Operating instructions Rescue equipment P660SG SUPER SILENT 175325085 GB Edition 07.2010 replaces 06.
Contents Page 1. Danger classes 3 2. Product safety 4 3. Proper use 7 4. Unit labelling 7 5. Functional description 8 5.1 General 8 5.2 Motor 9 5.3 Control valve 9 5.4 Pumps 9 5.5 Connection to rescue devices 9 5.6 Connection options 10 6. Connection of the hose lines 10 7. Installation and commissioning 11 7.1 Installation 11 7.2 Commissioning 11 8. Operation 14 8.1 Starting motors 14 8.2 Stopping motors 16 8.3 Controlling the valves 17 8.
1. Danger classes We distinguish between various categories of safety instructions. The table shown below shows you the overview via the assignment of symbols (pictograms) and signal words the concrete danger and the possible consequences.
2. Product safety LUKAS products are developed and produced in order to ensure the best performance and quality with proper use. The safety of the operator is the most important consideration of the product design. In addition, the operating instructions are to help use the LUKAS products safely. In addition to the operating instructions, all generally applicable, statutory and other binding rules for accident prevention and for environmental protection must be heeded and disseminated.
Heed all safety instructions and hazard warnings on the device and in the operating instructions. All safety instructions and hazard warnings on the device are to be kept intact and in a legible condition. Make sure that all safety covers are present on the device and in proper working condition. Any work procedure that detracts from the safety and/or stability of the device should be abandoned! Safety equipment must never be disabled! The maximum permissible operating pressure must not be changed.
In order to prevent re hazard, ensure suf cient ventilation when operating combustion engines and maintain a safety distance of at least 1 m (39.4 in.) to walls and other shields. Damage to electrical components may only be eliminated by a trained quali ed electrician, in compliance with all applicable national and international safety guidelines and regulations. Ensure that the combustion engine motor pumps always sit on a largely level horizontal surface, so that no fuel can leak.
3. Proper use LUKAS hydraulic units are speci cally designed to supply LUKAS rescue equipment with hydraulic uid so that they can be used to rescue victims in the event of accidents in road, rail and air travel as well as in building rescues. The use for the supply of pressure or uid to rescue equipment of other manufacturers is possible, but requires the technical testing and approval of LUKAS on a case-by-case basis.
5. Functional description 5.
In all LUKAS hydraulic units, a motor typically operates a hydraulic pump, which delivers uid from the tank and builds the pressure. The distribution of the uid is then controlled by integrated valves. 5.2 Motor These hydraulic units are equipped with a 4-cycle combustion engine, which is operated with petrol. (refer to chapter "Fuel") 5.
5.6 Connection options The connections for the hydraulic hoses are always provided on the unit. The unit is provided exclusively with monocouplings. 6.
NOTE: We recommend, when ambient temperatures are low and extension hoses / hose reels are used, connecting the coupling halves in a depressurised state because decoupling may otherwise require a very large exertion of force. For dust protection, the supplied dust caps must be reattached. WARNING / CAUTION / ATTENTION! The monocouplings must not be unscrewed and/or the hose lines reversed! 7. Installation and commissioning 7.
Procedure for fuel level: WARNING / CAUTION / ATTENTION! Never add fuel while you are smoking or in the vicinity of naked ames! a) When the tank is empty, ll it with unleaded petrol. b) The fuel level should never exceed the upper edge on the fuel strainer. (see gure below) c) It is essential that the fuel strainer is used on the ller neck.
Procedure for hydraulic uid level: a) Open the uid ller cap and check the hydraulic uid level by looking into the ller pipe (see gure below). If the bottom of the ller pipe is just barely still covered with hydraulic uid, the unit is at the lowest permissible hydraulic uid level. If the hydraulic uid is almost in the angled part of the ller pipe, the maximum permissible ll level has been reached.
5. The unit is now operational. To use it, place it on a suitable, level site! WARNING / CAUTION / ATTENTION! Observe the following: • Remove easily ammable or other hazardous material from the surroundings of the unit! • Install the unit at least 1 m (39.4 in.
3. Set the motor switch to position " " (CHOKE) (if the motor is warm, or the ambient temperature is high, start the motor with the switch in position " " (RUN)). 4. Slowly pull the handle of the recoil starter until it has crossed the compression point (resistance becomes noticeable), allow it to return to the basic position and then pull it through swiftly. 5. After starting, allow the starter handle to return to the basic position, while you continue to hold it in your hand.
8.2 Stopping motors The motor of the unit stops automatically when the fuel tank is empty. If the motor should be stopped before that, the following procedure is required: Flow chart for stopping: 1. Check that all connected rescue devices are in the original position (basic position). 2. Set the two valve switches to "0". Valve switch 3. Set the motor switch to position " Valve switch " (STOP). WARNING / CAUTION! Never touch the hot motor parts; it could cause severe burns.
8.3 Controlling the valves Two switches are provided on the valve. Each switch is assigned to the pressure connection beneath it. By ipping the respective switch, the pressurisation of the corresponding pressure line can be controlled. There are 2 control stages for each switch: 0 = Depressurised circulation (no pressure supply of the hydraulic line) 0 = Pressure supply of the pressure line 8.
Additional measures on the motor for longer storage periods: If the unit will not be used for a period of 6 months or more, the following measures must be taken: Drain plug on • Loosen the fuel line and carefully drain the the carburettor tank. The quality of petrol remaining in the tank deteriorates, and starting the motor becomes more dif cult. • Use a hand pump to drain the fuel from the tank and insert it in the lling port. • Loosen the drain plug on the carburettor. • Replace the motor oil.
