Instruction manual for rescue equipment Hydraulic units P650 175710085 EN Edition 11.2014 replaces 07.
Contents Page 1. Hazard classes 5 2. Product safety 6 3. Intended use 10 4. Labelling of the units 11 5. Functional description 11 5.1 General information 11 5.2 Structure of the units 12 5.3 Motor variants 13 5.4 Valve variants 14 5.5 Pumps 15 5.6 Frame with side parts 15 5.7 Connection to the rescue equipment 15 5.8 Hose reels 16 5.9 Carrying handle 16 5.10 Toolholder 16 6. Connection of the hose lines / devices 17 7. Set-up and start-up 19 7.1 Set-up 19 7.
11. Maintenance and repair 36 11.1 General information 36 11.2 Maintenance work on the hydraulic unit 37 11.3 Additional maintenance work on units with a combustion engine 39 11.4 Maintenance work on mounted hose reel 43 12. Troubleshooting 46 13. Technical data 53 13.1 Power unit 53 13.2 Noise emissions (Sound pressure level) 61 13.3 Sparking plug 63 13.4 Sparking plug socket 63 13.5 Fuel 63 13.6 Engine oil 64 13.7 Hydraulic fluid recommendation 64 13.
1. Hazard classes We distinguish between various categories of safety instructions. The table below gives you an overview of the assignment of symbols (pictograms) and key words to the speci¿c hazard and 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 the product design. Moreover, the operating instructions are intended to help the safe use of LUKAS products.
In the event of malfunctions, immediately shut down the equipment and secure it. The malfunction is to be repaired immediately. Observe all safety and danger notes on the device and in the operating instructions. Do not carry out any changes (additions or conversions) to the equipment without obtaining prior approval from LUKAS. All safety and danger notes on the device are to be kept complete and in a legible condition.
Keep combustion engines and their fuel away from ignition sources, as otherwise there is the danger of an explosion. All damaged electrical components e.g. scorched cables, etc. are to be replaced immediately! To avoid the danger of ¿re when using combustion engines, ensure suf¿cient ventilation and maintain a safety distance of at least 1 m (39.4 in.) to the walls and other screens.
WAR N IN G / C A U TION / AT T E NT I O N! The device is to be used exclusively for the purpose stated in the operating instructions (see chapter "Intended Use"). Any form of use beyond this is not considered intended use. The manufacturer / supplier is not liable for any resulting damages. The user bears sole responsibility for such use. Observance of the operating instructions and compliance with the inspection and maintenance conditions are covered by the de¿nition of intended use.
3. Intended 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. Labelling of the units G - ES P 650 4 Type group Coding for hydraulic units - DHR Motor variants Valve variants with electric starter Speci¿cations (e.g. DHR = with integral reels) Valve variants: S = 4 = Simultaneous mode 4POWER mode Motor variants: E = G = Electric motor (operation via mains supply) Gasoline engine 5. Functional description 5.1 General information The hydraulic pump on all LUKAS hydraulic units is always operated by a combustion engine or electric motor.
5.
5.3 Motor variants WARNING / CAUTION / ATTENTION! For all motor variants, also comply with the separate operating instructions of each motor manufacturer. 5.3.1 Electric motor These hydraulic units are equipped with an electric motor. The electric motor is driven by electricity from the mains supply or by electricity produced by generators.
5.4 Valve variants The valves are always permanently installed in a connecting block. This block is integrated directly in the hydraulic unit. Both hose lines (pressure and return) are always connected to the connecting block. The units are ¿tted either with a SIMO or a 4POWER connecting block. Both connecting blocks also have a TURBO function. More speci¿cally, this means that there are always 2 device connections linked internally to one another.
5.5 Pumps LUKAS hydraulic units are equipped with a double-Àow or four-Àow pump depending on the type. The pumps are permanently connected to the connecting block. Double-Àow pump for operation with SIMO valve Four-Àow pump for operation with 4POWER valve The pumps used are always equipped with two pressure levels for each pump capacity, one low-pressure and one high-pressure level.
5.8 Hose reels The hose reels were designed to store extension hose pairs leading between the hydraulic supply and the working equipment (hose pairs are included in the delivery as standard). The extension hose pairs are connected to the hose reels and rolled onto the drums. A hose reel with extension hose pairs can cover long distances between the hydraulic supply and the working equipment, allowing you to keep the hydraulic unit on a vehicle, for example.
6. Connection of the hose lines / devices CAUTION! When connecting the hose lines / devices, always ensure that the connection components are not soiled.
