HURST P 650 Instruction Manual

275710085 EN

Hydraulic power units P 650

(Original instruction manual)

replaces 01.2014

Instruction manual for rescue equipment

Edition 11.2014

Built to extend lives.™

2

3

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

7.2 Start-up 19

8. Operation 20

8.1 Starting the motor/engine 20

8.2 Stopping the motor/engine 21

8.3 Refuelling (combustion engines only) 22

8.4 Controlling the valves 22

8.5 Hose reels 24

8.6 Telescopic carrying handles 26

8.7 Toolholder 27

9. Removing the device / deactivation following operation 32

10. Tests 33

10.1 Recommended inspection intervals 33

10.2 Hydraulic units with combustion engine 34

10.3 Hydraulic units with electric motor 35

10.4 Hose reels 36

Contents Page

4

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 Unit 53

13.2 Noise emissions 60

13.3 Sparking plug 60

13.4 Sparking plug socket 60

13.5 Fuel 60

13.6 Engine oil 61

13.7 Hydraulic fl uid recommendation 61

13.8 Operating and storage temperature range 61

14. EPA Warranty 62

15. Declaration of Conformity 65

16. Notes 66

Contents Page

5

Wear helmet with face protection

Wear safety gloves

Wear safety shoes

Proper recycling

Observe principles of environmental protection

Read and observe operating instructions

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.

1. Hazard classes

Pictogram

Damage /

injury to

Key word Defi nition Consequences

People

DANGER! Immediate danger

Death or major

injury

WARNING!

Potentially

dangerous

situation

Potential death or

major injury

CAUTION!

Less dangerous

situation

Minor or slight

injury

Objects

ATTENTION!

Danger of damage

to objects /

environment

Damage to the

equipment,

damage to the

environment,

damage to

surrounding

materials

- NOTE

Advice for

application and

other important /

useful information

and advice

No injury /

damage to

persons /

environment /

equipment

6

2. Product safety

HURST 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 HURST products.
The generally applicable legal and other binding regulations pertaining to the prevention of
accidents and protection of the environment apply and are to be complied with in addition to
the operating instructions.
The device may only be operated by persons with appropriate training in the safety aspects
of such equipment – otherwise, there is a danger of injury occurring.
We would like to point out to all users that they should carefully read and adhere to the
operating instructions before they use the equipment.
We further recommend that a quali¿ ed instructor train you in the use of the product.

WARNING / CAUTION!

The operating instructions for the hoses, the accessories and the connected
hydraulic equipment must also be observed!

Even if you have already received instructions on how to use the equipment, you should still
read the following safety notes again.

WARNING / CAUTION!

Ensure that the accessories and connected equipment used are suitable for
the maximum operating pressure!

Please ensure that no body
parts or clothing get stuck
between the visibly moving
parts.

Immediately report any
changes that occur (including
changes in operating behavior)
to the appropriate persons/
departments! If necessary,
deactivate the device
immediately and secure
against restart!

Wear protective clothing,
safety helmet with visor, safety
shoes and protective gloves.

Inspect the device for visible
defects or damage before and
after use

It is prohibited to work under
load if this load is lifted
exclusively by hydraulic
equipment. If this work
is absolutely imperative,
additional mechanical supports
must be used.

Check all lines, hoses and
screwed connections for leaks
and externally visible damage,
and repair immediately!
Escaping hydraulic À uid can
cause injuries and ¿ res.

7

In the event of malfunctions,
immediately shut down the
equipment and secure it.
The malfunction is to be
repaired immediately.

Do not carry out any changes
(additions or conversions)
to the equipment without
obtaining prior approval from
HURST.

Observe all safety and danger
notes on the device and in the
operating instructions.

All safety and danger notes
on the device are to be kept
complete and in a legible
condition.

Please ensure that all safety
covers are present on the
equipment and that they
are in proper and adequate
condition.

Any mode of operation which
impairs safety and/or stability
of the device is forbidden!

Safety devices must never be
deactivated!

The maximum operating
pressure set on the equipment
must not be changed!

Before the device is switched
on/started up, and during its
operation, it must be ensured
that nobody is endangered by
the operation of the device.

Comply with all speci¿ ed
dates or dates speci¿ ed in
the operating instructions
pertaining to regular checks /
inspections of the equipment.

When working in the proximity
of live components and
wires, appropriate steps must
be taken to avoid current
transmission or high-voltage
discharge through the device.

Only genuine HURST
accessories and spare parts
are to be used for repairs.

When working with this
equipment or when
transporting it, ensure that you
do not get caught up in the
hose or cable loops and trip.

The build-up of static charge
with the potential consequence
of spark formation is to be
avoided when handling the
device.

When working with
combustion engine pumps,
never touch the motor and
exhaust system, since there is
a risk of burning.

Motor pumps may not be used
in explosion hazard areas!

Combustion engines must
not be used in enclosed
spaces, as there is a danger of
poisoning and/or asphyxiation!

If fuel for combustion engines
is spilled, this fuel must be
removed completely before
starting the motor.

Filling up during operation
of the combustion engine is
strictly prohibited!

8

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.

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.

Damage to electrical
components may only be
repaired by a quali¿ ed
electrician in compliance with
all applicable national and
international safety guidelines
and regulations.

Please ensure that the
combustion engine pumps
are always placed on as À at a
surface as possible in order to
prevent fuel from leaking.

