44
175070085 EN Hydraulic power unit P 630 SG (Translation of the original operating instructions) replaces 11.2013 Operating instructions for rescue equipment Edition 02.2017

Operating instructions for rescue equipment …rescue.lukas.com/lukas_rescue_media/09_Dokumentation/06_Antrieb/P...device: 5. 2. Product safety; LUKAS ... Motorised pumps must not

  • Upload
    leque

  • View
    215

  • Download
    1

Embed Size (px)

Citation preview

Page 1: Operating instructions for rescue equipment …rescue.lukas.com/lukas_rescue_media/09_Dokumentation/06_Antrieb/P...device: 5. 2. Product safety; LUKAS ... Motorised pumps must not

175070085 EN

Hydraulic power unit P 630 SG

(Translation of the original operating instructions)

replaces 11.2013

Operating instructions for rescue equipment

Edition 02.2017

Page 2: Operating instructions for rescue equipment …rescue.lukas.com/lukas_rescue_media/09_Dokumentation/06_Antrieb/P...device: 5. 2. Product safety; LUKAS ... Motorised pumps must not

2

Content Page1. Dangerclassifications 4

2. Productsafety 5

3. Intendeduse 9

4. Powerunitdesignation 10

5. Functionaldescription 10 5.1 General information 10 5.2 Installation of the power unit 11 5.3 Motor 12 5.4 Valves 13 5.5 Pumps 14 5.6 Frame with side sections 14 5.7 Connection to the rescue equipment 14

6. Connectingthehoses/devices 15 6.1 Coupling the mono-couplings 15

7. Set-upandcommissioning 17 7.1 Set-up 17 7.2 Commissioning 17

8. Operation 19 8.1 Starting the engine 19 8.2 Turningtheengineoff 20 8.3 Refuelling 20 8.4 Controlling the valves 21

9. Dismantlingtheequipment/deactivationfollowingoperation 22

10.Tests 23 10.1 Recommended test intervals 23 10.2 Visual and function check 24

11.Maintenanceandrepair 25 11.1 General information 25 11.2 Service work on the hydraulic unit 26 11.3 Additional service work 28

Page 3: Operating instructions for rescue equipment …rescue.lukas.com/lukas_rescue_media/09_Dokumentation/06_Antrieb/P...device: 5. 2. Product safety; LUKAS ... Motorised pumps must not

3

Content Page12.Faultanalysis 33

13.Technicaldata 38 13.1 Power Unit 38 13.2 Noise emissions (Sound pressure level) 40 13.3 Sparking plug 41 13.4 Sparking plug spanner 41 13.5 Fuel 41 13.6 Engine oil 42 13.7 Hydraulicfluidrecommendation 42 13.8 Operating and storage temperature range 42

14.ECDeclarationofConformity 43

Page 4: Operating instructions for rescue equipment …rescue.lukas.com/lukas_rescue_media/09_Dokumentation/06_Antrieb/P...device: 5. 2. Product safety; LUKAS ... Motorised pumps must not

4

Wearahelmetwithafaceguard

Wearprotectivegloves

Wearsafetyshoes

Properrecycling

Protecttheenvironment

Readandfollowoperatinginstructions

Wedifferentiatebetweenvariousdifferentcategoriesofsafetyinstructions.Thetableshownbelowshowsyouanoverviewoftheassignmentofsymbols(pictograms)andsignalwordstothespecificdangerandthepossibleconsequences.

1. Danger classifications

Pictogram Damage / injury to Key word Definition Consequences

Persons

DANGER! Immediatedanger Deathorsevereinjury

WARNING!Potentiallydangeroussituation

Potentialdeathorseriousinjury

CAUTION! Lessdangeroussituation

Minororslightinjury

Property

ATTENTION!Dangerofdamage

toproperty/environment

Damagetotheequipment,

damagetotheenvironment,damagetosurroundings

- NOTE

Handlingtipsandotherimportant/usefulinformation

andadvice

Noinjury/damagetopersons/environment/

device

Page 5: Operating instructions for rescue equipment …rescue.lukas.com/lukas_rescue_media/09_Dokumentation/06_Antrieb/P...device: 5. 2. Product safety; LUKAS ... Motorised pumps must not

5

2. Product safetyLUKAS products are developed andmanufactured to ensure the best performance andqualitywhenusedasintended.Thesafetyoftheoperatoristhemostimportantconsiderationinproductdesign.Furthermore,theoperatinginstructionsareintendedtohelpinusingLUKASproductssafely.Thegenerallyapplicablelegalandotherbindingregulationspertainingtothepreventionofaccidentsandprotectionoftheenvironmentapplyandaretobecompliedwithinadditiontotheoperatinginstructions.Theequipmentmustonlybeoperatedbypersonswithappropriate training in thesafetyaspectsofsuchequipment–otherwise,thereisadangerofinjury.Wewouldliketopointouttoallusersthattheyshouldreadcarefullytheoperatinginstructionsandtheinstructionscontainedthereinbeforetheyusetheequipment,andthattheyshouldcarefullyfollowsuch.Wefurtherrecommendyouhaveaqualifiedtrainershowyouhowtousetheproduct.

CAUTION!The operating instructions for the hoses, accessories and the connecteddevicesmustalsobeheeded!

Evenifyouhavealreadyreceivedinstructiononhowtousetheequipment,youshouldstillreadthroughthefollowingsafetyinstructionsagain.

CAUTION!Ensure that the accessories and connected equipment are suitable for themaximumoperatingpressure!

Pleaseensurethatnobodypartsorclothinggetstuckbetweenthevisiblymovingparts.

Immediatelyreportanychangesthatoccur(includingchangesinoperatingbehaviour)totheappropriatepersons/departments!Ifnecessary,theequipmentistobeshutdownimmediatelyandsecured!

Wearprotectiveclothing,safetyhelmetwithvisor,safetyshoesandprotectivegloves.

Checktheequipmentforvisibleflawsordamagebeforeandafteruse.

Workingundersuspendedloadsisnotpermittedwheresuchloadsarebeingliftedonlybymeansofhydraulicdevices.Ifthisworkisunavoidable,suitablemechanicalsupportsarealsorequired.

Checkalllines,hosesandscrewedconnectionsforleaksandexternallyvisibledamage,andrepairimmediately!Escapinghydraulicfluidcancauseinjuriesandfires.

Page 6: Operating instructions for rescue equipment …rescue.lukas.com/lukas_rescue_media/09_Dokumentation/06_Antrieb/P...device: 5. 2. Product safety; LUKAS ... Motorised pumps must not

6

Intheeventofmalfunctions,immediatelydeactivatethedeviceandsecureit.Repairthefaultimmediately.

Donotcarryoutanychanges(additionsorconversions)totheequipmentwithoutobtainingtheapprovalofLUKASbeforehand.

Observeallsafetyanddangerinformationonthedeviceandintheoperatinginstructions.

Allsafetyanddangerinformationonthedevicemustalwaysbecompleteandinalegiblecondition.

Pleaseensurethatallsafetycoversarepresentontheequipmentandthattheyareinproperandadequatecondition.

Anymodeofoperationwhichcompromisesthesafetyand/orstabilityofthedeviceisforbidden!

Safetydevicesmustneverbedisabled!

Themaximumoperatingpressuresetontheequipmentmustnotbechanged!

Makesurebeforeswitchingon/startingupthedeviceandduringitsoperation,thatthiswillputnooneindanger.

Observeallintervalsforrecurringtestsand/orinspectionsthatareprescribedorstatedintheoperatinginstructions.

Whenworkingclosetolivecomponentsandcables,suitablemeasuresmustbetakentoavoidcurrenttransfersorhigh-voltagetransferstotheequipment.