Before coupling, remove the dust protection caps, then connect male and female couplings and turn the locking sleeve of the female coupling in direction "1" until the locking sleeve latches. The connection has now been made and locked. Decoupling is accomplished by turning the locking sleeve in direction "0". Coupling of the hose lines when under pressure is also possible, assuming the connected equipment is not turned on.
7. Set-up and start-up 7.1 Set-up WARNING / CAUTION / ATTENTION! Combustion engine units and electrical units must not be used in a potentially explosive situation (danger of the formation of sparks). 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.).
This procedure means that the pump can slowly draw Àuid in and be well vented. The hydraulic Àuid reservoir is equipped with automatic venting, which means no further venting measures are required. 4. Check the Àuid levels in the reservoirs again. If necessary, top up the Àuid. 5. To conclude, you can now connect the extension hoses and/or hose reels (unless already connected to the unit) and/or couple the rescue equipment. 8.
8.1.2 Electric motors Before starting the electric motors, check that all electrical connections and cables are in proper order. First of all, connect the power cable (for motors with power supply) to the supply socket. The motor is started by pressing the ON/OFF switch on the side of the unit. The ring around the switch lights up when the unit is switched on. CAUTION! Electric motors draw a brief, very high starting current.
8.3 Refuelling (combustion engines only) The engine must be switched off during refuelling! Procedure: 1. Open the ¿ll cap on the fuel tank. 2. Fill the tank with fuel up to the maximum mark. WARNING / CAUTION / ATTENTION! Make sure you do not spill any fuel! If fuel comes into contact with hot engine components, in particular, there is a risk it may ignite and start a ¿re! If fuel is spilled by accident, it must be cleaned up immediately using a suitable absorbent cloth.
NOTE: All shift levers must always be moved all the way to their end position. 8.4.2 "4POWER mode" control valve Six levers are located on the connecting block of this valve. Each of the four small levers is assigned to a pressure port. Actuating the respective lever regulates the pressure in the corresponding pressure hose (" ") or depressurises the connection (" "). There are also two large levers that control the "TURBO" function.
8.5 Hose reels 8.5.1 Locking brake The locking brake is designed to prevent extension hose pairs from unrolling during transportation! Pull and turn knob through 90° to release the locking brake. To apply the locking brake, turn knob through approx. 90° until it engages automatically. 90° 90° 8.5.2 Crank handle The crank handle should make the hose easier to roll up! To use the crank handle, pull lever, fold outwards through 90° and release so that it engages.
8.5.4 Rolling up NOTE: We recommend using the crank handle to roll up the hoses! - Fold out the crank handle. - Check that the locking brake on the double hose reels is released. - Align the reels so that the unrolled hoses are rolled up in a straight line. You will ¿nd that the hoses roll up more easily. - You can now roll up the pair of extension hoses by turning the crank handle.
8.6 Telescopic carrying handles Units with a hose reel are ¿tted with carrying handles. Units without a hose reel can be retro¿tted with handles if required. The handles should be used to transport the P650. The telescopic carrying handles are screwed directly to the frame. The blanking plugs must be removed before the handles can be attached. Turn the handles clockwise (approx. 1 revolution) in the end positions (retracted or extended completely) to secure them properly.
8.7 Toolholder A device must ¿rst be detached from retaining clip before it can be removed from the toolholder. The device is then easy to remove. The device is ¿tted in the reverse order. Make sure that the handle tube on the rescue equipment engages properly in the retaining clip.
Procedure (fitting and adjusting the Toolholder): NOTE: If you wish to install a Toolholder at a later time or adapt an existing mount to a new device, follow the working steps described below. 1. Mount the retaining clip "A" on block "C" and secure using the screws "B". 2. Secure the two brackets "D" and "E" to mounting plate "G" using screws "F". A C G O B Position for S 700 K R J Using cutter models S700, it must be proceeded as follows with the retainer.
3. Then mount bracket "H" for the spreader and combi tool as well as bracket "J" for the cutters to mounting plate "K" (see illustration below). The brackets are secured in position using screws "L", "M", "N" and "O" as well as washers "P" and nuts "Q". H L O M N S 5xx J K Position for S 5xx Q P Using cutter models S 5xx and S 3xx, it must be proceeded with the retainer as in the illustrations and in each case a rubber spacer must be screwed into the mount bracket.
