Instruction manual for rescue equipment Hydraulic power units P 630 lite P 630 HV lite P 630 HV lite P 630 lite 175075085 EN Edition 11.
Content Page 1. Danger classi¿cations 5 2. Product safety 6 3. Proper use 10 4. Power unit designation 11 5. Functional description 11 5.1 5.2 5.3 5.4 5.5 5.6 General information Installation of the power unit Motor Valves in the pump block Pumps Connecting the P 630 HV lite power unit with rescue equipment 6. Connecting the couplings 11 12 13 14 15 15 17 6.1 Coupling the mono-couplings 6.2 Coupling the quick-disconnect couplings 17 19 7. Set-up and start-up 20 7.1 Set-up 7.
Content Page 13. Technical data 13.1 13.2 13.3 13.4 13.5 13.6 13.7 13.8 41 Power unit Noise emissions Sparking plug Sparking plug spanner Fuel Engine oil Hydraulic fluid recommendation Operating and storage temperature ranges 41 44 45 45 45 46 46 46 14. EC Declaration of Conformity 47 15.
1. Danger classifications We differentiate between various different categories of safety instructions. The table shown below provides an overview of the assignment of symbols (pictograms) and signal words to the speci¿c danger and the possible consequences.
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.
In the event of malfunctions, immediately deactivate the device and secure it. Repair the fault immediately. Do not carry out any changes (additions or conversions) to the equipment without obtaining the approval of LUKAS beforehand. Observe all safety and danger information on the device and in the operating instructions. All safety and danger instructions on the device must always be complete and in a legible condition.
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 will be a danger of explosion. Refuelling whilst the engine is running is strictly prohibited! In order to prevent the danger of ¿re, you should ensure adequate ventilation when operating combustion engines and you must keep a safety distance of at least 1m (39.4 in.
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.
3. Proper use LUKAS hydraulic units are specially designed to supply LUKAS rescue equipment with hydraulic Àuid so that this equipment can be used to rescue victims of road, rail or air traf¿c accidents as well as from buildings. Their use for supplying pressure / Àuid to rescue equipment of other manufacturers is possible, yet requires the technical inspection and approval by LUKAS in each individual case.
4. Power unit designation P 630 Model versions Type group HV lite = hose version Coding for hydraulic power units lite = version with quick-disconnect couplings 5. Functional description 5.1 General information On all LUKAS hydraulic power units, the hydraulic pump is operated with a motor. The pump conveys Àuid from the hydraulic oil tank and builds up the pressure in the tool. Fluid is distributed to the connected equipment through valves.
5.
P 630 HV lite 9 19 18 9 Hose connection 18 Connection pressure line 19 Connection tank line 5.3 Motor WARNING/CAUTION! See also the separate operating instructions of each engine manufacturer accompanying the delivery. 5.3.1 Petrol motor These hydraulic units are equipped with a combustion engine driven by the fuel "petrol". The power units are equipped with a cable starter with which the engine is started.
5.4 Valves in the pump block Both valves of the power unit in the pump block are ¿xed 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. 5.4.
5.5 Pumps The LUKAS model P 630 lite hydraulic power pump is equipped with a double-Àow pump for operation with the SIMO valve. The pump used always has two pressure stages per pump feed Àow, one low pressure and one high pressure. Low-pressure level (LP) = up to 14 MPa* Low-pressure level (HP) = up to 70 MPa* *) 1 MPa = 10 bar) The changeover from low pressure to high pressure is carried out automatically in the pump. This system is secured with a pressure limiting valve.
Connecting hose assemblies: Remove blind plug consisting of union nut and steel ball. Connection labelled with T1 or T2: Return line (blue) Connection labelled with P1 or P2: Supply line (grey) Fit the corresponding hose line and tighten the union nuts to a torque of 40 Nm. Connect equipment using mono or quickdisconnect couplings to mounted hoses.
6. Connecting the couplings ATTENTION! When connecting the hose assemblies / units, always ensure that the connection components are not contaminated with dirt. Clean prior to use if necessary! WARNING/CAUTION! Before connecting equipment, make sure that all the components used are suitable for the maximum operating pressure of the hydraulic unit! In cases of doubt, you must consult LUKAS directly before connecting the equipment! 6.