OnlyoriginalLUKASaccessoriesandsparepartsaretobeusedforrepairs.Whenworkingwiththisequipmentorwhentransportingit,ensurethatyoudonotgetcaughtupinthehoseorcableloopsandtrip.

Thebuild-upofstaticchargeandthereforepossiblesparkingmustbeavoidedwhenhandlingthedevice.

Donottouchtheengineandexhaustsystemwhenrunningwithcombustionenginepumpsbecauseofthedangerofburning.

Motorisedpumpsmustnotbeoperatedinareasatriskofexplosion!

Combustionenginesmustnotbeoperatedinenclosedspacesbecauseofthedangerofpoisoningand/orsmothering.

Page 7: Operating instructions for rescue equipment …rescue.lukas.com/lukas_rescue_media/09_Dokumentation/06_Antrieb/P...device: 5. 2. Product safety; LUKAS ... Motorised pumps must not

7

Keepcombustionenginesandtheirfuelsawayfromsourcesofignitionsinceotherwisetherewillbeadangerofexplosion.

Alldamagedelectricalcomponentse.g.scorchedcables,etc.aretobereplacedimmediately!

Inordertopreventthedangeroffire,youshouldensureadequateventilationwhenoperatingcombustionenginesandyoumustkeepasafetydistanceofatleast1m(39.4 in.)towallsandotherscreens.

Damagetoelectricalcomponentsmustonlyberepairedbyaqualifiedelectricianincompliancewithallapplicablenationalandinternationalsafetyguidelinesandregulations.

Makesurethatthecombustionenginesarealwaysstandingonasflatandhorizontalasurfaceaspossibletopreventfuelfromleakingout.

Whensettinguptheunits,youmustmakesurethattheyarenotimpairedbytheinfluencesofextremetemperatures.

Theequipmentisfilledwithhydraulicfluid.Thishydraulicfluidcanbedetrimentaltohealthifitisswallowedoritsvapourisinhaled.Directcontactwiththeskinmustbeavoidedforthesamereason.Also,whenhandlinghydraulicfluid,notethatitcannegativelyaffectbiologicalsystems.

Whenworkingwithorstoringtheequipment,ensurethatthefunctionandthesafetyoftheequipmentarenotimpairedbytheeffectsofsevereexternaltemperaturesorthattheequipmentisdamagedinanyway.Pleasenotethattheequipmentcanalsoheatupoveralongperiodofuse.

Makesurethereisadequatelightingwhileworking.

Beforetransportingtheequipment,alwaysensurethattheaccessoriesarepositionedinsuchawaythattheycannotcauseanaccident.

Alwayskeeptheseoperatinginstructionseasilyaccessibleattheplaceofoperation.

Ensuretheproperdisposalofallremovedparts,leftoveroil,hydraulicfluidandpackagingmaterials.

Ifyouspillanyfuelwhenusingcombustionengines,youmustremovethespilledfuelcompletelybeforestartingtheengine.

Refuellingwhilsttheengineisrunningisstrictlyprohibited!

Page 8: Operating instructions for rescue equipment …rescue.lukas.com/lukas_rescue_media/09_Dokumentation/06_Antrieb/P...device: 5. 2. Product safety; LUKAS ... Motorised pumps must not

8

The generally applicable, legal and other binding national and international regulationspertainingtothepreventionofaccidentsandprotectionoftheenvironmentapplyandaretobeimplementedinadditiontotheoperatinginstructions.

WARNING/CAUTION!Thedeviceisintended exclusively for the purpose stated in the operating instructions (see chapter "Proper Use"). Any other use is not in accordance with its designated use.Themanufacturer/supplierisnotliableforanydamagesresultingfromimproperuse.Theuserbearssoleresponsibilityforsuchuse.Proper use includes observance of the operating instructions and compliance with theinspectionandmaintenanceconditions.

Never work in a fatigued or intoxicated state!

WARNING/CAUTION!Ifyoustillinjureyourselfonthehydraulicunit,cleanthewoundimmediatelyandconsultadoctortohaveitattendedto!Ifyougethydraulicfluidinyoureye,rinseitimmediatelyseveraltimeswithclear,cleanwaterandconsultadoctor!Also,ifyouswallowhydraulicfluidyoushouldconsultadoctor!

Page 9: Operating instructions for rescue equipment …rescue.lukas.com/lukas_rescue_media/09_Dokumentation/06_Antrieb/P...device: 5. 2. Product safety; LUKAS ... Motorised pumps must not

9

3. Intended use

You can obtain accessories and replacement parts for the rescue apparatus from yourauthorisedLUKASdealer!

WARNING/CAUTION!Thesafetyinstructionsinthisoperatinginstructionmanualconcerningthesiteoferectionandtypeoferectionmustalwaysbeobserved!

LUKAS hydraulic units are specially designed to supply LUKAS rescue equipment withhydraulicfluidsothatthisequipmentcanbeusedtorescuevictimsofroad,railorairtrafficaccidentsaswellasfrombuildings.Their use for supplying pressure / fluid to rescue equipment of other manufacturers ispossible,yet requires the technical inspectionandapprovalbyLUKAS ineach individualcase.Theequipmentisnotdesignedtooperatewithouthosesorequipment(operatingtimewithouthosesorequipment<15minutes).

ATTENTION!Whenselectingtheunitstoconnecttotheunit,bearinmindthatthemaximumpossibleuseablevolumeofhydraulicfluidislimited.Thesumofthemax.requiredoperatingvolume(hydraulicfluid)ofallconnectedequipmentmustnotexceedthemaximumpossibleusablevolumeofthepowerunit!

NOTE:AlwaysregisteryourhydraulicunitontheLUKASHydraulikGmbHinternetsite.Thisistheonlywaytoguaranteeyourextendedwarrantycover.Beforeyouusecouplingsfromadifferentcompany,youmustcontactLUKASoranauthoriseddealer.

LUKASP630unitsarenot explosionprotected!Whenusing the equipment in explosion-risk areas youmust make sure thatoperationoftheunitdoesnottriggeranexplosion!TheresponsibilityforexplosionpreventionorforrulingoutworkwiththeP630restswiththeoperatorofthedeviceorwiththepersonresponsibleattheplaceofuse.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 isunavoidable,cleantheequipmentimmediatelyafterwardswithasuitablecleaningagent.

Page 10: Operating instructions for rescue equipment …rescue.lukas.com/lukas_rescue_media/09_Dokumentation/06_Antrieb/P...device: 5. 2. Product safety; LUKAS ... Motorised pumps must not

10

4. Power unit designation

P 630 S G

Codingforhydraulicpowerunits

Typegroup

Valvevariants

Motorvariants

Valve variants: S = Simultaneousoperation Motor variants: G = Petrolengine

InthecaseofallLUKAShydraulicpowerunits,thehydraulicpumpisoperatedwithamotor.Thepumpconveysthefluidfromthehydraulicoiltankandbuildsupthepressureinthetool.Fluidisdistributedtotheconnectedequipmentthroughcontrolvalves.TheP630SGisapowerunitwithframeandwithapetrolengineandsimultaneousoperation.

5. Functional description 5.1 General information

Page 11: Operating instructions for rescue equipment …rescue.lukas.com/lukas_rescue_media/09_Dokumentation/06_Antrieb/P...device: 5. 2. Product safety; LUKAS ... Motorised pumps must not

11

5.2 Installation of the power unit

1 7 5

43

9

10

2

11

12

13

14 15

1 Petroltank 2 Hydraulicfluidtank 3 Enginewithhydraulicpump 4 Connectingblockwith

controlvalves 5 Speedadjustinglever 7 Cable-pullstarter 9 "TURBO"controllever10 Mono-coupling(female)11 Fueltankcap12 Fillercaphydraulicfluid13 Frame14 Rubberbuffer15 Sidepanel16 Airfilter17 Choke18 Fueltap19 ON/OFFswitch(engine

switch)22 Engineoilfillercap/dipstick23 FilllevelindicatorEquipmentback

16

17 18 19

23

22

Page 12: Operating instructions for rescue equipment …rescue.lukas.com/lukas_rescue_media/09_Dokumentation/06_Antrieb/P...device: 5. 2. Product safety; LUKAS ... Motorised pumps must not

12

5.3 Motor

WARNING/CAUTION! See also the separate operating instructions of each engine manufacturer

accompanyingthedelivery.