4. Mounting plates "G" and "K" are secured to the frame of the unit using screws "T" as shown in the illustration below.
5. Now adapt the brackets to the respective devices. Loosen the ¿xing screws "F" and "S" or nuts "Q" slightly so that the brackets are easy to move. Do not unscrew the screws or nuts completely. The elongated holes "U" in the mounting plates allow you to adapt the brackets to almost every device or individual position of your choice. Next tighten all loose ¿xing screws or nuts to secure the bracket in the selected position. U 6. The mount is dismantled in reverse order.
9. Removing the device / deactivation following operation Once work has been completed, all connected equipment is to be reset to its base position before the unit is shut down. You can now stop or switch off the motor/engine on the unit and disconnect it from the mains supply, if using an electric motor.
10. Tests The hydraulic units are subject to very high mechanical loads. A visual inspection is therefore to be carried out after every use, however at least one visual inspection is to 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 Functional check Operating period per day Functional check up to 1 hour 1 x every year up to 8 hours 1 x per quarter up to 24 hours 1 x per month A functional check should be performed in addition to these intervals if: - the unit makes suspicious noises, - there are grounds for suspecting that the unit has sustained internal damage.
Functional check • No suspicious noises • Starter fully functional • Engine switch fully functional • Test for maximum load (Recommendation: use the LUKAS test kit, including testing instructions, for the functional check). 10.
10.
CAUTION! Since LUKAS hydraulic units are designed for top performance, only those components in the spare parts lists of the relevant unit may be replaced. Further components in the unit may only be replaced if: - you have taken part in appropriate LUKAS service training, - you have the express permission of LUKAS Customer Service (after request, veri¿cation that permission may be granted.
Procedure: 1. Place the unit on a slightly raised base so that the drain screw for the hydraulic Àuid is easy to access. 2. Place a suitable container under drain screw "A". 3. Open ¿ll cap "B", remove drain screw "A" and seal ring "C", and allow the hydraulic Àuid to drain into the container provided. B C A 4. 5. 6. Re¿t components "A" and "C" in the reverse order. Fill fresh hydraulic Àuid into the reservoir through the ¿ller neck and then close off the neck with ¿ll cap "B".
11.3 Additional maintenance work on units with a combustion engine (also read the separate instructions provided by the engine/motor manufacturer) Perform the following maintenance work every 50 operating hours: • Wash the air ¿lter element. Wash more frequently when using the unit in a dirty or dusty environment. • Check the sparking plug and clean if necessary Perform the following maintenance work every 100 operating hours: • Change the engine oil.
11.3.1 Changing and cleaning the air filter Maintaining the air ¿lter in good condition is essential. The ingress of dirt due to incorrect installation, incorrect maintenance or unsuitable ¿lter inserts causes damage and excess wear to the engine/motor. Always keep the air ¿lter insert clean. Procedure: 1. Remove the rear side panel on the hydraulic unit by detaching the mounting clips. 2. Unhook the cover and remove the ¿lter insert. 3.
11.3.2 Changing, cleaning and adjusting the sparking plug Procedure: 1. Remove the right side panel on the hydraulic unit by detaching the mounting clips. 2. Remove the sparking plug connector. The connector is attached ¿rmly and may require greater effort to remove. During removal, make sure you do not bend the connector or exert lateral force on the sparking plug. In a worst case scenario, you will destroy the sparking plug and will then have to carry out expensive repairs.
11.3.4 Externally charging and replacing the starter battery Procedure: 1. Remove the left side panel "A" on the hydraulic unit by detaching the mounting clips "B". 2. Starter battery "C" is now visible. First disconnect the negative ("-") and then the positive terminal ("+") on the battery. A B 3. If you would like to charge the starter battery using an external charger, connect the device now. (Read the instruction manual accompanying the charger) If the battery is defective, it must be replaced.
11.4 Maintenance work on mounted hose reel A visual inspection of the ¿tted hoses and couplings is to be carried out after every use or every six months. Components showing obvious signs of damage or leaks must be replaced. If screwed connections start to leak, check whether they are tight ¿rst of all. If the leak continues after the screwed connection has been tightened, the screwed connection is defective and must be replaced.
3. Screw the new extension hoses onto the elbow pieces with a torque of MA = 40 Nm. Do not forget to slide protective hoses "B" back over the screwed connections. The protective hose set must be fitted to the reel! B 4. Roll up the extension hose again. 5. The hydraulic Àuid reservoir must then be ¿lled and the unit vented. 11.4.