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 the locking sleeve in direction "0". Coupling of the hose assemblies when under pressure is also possible, assuming the connected equipment is not turned on.
6.2 Coupling the quick-disconnect couplings The device is connected to the hydraulic pump without risk of misconnection using monocoupling halves (female and male coupling). X Y Before coupling, remove dust caps and then pull back and hold the locking sleeve of the female coupling half (position X). Connect the male and female couplings and release the locking sleeve. Then turn the locking sleeve to position Y. The connection has been made and locked. Uncoupling is done in the reverse order.
7. Set-up and start-up 7.1 Set-up WARNING/CAUTION! Because of possible spark formation, combustion engine units and electrical equipment must not 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 (safe location / Àat surface / suf¿cient distance from vehicles, loads, sources of ignition, etc.). LUKAS units work perfectly at an angle of up to 20°.
4. Now bleed the hydraulic power unit: 5. Open and remove the tank cap so 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 next to the bolt. Pump block P 630 lite Venting plug 7. If oil comes out at the venting plug, the air has escaped out of the pump. First close the venting plug and then return the power unit to level. 8. Check the Àuid levels again. Top up if necessary. 9.
7.2.3 Commissioning (after the first filling or prior to use) 1. Check the Àuid level of the engine oil, the hydraulic Àuid and the fuel reservoir. Top up if necessary. For precise reading of the Àuid levels and for ¿lling, 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.
8.2 Stopping the engine 1. Set the 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 the engine off, please refer to the separate operating instructions of the engine manufacturer! CAUTION! Never touch hot engine parts: this could result in severe burns! 8.3 Refuelling The engine must be switched off for refueling! Procedure: 1. Open the fuel tank cap. 2.
8.4.1 "Simultaneous operation" control valve (SIMO) P 630 lite Two switching levers that control the valves (see the illustration at the top) are located on the pump block. Each of the two levers is assigned to the pressure connection below. The pressure application of the corresponding pressure hose is controlled ( ) or the connection is switched depressurised ( ) by moving the lever. NOTE: All switching levers must always be moved completely up to the stop.
9. Dismantling the equipment / deactivation following operation Once work has been completed, all connected equipment is to be reset to its neutral position (storage position) before the unit is shut down. Subsequently, you can switch the engine off.
10. Tests The hydraulic power units are subject to very high levels of 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.
10.1.2 Function check Operating time per day Functional test up to 1 hour 1 x annually up to 8 hours 1 x per quarter up to 24 hours 1 x per month In addition to these 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.
11. Maintenance and repair 11.1 General information LUKAS hydraulic units model P 630 require only limited maintenance. For service work, special training is not required; however, knowledge about the function of the power unit, the statutory 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.
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. Further 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 a check is carried out for the grant of permission.
Replacing the hydraulic fluid - procedure: 1. Place the power unit on a slightly elevated base so that the drain plug for the hydraulic Àuid can be easily reached. 2. Place a suitable collection container under the "A" drain plug. 3. Open the "B" ¿ller cap, remove the "A" drain plug and let the hydraulic Àuid run into the provided collection container. 4. Screw the "A" drain plug in again (tightening torque max. 5 Nm). B A 5. 6.
11.3 Additional service work NOTE: Non-observance of the maintenance plan can lead to malfunctions that are not covered by the warranty. For removing the sparking plug, use a commercially-available sparking plug spanner with universal joint and wrench size 16 mm (5/8 inch).
11.3.1 Replacing and cleaning the air filter NOTE: Keeping the air ¿lter 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 ¿lter inserts. Always keep the air ¿lter insert clean. Procedure: 1. Unscrew both bolts from the air ¿lter cover and remove the cover. 2. Remove the foam air ¿lter insert from the cover. 3. Take the paper air ¿lter insert from the air ¿lter housing. 4.
11.3.2 Replacing, cleaning and setting the sparking plug Procedure: In order to delivery 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. Inspect the sparking plug. Replace the sparking plug if it is damaged, extremely dirty, if the sealing washer is in poor condition or if the electrodes are worn. 4.