5.3.1 Petrol engineThesehydraulicunitsareequippedwithacombustionenginedrivenbythefuel"petrol".Thepowerunitsareequippedwithacable-pullstarterwithwhichtheengineisstarted.(For specific details, please consult the separate operating instructions of the enginemanufacturer!)

NOTE:TheengineinstalledintheLUKASpowerunitsdoesnotmatcheverydetailoftheenginedescribedinthemanufacturer'sseparateoperatinginstructions.Nevertheless, it is important that you follow all safety rules and operating,maintenance and storage instructions in the separate engine instructions asabsolutesincetheyarenotaffectedbyadjustmentsmadebyLUKAS.

HONDA motors have a main switch that must be activated to switch the power unit on and off.Thespeedadjustingleveronthesepowerunitshastwoswitchpositions.Switch position 1 (standard): Speed 3000 1/min " " and Switch position 2: Speed 3800 1/min " ".

Thesettingisadjustedbymovingthespeedadjustinglever.

Page 13: Operating instructions for rescue equipment …rescue.lukas.com/lukas_rescue_media/09_Dokumentation/06_Antrieb/P...device: 5. 2. Product safety; LUKAS ... Motorised pumps must not

13

5.4 ValvesBothvalvesofthepowerunitinthepumpblockarefixedinplace.Thepumpblockisfullyintegrated into the hydraulic power unit. The hose assemblies (pressure line (grey) andreturn(blue))mustbeconnectedtothepumpblock.Therescueequipmentisconnectedtothehoseassemblies.ModelP630unitsareequippedwithaSIMOconnectingblock.

TheconnectingblockoftheP630SGalsohasaTURBOfunction.Witha“TURBO”controllever,eitherbothconnecteddevicescanbesuppliedsimultaneouslywithhydraulicfluid,orasingledevicecanbesuppliedwithdoublethevolume(=TURBOfunction). By supplying at double the feed rate, the speed of the connected device isincreased.

Thehosesareconnectedwiththeconnectingblockviamono-couplings.

5.4.1 Control valve "simultaneous operation" (SIMO)Thisvalveenablestheconnectionoftwopressurehosesandtworeturnhoses.Ithastwoswitching options, each of which controls the pressure application of the pressure hosethatismarkedaccordingly.Thismeansthattwo devices can be supplied with pressure simultaneously and independently of each other.Without impairingtheworkoutput, itenablesworkwithtwodevicessimultaneouslyandindependentlyofeachother.

ATTENTION!When operating several pieces of rescue equipment with one unit, ensurethat theusablevolumeofhydraulicfluid in thepowerunit isgreater than themaximumpossibleoperatingfluidvolumeofallconnectedrescueequipment.

Page 14: Operating instructions for rescue equipment …rescue.lukas.com/lukas_rescue_media/09_Dokumentation/06_Antrieb/P...device: 5. 2. Product safety; LUKAS ... Motorised pumps must not

14

TheLUKAShydraulicpowerunitsmodelP630areequippedwithaSIMOconnectingblock.Thepumpisrigidlyconnectedtotheconnectingblock. Double-flowpumpforoperatingwithSIMOvalve

Thepumpusedalwayshastwopressurestagesperpumpfeedflow,onelowpressureandonehighpressure.

Low-pressurelevel(LP) = upto14MPa*

High-pressurelevel(HP)= upto70MPa*

Thechangeoverfromlowpressuretohighpressureiscarriedoutautomaticallybythepump.Thissystemissecuredwithapressurelimitingvalve.Therefore,themaximumpermissiblesystempressurecannotbeexceeded.

5.5 Pumps

*)1MPa=10bar)

5.6 Frame with side sectionsTheP630hydraulicpowerunitismountedwithinaframe.Theframeandsidepanelsarealsoused,despitetherobustdesign,toprotectthepowerunitfromexternalinfluences,suchasforexample,dirtordamage.

5.7 Connection to the rescue equipment

Connectiontotherescueequipmentisviaextensionhosepairsorviahosereels.Theyaresuppliedinvariouslengths.(Forspecificdetails,pleaseconsulttheLUKASrangeofaccessoriesorcontactyourLUKASdealer.)

WARNING/CAUTION!Forsafetyreasons,thepressuresetonthisvalvemustnotbeadjusted(withouttheapprovalofLUKASdirectly)!

Page 15: Operating instructions for rescue equipment …rescue.lukas.com/lukas_rescue_media/09_Dokumentation/06_Antrieb/P...device: 5. 2. Product safety; LUKAS ... Motorised pumps must not

15

ATTENTION!Whenconnectingthehoseassemblies/units,alwaysensurethattheconnectioncomponentsarenotdirty.Cleanpriortouseifnecessary!

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 directlybeforeconnectingtheequipment!

6. Connecting the hoses / devices

Mono-couplinghalve(male)

Mono-couplinghalve(female)

Dustprotectioncaps

Thehoselines/unitsareconnectedviaquick-disconnectcouplinghalves(femaleandmale)tothehydraulicpumporhosereelinsuchawaythattheycannotbeswappedover.

6.1 Coupling the mono-couplings

0

1

0

Page 16: Operating instructions for rescue equipment …rescue.lukas.com/lukas_rescue_media/09_Dokumentation/06_Antrieb/P...device: 5. 2. Product safety; LUKAS ... Motorised pumps must not

16

BA C

C

Remove the dust caps before coupling together. Then push themale and female partstogetherand turn the locking sleeveon the female coupling in thedirection "1" until thelockingsleeveclicks inplace.Theconnectionhasbeenmadeand locked.Decoupling isaccomplishedbyturningthelockingsleeveindirection"0".Couplingofthehoseassemblieswhenunderpressureisalsopossible,assumingthattheconnectedequipmentisnotturnedon.

NOTE:We recommend connecting the coupling halves in a depressurised statewhenworkinginareaswithlowambienttemperatureandusingextensionhoseassemblies/hosereels,asotherwisethecouplingmayrequiretheapplicationofagreatdealofforce.

Fordustprotection,thesupplieddustcapsmustberefitted.

Using the dust protection caps: Thedustprotectioncaps"A"havetwoexternalgrooves"B".Thedustprotectioncapsmustbeinsertedinthefemalecouplinginsuchawaythatthegroovescanbeguidedoverthepins"C".Screwinthedustprotectioncapstothestoptofixinthefemalecouplings.

Page 17: Operating instructions for rescue equipment …rescue.lukas.com/lukas_rescue_media/09_Dokumentation/06_Antrieb/P...device: 5. 2. Product safety; LUKAS ... Motorised pumps must not

17

7. Set-up and commissioning

7.1 Set-up

7.2 Commissioning

WARNING/CAUTION!Because of possible spark formation, combustion engine units and electricalequipment cannot be used in an explosion-risk area. Units with combustionenginesmustnotbeusedinenclosedspaces,asthereisadangerofpoisoningand/orasphyxiation!

Theunitistobesetupinasuitablelocation(securelocation/flatsurface/sufficientdistancefromvehicles,loads,sourcesofignition,etc.).LUKASunitsworkperfectlyatanangleofupto20°.However,inordertoguaranteemaximumsafetyandfluidwithdrawal,theyshouldbeoperatedinashorizontalapositionaspossible.