Procedure for couplings on hose pairs: 1. First of all, empty the hydraulic reservoir as described in the chapter "Replacing the hydraulic Àuid". 2. Pull the cover back from the couplings. 3. Loosen the union nuts on the hose lines and remove the coupling. CAUTION! As the case may be, make sure that port 'T' / 'T1' of the hose reel is always connected to port 'T' of the mono-coupling. 4.
12. Troubleshooting In the case of defects which directly affect the motor / engine, please consult the separate operating instructions of the motor / engine manufacturer.
Trouble Combustion engine will not start Check Check fuel level in tank Cause Fuel tank empty Solution Top up fuel Electric starter present? Electric starter battery Àat Check fuel line Fault in the fuel line Charge electric starter battery or use pull cord starter Shut down immediately and have repaired by authorised dealer, motor / engine manufacturer or directly by LUKAS Actuate starter button or pull cord starter Check the starter Starter button or pull button and cord starter not engine switch
Trouble The motor / engine is running, but the connected rescue equipment does not move when the valve is actuated. The connected rescue equipment does not move on activation of the valve, or moves only very slowly or unevenly.
Trouble Connected rescue device does not reach its ¿nal position Check Check hydraulic Àuid volume in hydraulic reservoir Connected rescue device does not reach its speci¿c performance data Check the details During the of the rescue functional check: A pressure gauge device installed between the rescue equipment and the hydraulic power pack does not indicate the maximum operating pressure of the equipment.
Trouble Fluid escaping from the hydraulic Àuid reservoir Check Connected device is not yet in base position and Àuid is escaping from the ¿ller screw? Cause Return of the hydraulic Àuid from the rescue device exceeds the reservoir’s maximum quantity when ¿lled.
Trouble It is frequently not possible to couple hose lines Check Leak in the couplings Fluid escaping from hoses or joints Surface of the hoses damaged Hydraulic Àuid escaping from inside the hose drum.
If it is not possible to rectify the malfunctions, inform an authorised LUKAS dealer or the LUKAS Customer Service department immediately! The address of the LUKAS Customer Service Department is: LUKAS Hydraulik GmbH A unit of the IDEX Corporation Weinstrasse 39, D-91058 Erlangen Phone: (+49) 09131 / 698 - 348 Fax.
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.
13.1.2 Type series P 650 SE and P 650 SE - DHR, 230 V / 50 Hz Device type P 650 SE Ref. number 81-53-52 (175760000) 81-54-22 (175762000) Motor type Power P 650 SE - DHR 230V / 50 Hz ; Electric motor [kW] 2,2 [HP] 2.95 -1 Speed [min ] 2960 [rpm.] Max. operating pressure (HP)1) [MPa]3) Max. operating pressure (LP)2) 3) [MPa] 14 [psi.] 2000 Flow rate (HP)1) [l/min] 2 x 0,7 / turbo 1 x 1,4 [gal.-US/min] 2 x 0.2 / turbo 1 x 0.4 Flow rate (LP)2) [l/min] 2 x 2,6 / turbo 1 x 5,0 [gal.
13.1.3 Type series P 650 4E and P 650 4E - DHR Device type P 650 4E P 650 4E - DHR Ref. number 81-53-54 (175780000) 81-53-24 (175782000) Motor type Power Speed 400V / 50 Hz ; Electric motor [kW] 3,5 [HP] 4.7 [min-1] 2980 [rpm.] Max. operating pressure (HP)1) [MPa]3) Max. operating pressure (LP)2) [MPa]3) [psi.] 2000 Flow rate (HP)1) [l/min] 4 x 0,6 / turbo 2 x 1,2 Flow rate (LP)2) [l/min] Max. fill quantity Hydraulic fluid Max. usable quantity Hydraulic fluid 70 [psi.
13.1.4 Type series P 650 SG Device type P 650 SG Ref. number 81-53-51 (175710000) 81-53-50 (175720000) Motor type Power P 650 SG - ES 4-stroke gasoline engine [kW] 4,2 [HP] 5.7 -1 Speed [min ] 3300 [rpm.] Max. operating pressure (HP)1) [MPa]3) Max. operating pressure (LP)2) [MPa]3) [psi.] 2000 Flow rate (HP)1) [l/min] 2 x 0,82 / turbo 1 x 1,7 [gal.-US/min] 2 x 0.2 / turbo 1 x 0.4 Flow rate (LP)2) [l/min] 2 x 3,1 / turbo 1 x 6,1 [gal.-US/min] 2 x 0.82 / turbo 1 x 1.6 Max.