Visual inspection Hydraulic unit • are all hydraulic connections still tightened, • generally sealed, no leaks present (oil "sweat" has no effect on the operation), • is damage visible on the motor, hydraulic components or the housing, • are identi cation plate, all control decals, instruction decals, labels and warnings present and legible, • are all covers (e.g.
11. Repairs 11.1 General Service work may only be performed by the device manufacturer or by personnel trained by the device manufacturer and authorized LUKAS dealers. For all components, only original LUKAS replacement parts may be supplied in exchange, as are listed in the spare parts list, because in this way also any required special tools, assembly instructions, safety aspects, tests absolutely must be taken into consideration (see also the chapter "Care and maintenance" for more information).
11.2.3 Replacing the hydraulic uid - Replace the hydraulic uid after approximately 200 uses, however at the latest after three years. - Whenever possible, the replacement of the uid should be carried out when the unit is at the operating state temperature. - The motor must be switched off! - The replaced hydraulic uid must be disposed of properly. Procedure: 1. Place the collection pan under the drain plug for the hydraulic uid of the unit. 2.
11.2.4 Replacing the motor oil - Replace the motor oil after approximately 100 operating hours. - Whenever possible, the replacement of the uid should be carried out when the unit is at the operating state temperature. - The motor must be switched off! - The replaced motor oil must be disposed of properly. Procedure: 1. Place the collection pan under the drain plug for the motor oil of the unit. 2. Loosen the oil ller cap and oil drain plug of the unit and ll uid in the provided collection pan. 3.
11.2.5 Replacing and cleaning the air lter It is very important to maintain the air lter in a good state. Dirt penetrating due to incorrect installation, incorrect maintenance, or unsuitable lter inserts leads to damage and wear on the motor. Always keep the air lter insert clean. Procedure: 1. Unhook the cover and remove the lter insert. 2. Paper insert: In order to clean it, carefully tap it to loosen any dirt and then blow off the dust.
2. If the spark plug is covered with soot, you must remove the soot with a spark plug cleaner or a brush. If the spark plug is irreparably damaged (e.g. due to melt-off of the electrodes), it must be replaced by a new one. 3. Set the gap between the electrodes to 0.6 to 0.7 mm. 0.6 - 0.7 mm 4. Then reinstall the spark plug. 11.3 Repairs To perform the allowed repairs, observe the corresponding spare parts lists with the remarks and drawings illustrated thereon.
12. Troubleshooting Problem Motor does not start Motor runs, but connected rescue device does not move when the valve is actuated Cause Fuel tank empty Lever not set to choke Spark plug socket not attached correctly Remedy Add fuel Set lever to choke Press the spark plug socket rmly onto the spark plug Spark plug dirty Clean the electrodes of the spark plug Spark plug defective Combustion engine defective Replace the spark plug.
Problem Connected rescue device not reaching its limit position Cause Fluid level in the hydraulic tank too low Attention: move the rescue device back into the basic position before adding uid! Usable hydraulic uid quantity of the unit is insuf cient Connected rescue device Max. permissible operating does not achieve its pressure of the pump is power-related performance not reached data Fluid leaks on the hydraulic uid tank (especially at the re ll tap) Remedy Add hydraulic uid up to max.
If the defects cannot be remedied, notify an authorized LUKAS dealer or contact LUKAS Customer Service directly! The address of LUKAS customer service is: LUKAS Hydraulik GmbH Weinstraße 39, Postfach 2560, D-91058 Erlangen D-91013 Erlangen Phone: (+49) 09131 / 698 - 348 Fax.
13. Technical data Because all values are subject to tolerances, there cannot be any differences between the data of your device and the data of the following tables! 13.1 Unit Device type Ref.no. Dimensions lxwxh Motor type Motor power Rotational speed max. operating pressure (HP)1) max. operating pressure (LP)2) Flow rate (HP)1) Flow rate (LP)2) max. ll quantity max. usable quantity P 660 SG 175325000 585 x 300 x 450 23.03 x 11.81 x 17.72 4-stroke gasoline engine 2,1 2.82 [mm] [in.
13.2 Noise emissions Device type Ref.no. idle running (measuring distance: 1m) full load (measuring distance: 1m) idle running (measuring distance: 5m) full load (measuring distance: 5m) P 660 SG 175325000 [dB(A)] 77 [dB(A)] 79 [dB(A)] 69 [dB(A)] 73 13.3 Spark plug Spark plug type: BMR4A (NGK) 13.4 Fuel Fuel: unleaded regular 13.
13.6 Hydraulic uid recommendation Mineral oil DIN ISO 6743-4 for LUKAS hydraulic equipment and others A A Oil temperature range Oil code Viscosity rating -20 .... +55°C HM 10 VG 10 Oil temperature range Oil code Viscosity rating HM 10 VG 10 -4.0 .... +131°F recommended viscosity range: 10...200 mm²/s Remarks Remarks (10…200 cSt.) Supplied with HM 10 DIN ISO 6743-4.
14.
WARNING / CAUTION / ATTENTION! Before connecting devices, make sure that all components used are suitable for the maximum operating pressure of the hydraulic unit! In case of doubts, LUKAS must be consulted directly before connecting the devices! Please properly dispose of all packing materials and removed parts. LUKAS Hydraulik GmbH Phone: (+49) 0 91 31 / 698 - 0 Fax.: (+49) 0 91 31 / 698 - 394 e-mail: lukas.info@idexcorp.com Made in GERMANY P660SG_BA_GB_175325085_0710.