ATTENTION!Nevermixupthefuelandhydraulicfluidtankswhenfillingthetank;thiscandamagethepowerunit!

NOTE:Theengineoil levelmustbeinspectedbeforethefirstcommissioningorafterlongerperiodsofstorage.Firstfilltheengineortopuptheengineoil!Forsafetyreasons,LUKASpowerunitsdonotcontainengineoilupondelivery!

7.2.1 First commissioning-Powerunitwithoutengineoil,hydraulicfluidandpetrol.

1.Pour in the engine oil according to the instructionsin the scope of delivery included with the separatemanufacturer operating instructions regarding the filleropening(engineoilfillercap,seechapter"Installationofthepowerunit").

2.Pourhydraulicoilintothehydraulicfluidtankuntilthefilllevel indicator in the viewingwindow is betweenMIN/MAX (see illustration on the right). The upper markshowstheabsolutefilllevelwhenconnectingadditionalequipmentwithincreasedusablevolume.Theresultingfillquantityisupto3.0l.

3.Pour fuel (petrol) into the tankuntil thefill level is justbelow thefilleropening. If thepowerunit is restingonan inclinedsurface,donotfill the tank to itsmaximumcapacity.

Hydraulic oil filllevelindicator

Page 18: Operating instructions for rescue equipment …rescue.lukas.com/lukas_rescue_media/09_Dokumentation/06_Antrieb/P...device: 5. 2. Product safety; LUKAS ... Motorised pumps must not

18

4.Nowbleedthehydraulicpowerunit:

5.Openandremovethetankcapsothatairentersthetank.

6.Opentheventingplugonthepumpblock,tiltthepowerunitbackwardsbyapprox.45°(seeillustration)andwaituntiloilcomesoutfromthebolt.

7.Whenoilcomesoutattheventingplug,theairhasbeenremovedfromthepump.Firstclosetheventingplugandthenreturnthepowerunittothelevel.

8.Checkthefluidlevels.Topupifnecessary.

9.Nowconnect theextensionhosesand/orhose reels (unlessalreadyconnected to theunit)and/orcoupletherescueequipment.

VentingplugPumpblockP 630 SG

Page 19: Operating instructions for rescue equipment …rescue.lukas.com/lukas_rescue_media/09_Dokumentation/06_Antrieb/P...device: 5. 2. Product safety; LUKAS ... Motorised pumps must not

19

7.2.3 Commissioning(afterthefirstfillingorpriortouse)

1.Check the fluid level of the engine oil, the hydraulic fluid and the fuel tank.Top up ifnecessary. For precise reading off of the fluid levels and for filling, the hydraulic unitshouldbeaslevelaspossible.

2.Nowconnecttheextensionhosesand/orhosereels(unlessalreadyconnectedtotheunit)and/orcoupletherescueequipment.

Beforestartingthecombustionengine,checkthatthefueltankisfullandthattheengineoilleveliswithinthepermittedtolerances.Ifnecessary,topuptherelevantfluid.

1.Openthepetroltap2.SettheON/OFFswitchtotheONposition.3.MovetheleverfromswitchingpositionAtoswitching

positionB(choke)whenstartingcold4.Pullthecable-starter.5.When themotor is running,switch the leverback to

positionA.

For the detailed procedure for starting the combustionengine,pleaseseetheseparate operating instructions of the engine manufacturer!

BA

8.1 Starting the engine

8. Operation

Page 20: Operating instructions for rescue equipment …rescue.lukas.com/lukas_rescue_media/09_Dokumentation/06_Antrieb/P...device: 5. 2. Product safety; LUKAS ... Motorised pumps must not

20

Theenginemustbeswitchedoffforrefuelling!Procedure:1.Openthefueltankcap.2. Fillthetankwithfueluntilthefilllevelisjustbelowthefilleropening.

3.Closethefueltankagainwiththefueltankcap.

WARNING/CAUTION!Besurenottospill fuel. Inparticular,hotenginepartsmustnotcomeintocontactwithfuel;dangeroffireotherwise!Iffuelisspilled,itmustbecleanedupimmediatelywithasuitableabsorbentcloth.Indoingso,becarefulnottoburnyourselfononeofthehotengineparts!Theusedclothmustthenbecleanedordisposedofaccordingtotherelevantprovisionsandguidelines!

8.3 Refuelling

1.SettheON/OFFswitchtotheOFFposition.2.Whentheenginehascometoastandstill,closethe

fueltap.

For more details on switching off the engine, please refer to the separate operatinginstructions of the engine manufacturer!

CAUTION!Nevertouchhotengineparts:thiscouldresultinsevereburns!

8.2 Turning the engine off

Page 21: Operating instructions for rescue equipment …rescue.lukas.com/lukas_rescue_media/09_Dokumentation/06_Antrieb/P...device: 5. 2. Product safety; LUKAS ... Motorised pumps must not

21

8.4 Controlling the valves

8.4.1 "Simultaneous operation" control valve (SIMO) P 630 SG

Thepumpblockalsohasa“TURBO”controllever,allowingthe user to switch to the “TURBO” function (see diagramabove).Withthisfunction,theswitchpositionofthe“TURBO”controllevercanbeusedtosupplyoneofthetwoconnectionswithdoublethevolume.The"TURBO"functionisactivatedbyturningthe“TURBO”controllevertowardstheconnectionthatistobepressurisedatthedoubledpumpingoutput.

NOTE:The“TURBO”controllevermustalwaysbemovedcompletelyuptothestop.

Page 22: Operating instructions for rescue equipment …rescue.lukas.com/lukas_rescue_media/09_Dokumentation/06_Antrieb/P...device: 5. 2. Product safety; LUKAS ... Motorised pumps must not

22

9. Dismantling the equipment / deactivation following operation

WARNING for power units with combustion engines!Checkthattheengineswitchissettothe“OFF“positionandremainstheretopreventtheunwantedstartingofthepowerunit!

Oncetheworkhasbeencompleted,allconnectedequipment is tobereset to itsneutralposition(storageposition)beforetheunitisshutdown.Youcanthenswitchofftheengineofthepowerunit.

Mono-couplings:If the connected hose assemblies are to be dismantled during shut-down, decouple asdescribedinchapter"Couplingthemono-couplings".Ensurethatyouputthedustprotectioncapsbackontothemono-couplinghalves.

Cleanthehydraulicpowerunitofanystubborndirtpriortostorage.

If theequipment is tobestored fora longerperiodof time, theexterior is tobecleanedcompletely and themechanicallymobile parts are to be lubricated. If storing a unitwithcombustionengine,youshouldalsoremovethefuelfromthefueltank.Avoidstoringthehydraulicpowerunitsinadampenvironment.Observe the additional regulations in the separate operating instructions for the hoses.

CAUTION!Depending on the size and weight of the hydraulic power unit it should betransportedtothestoragelocationbyoneormorepersons.

Page 23: Operating instructions for rescue equipment …rescue.lukas.com/lukas_rescue_media/09_Dokumentation/06_Antrieb/P...device: 5. 2. Product safety; LUKAS ... Motorised pumps must not

23

10. TestsThe hydraulic power units are subject to very high levels ofmechanical stress.A visualinspectionmustthereforebecarriedoutaftereveryuseandatleastonevisualinspectionmustbecarriedouteverysixmonths.This reveals wear and tear in good time; punctual replacement of these wearing partspreventsdamageto theequipment.Alsocheckregularly thatall thesecuringscrewsaretightened(ifapplicable,complywithprescribedtighteningtorques)Every3yearsorwhentheremightbedoubtsregardingthesafetyorreliabilityoftheunit,anadditionalfunctioncheckistobecarriedout(inthisconnection,complywiththeapplicablenational and international regulationswith regard to themaintenance intervals of rescueequipment).Operating time per day In the Federal Republic ofGermany, regular safetyinspections according to the regulations of the Gesetzlichen Unfallversicherung (GUV;connoted‘Legalaccidentinsurance’)aremandatory.