13.1.5 Type series P 650 SG - DHR Device type P 650 SG - DHR Ref. number 81-54-21 (175712000) 81-54-20 (175722000) Motor type Power P 650 SG - ES - DHR 4-stroke gasoline engine [kW] 4,2 [HP] 5.63 -1 Speed [min ] 3300 [rpm.] Max. operating pressure (HP)1) [MPa]3) Max. operating pressure (LP)2) [MPa]3) [psi.] 2000 Flow rate (HP)1) [l/min] 2 x 0,9 / turbo 1 x 1,7 Flow rate (LP)2) [l/min] Max. fill quantity Hydraulic fluid Max. usable quantity Hydraulic fluid Max.
13.1.6 Type series P 650 4G Device type P 650 4G Ref. number 81-53-57 (175730000) 81-53-56 (175740000) Motor type Power P 650 4G - ES 4-stroke gasoline engine [kW] 5,1 [HP] 6.84 -1 Speed [min ] 3600 [rpm.] Max. operating pressure (HP)1) [MPa]3) Max. operating pressure (LP)2) [MPa]3) [psi.] 2000 Flow rate (HP)1) [l/min] 4 x 0,7 / turbo 2 x 1,4 [gal.-US/min] 4 x 0.18 / turbo 2 x 0.37 Flow rate (LP)2) [l/min] 4 x 2,55 / turbo 2 x 5,0 [gal.-US/min] 4 x 0.67 / turbo 2 x 1.3 Max.
13.1.7 Type series P 650 4G - DHR Device type P 650 4G - DHR Ref. number 81-54-27 (175730000) 81-54-26 (175740000) Motor type Power P 650 4G - ES - DHR 4-stroke gasoline engine [kW] 5,1 [HP] 6.84 -1 Speed Max. operating pressure (HP)1) [min ] 3600 [rpm.] [MPa]3) 70 [psi.] 10000 3) Max. operating pressure (LP)2) Flow rate (HP)1) Flow rate (LP)2) [MPa] 14 [psi.] 2000 [l/min] 4 x 0,7 / turbo 2 x 1,4 [gal.-US/min] 4 x 0.18 / turbo 2 x 0.37 [l/min] 4 x 2,55 / turbo 2 x 5,0 [gal.
13.1.8 Type series P 650 SE and P 650 SE - DHR, 230 V / 60 Hz Device type P 650 SE P 650 SE - DHR Ref. number 175750000 175752000 Motor type Power 230V / 60 Hz ; Electric motor [kW] 2,65 [HP] 3.6 -1 Speed [min ] 3540 [rpm.] Max. operating pressure (HP)1) [MPa]3) Max. operating pressure (LP)2) 3) [MPa] 14 [psi.] 2000 Flow rate (HP)1) [l/min] 2 x 0,8 / turbo 1 x 1.6 Flow rate (LP)2) [l/min] Max. fill quantity Hydraulic fluid [l] 5,5 [gal.-US] 1.45 Max.
13.2 Noise emissions (Sound pressure level) Device type P 650 SE P 650 SE P 650 SG P 650 4G P 650 4E und und und und und P 650 SE - P 650 SE - P 650 SG - P 650 4G - P 650 4E DHR (50Hz) DHR (60Hz) DHR DHR DHR No-load operation (measuring distance acc. to EN) [dB(A)] 73 78 82 83 73 Full-load operation (measuring distance acc. to EN) [dB(A)] 80 83 87 87 79 No-load operation (measuring distance acc. to NFPA) [dB(A)] 67 72 76 76 67 Full-load operation (measuring distance acc.
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 ...P6504G, P6504G-ES, P6504G-DHR, P6504G-ES-DHR, type ...81-53-57, 81-53-56, 81-54-27, 81-54-26, maximum working pressure ...700 bar, engine speed ....3600 [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 ȝPa ....
13.3 Sparking plug Sparking plug type: BR6HS (NGK) 13.4 Sparking plug socket Articulated sparking plug socket, size 21 mm 13.5 Fuel Fuel: Lead-free gasoline ROZ 91 to ROZ 98 Max.
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 viscosity range: 10...200 mm²/s Supplied with HM 10 DIN ISO 6743-4. (10…200 cSt.
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WARNING / CAUTION / ATTENTION! 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 dismantled parts properly. LUKAS Hydraulik GmbH A unit of the IDEX Corporation Phone: (+49) 0 91 31 / 698 - 0 Fax.: (+49) 0 91 31 / 698 - 394 e-mail: lukas.info@idexcorp.com www.lukas.