11.3.4 Mono-couplings The mono-couplings must be replaced if: - there is external damage, - the locking does not function, - hydraulic Àuid continues to leak in the coupled/uncoupled state. WARNING/CAUTION! Never repair couplings: they must be replaced by genuine LUKAS parts! Procedure for coupling to hose pairs: 1. First empty the hydraulic tank as described in the chapter "Replacing the hydraulic Àuid". 2. Pull the cover back from the couplings. 3.
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 MA = 40 Nm and push the cover of the couplings back. 5. The hydraulic Àuid reservoir must then be re¿lled and the power unit vented. 11.3.
12. Fault analysis Fault Combustion engine will not start NOTE: In case of faults which directly affect the combustion engine, please also observe the separate instructions in the operating instructions of the engine manufacturer.
Fault The engine is running, but the connected rescue equipment is not moving / moving very slowly upon activation of the valve. Check Check hose Cause Hose assembly not connected properly or damaged Solution Check connection of hose and reconnect if necessary. Check the switch position of the valve lever on the pump block of the hydraulic unit Valve not switched to supply line pressurisation. Switch valve to pressure load of the supply line.
Fault Connected rescue device does not reach its end position Check Cause Check hydraulic Insuf¿cient Àuid in the Àuid volume in hydraulic reservoir hydraulic reservoir Connected rescue device does not reach its speci¿c performance data During function test: Check the details A pressure gauge of the rescue installed between the device rescue equipment and the hydraulic power unit does not indicate the maximum operating pressure of the equipment.
Fault Fluid coming out of hydraulic Àuid tank Check Connected unit not in rest position yet and Àuid coming out of ¿ller cap? Cause Return of the hydraulic Àuid from the rescue device exceeds the reservoir’s maximum quantity when ¿lled.
Fault It is frequently not possible to couple hose assemblies Check Cause Hydraulic Àuid not adapted to the application situation Solution Hydraulic Àuid must be replaced (see chapter "Recommended hydraulic Àuids") Coupling defective Coupling must be replaced immediately Leak from the couplings Coupling defective Coupling must be replaced immediately Leakage at the drive shaft of the hydraulic pump Shaft seal defective.
13. Technical data Because all values are subject to tolerances, there may be small differences between the data 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.
Dimensions of the power unit P 630 HV lite: 42
13.1.2 Technical data power unit Device type P 630 lite P 630 HV lite Article number 81-53-25 81-53-26 4-stroke petrol engine Engine type Engine power rating [kW] 2.2 [HP] 3.0 [min-1] Engine speed 3000 / 3800 [rpm.] Feed rate (HD)1) [l/min] 2 x 0.55 / 2 x 0.7 [gal.-US/min] 2 x 0.15 / 2 x 0.18 Feed rate (ND)2) [l/min] 2 x 2.4 / 2 x 3.0 [gal.-US/min] 2 x 0.63 / 2 x 0.79 3) Max. operating pressure (HD)1) [MPa] 70 [psi.] 10000 Max. operating pressure (ND)2) [MPa]3) max.
13.2 Noise emissions Device type P 630 HV lite / P 630 lite Speed 3000 [1/min] / [rpm] 3800 [1/min] / [rpm] Idle run (according to EN) [dB(A)] 80 84 Full load (according to EN) [dB(A)] 84 88 Idle run (according to NFPA) [dB(A)] 73 77 Full load (according to NFPA) [dB(A)] 77 80 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 630 lite, type ...
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.
13.6 Engine oil 13.7 Hydraulic fluid recommendation Mineral oil DIN ISO 6743-4 for LUKAS hydraulic equipment and others Oil temperature range -20 .... +55°C Oil code HM 10 Viscosity rating VG 10 Remarks A Oil temperature range -4.0 .... +131°F Oil code HM 10 Viscosity rating VG 10 Remarks A recommended range of viscosity: 10...200 mm²/s Supplied with HM 10 DIN ISO 6743-4. (10…200 cSt.
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WARNING/CAUTION! Before connecting equipment, make sure that all the components used are suitable for the maximum operating pressure of the hydraulic unit! In cases of doubt, you must consult LUKAS directly before connecting the equipment! Please dispose of all packaging materials and removed items properly. LUKAS Hydraulik GmbH A Unit of IDEX Corporation Tel.: (+49) 0 91 31 / 698 - 0 Fax.: (+49) 0 91 31 / 698 - 394 e-mail: lukas.info@idexcorp.com www.lukas.