ATTENTION!Cleanoffanydirtbeforecheckingtheequipment!

WARNING/CAUTION!To perform inspections,maintenance and repairs, personal safety equipmentappropriatefortheworkisanabsoluterequirement.(whennecessaryalsousescreens).

LUKASoffersasuitabletestkitforthefunctiontestofthehydraulicunits.(Forspecificdetails,pleaseconsulttheLUKASrangeofaccessoriesorcontactyourLUKASdealer.)

10.1 Recommended test intervals10.1.1 General visual inspection

Avisualinspectionmustbecarriedoutaftereveryuse,butatleastonceeverysixmonths.

Page 24: Operating instructions for rescue equipment …rescue.lukas.com/lukas_rescue_media/09_Dokumentation/06_Antrieb/P...device: 5. 2. Product safety; LUKAS ... Motorised pumps must not

24

Visual Inspection

• Tightnessofallhydraulicconnections,• Generaltightness,noleakage(sweatedoilsdonothaveanyinfluenceonthefunction),• isthereanydetectabledamagetotheengine,connectingblocks,ontheframeortheside

sections,• Isthereanysignofdamagetothehydraulicsorfueltank,• Sideplatespresentandtightened,• Presenceand legibility of the identificationplate, all actuation signs, instruction signs,

markingsandwarnings,• Thepresenceandperfectconditionofallcovers(e.g.exhaustdeflector),• Allfluidlevelsarewithinthespecifiedtolerances,• Aretherotaryswitchesandswitchingleversinproperworkingorderandundamaged,• Couplingsmustbeeasytocouple,• Dustprotectioncapsmustbeavailable,• Allrequiredaccessoryparts(e.g.sparkingplug,sparkingplugspannerandfuelcan)are

present.• Checkforleaks.

Functional test• Unconventionalornoticeablenoisesheardduringoperation• Cable-pullstarterfullyfunctional,• Engineswitchfullyfunctional,• Testformaximumload.

10.2 Visual and function check

Operating time per day Functional test

upto1hour 1xannually

upto8hours 1xperquarter

upto24hours 1xpermonth

In addition to these test intervals you need to carry out a function test if: - theunitmakessuspiciousnoises, - thereisajustifiedsuspicionofinternaldamagetotheunit.

Ifthenoisesandsuspicionsreferredtoaboveariseseveraltimesinamonth,orifmaximumpressurecannotbeachievedduringthefunctiontest,youneedtocontactLUKAScustomerservice immediately. The contact details are given in the Chapter "Fault analysis".

10.1.2 Function check

NOTE:usetheLUKAStestkit,includingtestinginstructions,forthefunctiontest.

Page 25: Operating instructions for rescue equipment …rescue.lukas.com/lukas_rescue_media/09_Dokumentation/06_Antrieb/P...device: 5. 2. Product safety; LUKAS ... Motorised pumps must not

25

11.1 General informationLUKAShydraulicunitsmodelP630requireonlylimitedmaintenance.Forservice work, specialtrainingisunnecessary;however,knowledgeofthefunctionofthepowerunit,thelegalsafetyinstructionsanddealingwiththerequiredtoolsarebasicprerequisites.

ATTENTION!Neveruseunnecessaryforceduringmaintenanceworkthatcoulddamagethecomponentsofthepowerunitorcompromiseoperationalsafety.

Duetothecomplexinstallation,service workonthehydraulicpowerunitmustonlybeexecutedbytheequipmentmanufacturer,personneltrainedbytheequipmentmanufacturer,orauthorisedLUKASdealers.

WARNING/CAUTION!Protective clothes must be worn when maintenance and repairs are beingcarriedout,sincethedevicesmayalsobepressurisedwhennotinoperation.

Duringwork,ensurethatallcomponentsareparticularlyclean,sincedirtcandamagetherescueequipment!

11. Maintenance and repair

Page 26: Operating instructions for rescue equipment …rescue.lukas.com/lukas_rescue_media/09_Dokumentation/06_Antrieb/P...device: 5. 2. Product safety; LUKAS ... Motorised pumps must not

26

ATTENTION!Since LUKAS hydraulic units are designed for top performance, only thosecomponentsinthereplacementpartslistsfortherelevantunitcanbereplaced.Anyothercomponentsintheunitmayonlybereplacedif:- YouhaveparticipatedinanappropriateLUKASservicetrainingcourse.- YouhavetheexpresspermissionofLUKAScustomerservice(uponrequest,

wewillcheckforthegrantofpermission.Examinationineachindividualcasenecessary!)

Whencleaningunitsandequipment,notethatnocleaningagentmaybeusedthathasapHvalueoutsidetherange5-8!

ATTENTION!Attentionmustbepaidtoensuringthatnooperatingfluidscanescapefromunitswithcombustionenginesduringrepairwork!

11.2 Service work on the hydraulic unit

11.2.1 Care instructionsTheexteriorofthedevicemustbecleanedfromtimetotime(not the electrical contacts) andthemetallicsurfaces(not the electrical contacts)mustbetreatedwithasuitableagenttoprotectagainstcorrosion.(Incaseofdoubt,contactyourauthorisedLUKASdealerorLUKASdirectly!)

11.2.2 Function and load test Ifthereisanydoubtregardingthesafetyorreliabilityoftheequipment,afunctionandstresstestmustalsobeperformed.LUKASoffersappropriatetestingequipmentforthis.

11.2.3 Replacing the hydraulic fluid- Afterapprox.200deployments,butafterthreeyearsatthelatest,replacethehydraulic

fluid.- Thefluidshouldbereplacedafterithaswarmedup.- Theenginemustbeswitchedoff!- Theusedhydraulicfluidmustbedisposedofproperly.

Page 27: Operating instructions for rescue equipment …rescue.lukas.com/lukas_rescue_media/09_Dokumentation/06_Antrieb/P...device: 5. 2. Product safety; LUKAS ... Motorised pumps must not

27

A

B

5. Pourthenewhydraulicfluidthroughthefillerneckintothehydraulictankandclosetheneckagainwithfillercap"B".

6. TheunitthenhastobebledagainasdescribedintheChapter"Commissioning".

Replacing the hydraulic fluid - procedure:1. Placethepowerunitonaslightlyelevatedbasesothatthedrainplugforthehydraulic

fluidcanbeeasilyreached.2. Placeasuitablecollectioncontainerunderthe"A"drainplug.3. Openthe"B"fillercap,removethe"A"drainplugandletthehydraulicfluidrunintothe

providedcollectioncontainer.4. Screwthe"A"drainpluginagain(tighteningtorquemax.5Nm).

11.2.4 Changing decalsAlldamagedand/orillegibledecals(safetynotices,typeplateetc.)mustbereplaced.

Procedure:1.Removedamagedand/orillegibledecals.2.Cleansurfaceswithindustrialalcohol.3. Affixnewdecals.

Takecaretoaffixthedecalsinthecorrectpositions.Ifthisisnolongerknown,youshouldaskyourauthorisedLUKASdealerorcontactLUKASdirectly.

Page 28: Operating instructions for rescue equipment …rescue.lukas.com/lukas_rescue_media/09_Dokumentation/06_Antrieb/P...device: 5. 2. Product safety; LUKAS ... Motorised pumps must not

28

NOTE:Non-observanceofthemaintenanceplancanleadtomalfunctionsthatarenotcoveredbythewarranty.

