluid of all connected equipment must not exceed the maximum possible usable volume of the power unit NOTE Always register your hydraulic unit on the LUKAS Hydraulik GmbH internet site This is the only way to guarantee your extended warranty cover Before you use couplings from a different company you must contact LUKAS or an authorised dealer 10 4 Power unit designation Type group Motor variants Coding for hydraulic Valve variants power units Valve variants S Simultaneous operation Motor variants G Petrol engine 5 Functional description 5 1 General information In the case of all LU
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