Fordismantlingthesparkingplug,useacommercially-availablesparkingplugspannerwithuniversaljointandspannersizeof16mm(5/8inch).Astraight/rigidsparkingplugspannerwoulddamageorbreakoffthesparkingplug!

(also observe the separate instructions from the engine manufacturer)

First month or after the first 20 hours (first time):• Replaceengineoil(seeoperatinginstructionsoftheenginemanufacturer).

You must conduct the following service measures every 50 operating hours:• Cleantheairfilterelement.• Afterusinginadustyenvironment,inspecttheairfilterelementandcleanimmediately,

ifnecessary.

You must conduct the following service measures every 100 operating hours:• Replaceengineoil.• Checkthesparkingplug,cleanifnecessary/settheelectrodegapofthesparkingplug

You must conduct the following service measures every 200 operating hours:• Replacethesparkingplug• Replaceairfilter

(Thefollowingserviceworkshouldbeexecutedbyanauthoriseddealer,LUKASdirectlyorthe engine manufacturer.)

You must conduct the following service measures every 300 operating hours:• Replacethesparkingplugandthefilterelement• Cleanandadjustthecarburettor,valveclearance,valveseatandcylinderhead.

You must conduct the following service measures every 1000 operating hours or every 2 years:

• Checkthestarter• Inspecttheenginefordamage• Checkthefuellineandreplace,ifnecessary.

11.3 Additional service work

Page 29: Operating instructions for rescue equipment …rescue.lukas.com/lukas_rescue_media/09_Dokumentation/06_Antrieb/P...device: 5. 2. Product safety; LUKAS ... Motorised pumps must not

29

11.3.1 Replacing and cleaning the air filter

Procedure:Ifpresent,removetherearsidepanelofthehydraulicpowerunit,inthatthefixingclipandthesidepanelareremoved.1.Unscrewbothboltsfromtheairfiltercoverandremovethecover.2.Removethefoamairfilterinsertfromthecover.3.Takethepaperairfilterinsertfromtheairfilterhousing.4.Checkbothairfilterinsertsandreplaceifdamaged.Thepaperairfilterinsertmustalways

bereplacedatplannedintervals.5.Cleantheairfilterinsertsifreusingthem. Paperairfilterinsert:Tapoutthepaperairfilterinsertafewtimesonahardsurfaceto

removedirtorblowcompressedair[notmorethan207kPa(2.1kg/cm)]fromtheairfilterhousingsidethroughthefilterinsert.Neverattempttobrushoutdirtbecauseitwouldbepressedinbythebristles.Replacethepaperairfilterinsertifitisexceedinglydirty.

Foam air filter insert: Clean in warm soapy water, rinse and allow to dry thoroughly. Orcleaninnon-flammablesolventandletdry.Donotintroduceanyoiltothefoamairfilterinsert.

6.Wipeawaydirtfromtheinsideoftheairfilterhousingwithadampcloth.Ensurethatdirtdoesnotpenetratetheairductleadingtothecarburettor.

7.Thenre-fitthefilter.

NOTE:Keepingtheairfilteringoodconditionisextremelyimportant.Penetratingdirtleadstodamageandwearintheengineincaseofincorrectinstallation,incorrectdamageorunsuitablefilterinserts. Alwayskeeptheairfilterinsertclean.

AirfiltercoverBolts

Foamairfilterinsert:

Paperairfilterinsert:

Airfilterhousing

Page 30: Operating instructions for rescue equipment …rescue.lukas.com/lukas_rescue_media/09_Dokumentation/06_Antrieb/P...device: 5. 2. Product safety; LUKAS ... Motorised pumps must not

30

11.3.2 Replacing, cleaning and setting the sparking plug

Procedure:Inordertodelivergoodperformance,thesparkingplugmusthaveacorrectelectrodegapandbefreefromdeposits.1.Detachthesparkingplugconnectorandremoveanydirtnearthesparkingplug.2.Unscrewthesparkingplugusinga16mm(5/8inch)sparkingplugspanner.3.Checkthesparkingplug.Replacethesparkingplugifitisdamaged,extremelydirty,the

sealingwasherisinpoorconditionortheelectrodesareworn.4.Measure theelectrodegapon thesparkingplugwithawire feelergauge.Correct the

electrodegap,ifrequired,bycarefullybendingthesideelectrode.Targetelectrodegap:0.6-0.7mm(0.024-0.028in)

5.Carefullyscrewinthesparkingplugbyhandinordertoavoidstrippingthethread.6.Tightenthesparkingplugaftermountingwitha5/8-inchsparkingplugspannerinorderto

compressthewasher.7.Anewsparkingplugshouldbetightenedbyanadditional1/2turnafterfittinginorderto

compressthewasher.8.Ausedsparkingplugshouldbetightenedbyanadditional1/8to1/4turnafterfittingin

ordertocompressthewasher.9.Placethesparkingplugconnectoronthesparkingplug.

NOTE: Aloosesparkingplugcanoverheatanddamagetheengine.Asparkingplugthatistootightcandamagethethreadinthecylinderhead.

0.6-0.7mm(0.024-0.028in)

Gasket

Sideelectrode

11.3.3 Replacing the engine oil and the engine oil filter

Fortheprocedureforreplacingtheengineoilandengineoilfilter,pleaserefertotheseparateoperatinginstructionsoftheenginemanufacturer!

Sparkingplugspanner

Sparkingplugcon-nector

Page 31: Operating instructions for rescue equipment …rescue.lukas.com/lukas_rescue_media/09_Dokumentation/06_Antrieb/P...device: 5. 2. Product safety; LUKAS ... Motorised pumps must not

31

11.3.4 Mono-couplingsThemono-couplingsmustbereplacedif:- thereisexternaldamage,- thelockingdoesnotfunction,- hydraulicfluidcontinuestoleakinthecoupled/uncoupledstate.

WARNING/CAUTION!Neverrepaircouplings:theymustbereplacedbygenuineLUKASparts!

Procedure for coupling to valve block:

1. Firstemptythehydraulictankasdescribedinthechapter"Replacingthehydraulicfluid".2.Removescrewedfittingsonthecoupling.3.Removecouplingsandunderlyingseals4.Positionthenewcoupling,togetherwiththeseals,ontothevalveblock.5.Re-attachthecouplingswiththeboltsandtightentoatorqueofMA=40Nm.6. Thehydraulicfluidtankmustberefilledandthepowerunitvented.

3. Loosentheunionnutsonthehoselinesandremovethecoupling.

Procedure for coupling to hose pairs:

1. Firstemptythehydraulictankasdescribedinthechapter"Replacingthehydraulicfluid".2. Pullthekink-protectionbackfromthecouplings.

Page 32: Operating instructions for rescue equipment …rescue.lukas.com/lukas_rescue_media/09_Dokumentation/06_Antrieb/P...device: 5. 2. Product safety; LUKAS ... Motorised pumps must not

32

11.3.5 Quick-disconnect couplings

Thequick-disconnectcouplingsmustbereplacedif:- thereisexternaldamage,- thelockingdoesnotfunction,- hydraulicfluidcontinuestoleakinthecoupled/uncoupledstate.

WARNING/CAUTION!Neverrepaircouplings:theymustbereplacedbygenuineLUKASparts!

DuringassemblytightentheunionnutsonthehoselinetoatorqueofMA=35Nm.

Procedure:

1. Loosentheunionnutsonthehoselineandremovethecoupling.2.Positionthenewcouplingandtightentheunionnutonthehoseassembliestoatorqueof

MA=35Nm.

ATTENTION!Thereturnhose,whichisscrewedontotheport“T”oftherescuetool,mustbeequippedwithaquick-disconnect-coupling(male)always.However, the supply hose line must be equipped with a quick-disconnect-coupling(female).

ATTENTION!Ensurethatconnection“T1”/"T2"onthepumpblockisalwaysconnectedtoconnection“T”onthemono-coupling.

4.PositionthenewcouplingandtightentheunionnutsonthehoseassembliestoatorqueofMA=40Nmandpushthekink-protectionofthecouplingsback.

5. Thehydraulicfluidtankmustberefilledandthepowerunitvented.

Page 33: Operating instructions for rescue equipment …rescue.lukas.com/lukas_rescue_media/09_Dokumentation/06_Antrieb/P...device: 5. 2. Product safety; LUKAS ... Motorised pumps must not

33

NOTE: Incaseoffaultswhichdirectlyaffectthecombustionengine,pleasealsoobservetheseparateinstructionsintheoperatinginstructionsoftheenginemanufacturer.

Fault Check Cause SolutionCombustionenginewillnotstart

Checkfuellevelintank

Fueltankempty Topupfuel

Checkfuelline Faultinthefuelline Shutdownimmediatelyandhaverepairedbyauthoriseddealer,motor/enginemanufacturerordirectlybyLUKAS

Inspectengineswitch

Cable-pullstarter Activatecable-pullstarter

MotorswitchnotsettoChoke

SetmotorswitchtoChoke

Hydraulicunitorenginenotsuitablefortheworkingenvironment

Ambienttemperaturetoolow

Forthesolution,consulttheseparateoperatinginstructionsoftheenginemanufacturer.Useadifferenthydraulicfluidoroperatingfluidthatissuitablefortherelevantambienttemperature(seeChapterI"TechnicalData")

Notenoughoxygenintheairbecauseofthealtitudeofapplicationlocationofthehydraulicmotor

Useadifferentmoresuitablehydraulicunit.

Havetheenginesettothealtitudeofapplicationofthehydraulicpowerunitbyanauthoriseddealer,enginemanufacturerorLUKASdirectly(onlyiftheunitistobeusedfrequentlyatthisaltitude).

Checkairfilter Airfiltercontaminated Cleanorreplacetheairfilter.

Areallvalvessettopressure-free(restsetting)?

Combustionmotordefectiveoroverloadedduetodifferentdefectintheunit

Haverepairedbyauthoriseddealer,motor/enginemanufacturerordirectlybyLUKAS

12. Fault analysis

Page 34: Operating instructions for rescue equipment …rescue.lukas.com/lukas_rescue_media/09_Dokumentation/06_Antrieb/P...device: 5. 2. Product safety; LUKAS ... Motorised pumps must not

34

Fault Check Cause SolutionThemotorisrunning,buttheconnectedrescueequipmentisnotmoving/movingveryslowlyuponactivationofthevalve.

Checkhose Hoseassemblynotconnectedproperlyorisdamaged

Checkconnectionofhoseandreconnectifnecessary.

Checktheswitchpositionofthevalveleveronthepumpblockofthehydraulicunit

Valvenotswitchedtosupplylinepressurisation.

Switchvalvetopressureloadofthesupplyline.

Defectivepumpunit HaverepairedbyauthoriseddealerordirectlybyLUKAS

Connectadifferentunitandcheckwhetheritworkswhenactuated

Thepreviouslyconnectedunitisdefective.

Rectificationseeoperatinginstructionsoftheconnectedunit

Mono-coupling(female)defective

Replacemono-coupling(female)

Theconnectedrescueequipmentdoesnotmoveonactivationofthevalve,ormovesonlyveryslowlyorunevenly.

Connectadifferentunitandcheckwhetheritworkswhenactuated

Thepreviouslyconnectedunitisdefective.

Rectificationseeoperatinginstructionsoftheconnectedunit

Checktheswitchingpositionofthe“TURBO”controlleveronthepumpblockofthehydraulicsystem.

The“TURBO”controlleverisnotfullyswitched.

Checktheswitchingpositionofthe"TURBO"controlleverandreswitchifnecessary(toendposition).

Defectivepumpunit HaverepairedbyauthoriseddealerordirectlybyLUKAS

Airinhydraulicsystem Ventthehydraulicsystem

Plug-incoupling(female)defective

Replaceplug-incoupling(female)

Mono-coupling(female)defective

Replacemono-coupling(female)

Page 35: Operating instructions for rescue equipment …rescue.lukas.com/lukas_rescue_media/09_Dokumentation/06_Antrieb/P...device: 5. 2. Product safety; LUKAS ... Motorised pumps must not

35

Fault Check Cause SolutionConnectedrescuedevicedoesnotreachitsfinalposition

Checkhydraulicfluidvolumeinhydraulictank

Insufficientfluidinthehydraulictank

TopuphydraulicfluidtothemaximumfillinglevelCaution! Before topping up the rescue equipment, return to the base position!

Usablehydraulicfluidvolumeoftheunitisinsufficient

Useadifferentrescuedevicewithademandquantitybelowthemaximumusablequantityoftheunit

Connectedrescuedevicedoesnotreachitsspecificperformancedata

Maximumpermittedoperatingpressureofthepumpisnotreached

HavethepressurelimitingvalveresetorrepairedbyauthoriseddealerordirectlybyLUKAS

Pumpblockdefective HaverepairedbyauthoriseddealerordirectlybyLUKAS

Connectedunitdefective

Rectificationseeoperatinginstructionsoftheconnectedunit

Duringfunctiontest:Apressuregaugeinstalledbetweentherescueequipmentandthehydraulicpowerunitdoesnotindicatethemaximumoperatingpressureoftheequipment.

Checkthedetailsoftherescuedevice

Theoperatingpressureoftheconnectedrescuedeviceislockedinternally

Norepairorfaultrectificationrequired

Connectedrescuedeviceisdefective

Consulttheseparateoperatingmanualfortheconnectedrescuedevice

Hydraulicunitdefective HaverepairedbyauthoriseddealerordirectlybyLUKAS

Page 36: Operating instructions for rescue equipment …rescue.lukas.com/lukas_rescue_media/09_Dokumentation/06_Antrieb/P...device: 5. 2. Product safety; LUKAS ... Motorised pumps must not

36

Fault Check Cause SolutionFluidcomingoutfromhydraulicfluidtank

Connectedunitnotinbasepositionyetandfluidcomingoutoffillercap?

Returnofthehydraulicfluidfromtherescuedeviceexceedsthetank’smaximumquantitywhenfilled.

Reducefluidlevelinthehydraulictankto“Minimum”mark,movetheunittothebasepositionandthenfillbackupwithhydraulicfluidtothe“Maximum”level

Fluidleaksfromadifferentlocation?

Leakfromtank,linesorseals

ReplacedefectivecomponentsorrepairbyauthoriseddealerorLukasdirectly

Leakingfluidbetweenengineandflangebearing

Radialshaftsealonthedriveshaftisdefective

HaverepairedbyauthoriseddealerordirectlybyLUKAS

Hydraulicfluidmilkyandcloudy

Water/condensationinthesystem

Replacethehydraulicfluidimmediately

Hosescannotbecoupled

Couplingdefective Couplingmustbereplacedimmediately

Page 37: Operating instructions for rescue equipment …rescue.lukas.com/lukas_rescue_media/09_Dokumentation/06_Antrieb/P...device: 5. 2. Product safety; LUKAS ... Motorised pumps must not

37

Fault Check Cause SolutionItisfrequentlynotpossibletocouplehoseassemblies

Hydraulicfluidnotadaptedtotheapplicationsituation

Hydraulicfluidmustbereplaced(seechapter"Recommendedhydraulicfluids")

Couplingdefective Couplingmustbereplacedimmediately

Leakinthecouplings Couplingdefective Couplingmustbereplacedimmediately

Leakageatthedriveshaftofthehydraulicpump

Shaftsealdefective. Repairbyanauthoriseddealer,bypersonnelspeciallytrainedbyLUKAS,orbyLUKASitself

ContactanauthorisedLUKASdealerortheLUKASCustomerServiceDepartmentdirectlyifthemalfunctionscannotberectified.TheaddressfortheLUKASCustomerServicedepartmentis:

LUKAS Hydraulik GmbHA Unit of IDEX Corporation

Weinstraße39, D-91058ErlangenTel.: (+49)09131/698-348Fax.: (+49)09131/698-353

NOTE: Incaseoffaultswhichaffectthecombustionengine,pleasealsoobservetheinstructionsintheseparateoperatinginstructionsoftheenginemanufacturer.

Page 38: Operating instructions for rescue equipment …rescue.lukas.com/lukas_rescue_media/09_Dokumentation/06_Antrieb/P...device: 5. 2. Product safety; LUKAS ... Motorised pumps must not

38

13. Technical data

NOTE:The following tables contain only the technical data required for standardacceptance.AdditionaldataconcerningyourunitcanbeobtainedfromLUKASonrequest.The limitation of themax. fill quantity of the hydraulic tank results from the"operabilityatanincline"prescribedinthestandards.

Becauseallvaluesaresubjecttotolerances,theremaybesmalldifferencesbetweenthedataforyourdeviceandthedatainthefollowingtables!The values may also differ because of reading inaccuracies and/or tolerances in themeasuringequipmentused.

13.1 Power Unit13.1.1 Basic dimensions of the power unit (mm [inch])

Power unit P 630 SG:

Page 39: Operating instructions for rescue equipment …rescue.lukas.com/lukas_rescue_media/09_Dokumentation/06_Antrieb/P...device: 5. 2. Product safety; LUKAS ... Motorised pumps must not

39

1) HD = Highpressure 2) ND=Lowpressure 3) 1MPa=10bar

13.1.2 Technical data P 630 SG

Device type P 630 SGArticle number 81-53-20

Motor type 4-strokepetrolengine

Engine power rating[kW] 1,8/2,2[HP] 2.4 / 3.0

Engine speed[min-1]

3000/3800[rpm.]

Feed rate simultaneous (HD)1)

[l/min] 2x0,55/2x0,7[gal.-US/min] 2x0.15/2x0.19

Feed rate turbo (HD)1)

[l/min] 1x1,1/1x1,35[gal.-US/min] 1x0.29/1x0.36

Feed rate simultaneous (ND)2)

[l/min] 2x2,4/2x3,0[gal.-US/min] 2x0.63/2x0.79

Feed rate turbo (ND)2)

[l/min] 1x4,7/1x5,8[gal.-US/min] 1x1.24/1x1.53

Max. operating pressure (HD)1)

[MPa]3) 70[psi.] 10000

Max. operating pressure (ND)2)

[MPa]3) 14[psi.] 2000

Max. fill volume hydraulicfluid

[l] 2,2[gal.-US] 0.58

Max. fill volume Petrol

[l] 0,77[gal.-US] 0.17

Weight (with petrol and hydraulic fluid)

[kg] 23,9

[lbs.] 56.7

Valve variants SimultaneousoperationMax. unit connection facilities 2

Page 40: Operating instructions for rescue equipment …rescue.lukas.com/lukas_rescue_media/09_Dokumentation/06_Antrieb/P...device: 5. 2. Product safety; LUKAS ... Motorised pumps must not

40

13.2 Noise emissions (Sound pressure level)

Device type P 630 SGSpeed 3000[1/min]/[rpm] 3800[1/min]/[rpm]Idle run(accordingtoEN) [dB(A)] 80 84

Full load(accordingtoEN) [dB(A)] 84 88

Idle run(accordingtoNFPA) [dB(A)] 73 77

Full load(accordingtoNFPA) [dB(A)] 77 80

Explanation of dual number noise emission values according to DIN EN 13204:2012-09Serialnumberofthemachine,operatingconditionsandothercharacteristicproperties:Model...P630SG,type...81-53-20,maximumworkingpressure...700bar,enginespeed....3800[1/min]/[rpm]INDICATEDDUALNUMBERNOISEEMISSIONVALUESaccordingtoENISO4871MeasuredA-ratedemissionsoundpressurelevelLpA,indB,referredto20μPa....88Measurementuncertainty,KpA,indB.....4MeasuredA-ratedemissionsoundpowerlevel(ifrequired)LWA,indB,referredto1pW....101Measurementuncertainty,KpA,indB.....4ValuesdeterminedaccordingtoEN13204,AppendixB,usingbasicstandards ENISO3744andENISO11201.NOTE!Thesumofthemeasurednoiseemissionvaluesandtheassociatedmeasure-mentuncertaintythatcanoccurduringthemeasurementrepresenttheupperlimitofthemeasuredvalues.

Page 41: Operating instructions for rescue equipment …rescue.lukas.com/lukas_rescue_media/09_Dokumentation/06_Antrieb/P...device: 5. 2. Product safety; LUKAS ... Motorised pumps must not

41

13.3 Sparking plug

13.5 Fuel

Sparking plug type: CR5HSB(NGK) U16FSR-UB(DENSO)

Fuel: Lead-freepetrol ROZ91toROZ98

13.4 Sparking plug spanner

Universal joint sparking plug spanner with spanner size 16 mm (5/8 inch)

Page 42: Operating instructions for rescue equipment …rescue.lukas.com/lukas_rescue_media/09_Dokumentation/06_Antrieb/P...device: 5. 2. Product safety; LUKAS ... Motorised pumps must not

42

13.7 Hydraulic fluid recommendation

13.8 Operating and storage temperature range

MineraloilDINISO6743-4forLUKAShydraulicequipmentandothers

Oiltemperaturerange Oildesignation Viscosityrating RemarksA -20....+55°C HM10 VG10

Oiltemperaturerange Oildesignation Viscosityrating RemarksA -4.0 .... +131°F HM10 VG10

recommendedrangeofviscosity:10...200mm²/s(10…200 cSt.)SuppliedwithHM10DINISO6743-4.

ATTENTION!Beforeyouusehydraulicfluidsfromadifferentmanufacturer,youmustcontactLUKASoranauthoriseddealer.

Operating temperature [°C]/[°F] -20 … +55 -4 … +131

Ambient temperature (deviceinoperation) [°C]/[°F] -25 … +45 -13 … +113

Storage temperature (devicenotinoperation) [°C]/[°F] -30 … +60 -22 … +140

13.6 Engine oil

Page 43: Operating instructions for rescue equipment …rescue.lukas.com/lukas_rescue_media/09_Dokumentation/06_Antrieb/P...device: 5. 2. Product safety; LUKAS ... Motorised pumps must not

43

14. EC Declaration of Conformity

Page 44: Operating instructions for rescue equipment …rescue.lukas.com/lukas_rescue_media/09_Dokumentation/06_Antrieb/P...device: 5. 2. Product safety; LUKAS ... Motorised pumps must not

LUKAS Hydraulik GmbHA Unit of IDEX Corporation

Weinstraße 39, D-91058 ErlangenTel.: (+49) 0 91 31 / 698 - 0Fax.: (+49) 0 91 31 / 698 - 394e-mail: [email protected]

Made in GERMANY

© Copyright 2017 LUKAS Hydraulik GmbHP630SG_manual_175070085_en.indd

Subj

ect t

o ch

ange

s

Please dispose of all packaging materials and removed items properly.

WARNING/CAUTION! Beforeconnectingtheequipment,makesurethatall the components used are suitable for the

maximum operating pressure of the hydraulic unit!Incasesofdoubt,you must consult LUKAS

directlybeforeconnectingtheequipment!