When setting up the units, it
must be ensured that they are
not impaired by the inÀ uences
of extreme temperatures.

The device is ¿ lled with
hydraulic À uid. These hydraulic
À uids can be harmful to your
health if swallowed or if their
vapors inhaled. Direct contact
with the skin is to be avoided
for the same reason. Please
also note that hydraulic À uids
can also have a negative
effect on biological systems.

When working with or storing
the device, ensure that the
function and the safety of the
device are not impaired by the
effects of extreme external
temperatures or that the
device is damaged in any way.
Please note that the device
can also heat up over a long
period of use.

Ensure adequate lighting
when you are working.

Before transporting the
device, always ensure that the
accessories are positioned
such that they cannot cause
an accident.

Always keep these operating
instructions within reach where
the device is used.

Ensure the proper disposal of
all removed parts, leftover oil,
hydraulic À uid and packaging
materials.

9

WARNING / CAUTION / ATTENTION!

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.

Never work when you are overtired or intoxicated!

WARNING / CAUTION!

Should you sustain an injury while working with the hydraulic unit, clean the
wound immediately and seek medical attention!
If hydraulic À uid enters your eye, rinse immediately several times with clear, clean
water and seek medical attention!
You should also seek medical attention after ingesting hydraulic À uid!

10

3. Intended use

You can obtain accessories and replacement parts for the rescue apparatus from your
authorized HURST dealer!

WARNING / CAUTION / ATTENTION!

Always observe the safety notes of these operating instructions with regard to

place of installation and type of installation!

Type P 650 units manufactured by HURST are not explosion-proof!

HURST hydraulic units are specially designed to supply HURST rescue equipment with
hydraulic À uid 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 / À uid to rescue equipment of other manufacturers is
possible, yet requires the technical inspection and approval by HURST in each individual
case.
The P650 power units were not developed for being operated without hoses or devices
(operating time < 15 minutes).

CAUTION!

When selecting a device for connection, remember that the maximum possible
useable volume of the hydraulic À uid is limited.
The maximum total volume of hydraulic À uid required by all connected devices
must not exceed the maximum possible useable volume of the unit!
Due to the limited useable volume, a maximum of 2 rescue rams can be
connected for reasons of safety (only at maximum ¿ ll quantity).
Type R424 cylinders are an exception to the rule, however.

Two of these cylinders should never be coupled and operated
simultaneously!

NOTE:

Always register your hydraulic unit on the HURST website. This is the only way
to guarantee your extended warranty cover.

You must always contact HURST or an authorized dealer before using couplings
from another manufacturer.

CAUTION!

The P 650 power units were not developed for being operated without hoses
or devices (operating time < 15 minutes).

11

-

4. Labelling of the units

P

650 4 G

Coding for

hydraulic units

Type group

Valve variants

Motor variants

DHR

Speci¿ cations

(e.g. DHR = with

integral reels)

Valve variants:

S = Simultaneous mode
4 = 4POWER mode

Motor variants:

E = Electric motor (operation via mains supply)
G = Gasoline engine

The hydraulic pump on all HURST hydraulic units is always operated by a combustion
engine or electric motor. The pump conveys À uid from the reservoir and builds up hydraulic
pressure. The distribution of the À uid is controlled by mounted valves.

Two versions of type P650 unit are available:

1. small frame without reel

2. large frame with mounted reel

The telescopic carrying handles are an optional accessory for the ¿ rst version and can
always be retro¿ tted.
The telescopic carrying handles and the toolholder are an optional accessory for the second
version and can always be retro¿ tted.

5. Functional description

5.1 General information

ES

with electric starter

-

NOTE:

A hose reel is only included with the second version and cannot be retro¿ tted

at a later date!

12

5.2 Structure of the units

1

2

3

4

5

6

7

8

9

10

10

11 12

13

14

14

1515

1 Hydraulic À uid reservoir
2 Gasoline tank
3 Engine with hydraulic

pump

4 Connecting block with

control valves
5 Engine switch
6 Electric starter button
7 Pull cord starter
8 Valve control lever
9 "TURBO" control lever
10 Mono-couplings
11 Hydraulic À uid ¿ ll cap
12 Gasoline ¿ ll cap
13 Frame
14 Side panel
15 Rubber buffer
16 ON/OFF switch for

electric motor
17 Telescopic carrying

handle
(also optionally available

for retro¿ tting)
18 Hose reel
19 Crank handle (hose reel)
20 Lock (hose reel)
21 Hose guide
22 Toolholder

10 21

21

17

18

18

20

19

16

17

22

111217

13

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. In the case of
operation with generators, make sure that voltage À uctuations do not occur, as these have a
direct inÀ uence on the pumping capacity and stability of the hydraulic unit.
The possible operating voltage, the current frequency and the required intensity of current
can be found in the chapter entitled „Technical data".

NOTE:

Not all the technical details of the engine installed in HURST units correspond
to the engine described in the separate operating instructions provided by the
manufacturer. Components such as the gasoline tank have been modi¿ ed to
guarantee the safety of the overall hydraulic unit because the unit is used for
rescue operations.
However, it is important that you observe all safety regulations and operating,
maintenance and storage instructions included in the separate manual
accompanying the engine without fail because they are unaffected by any
adaptations made by HURST.

If the battery discharges completely after a period of inactivity, you must start the unit using
the cord pull starter and allow the unit to operate until almost a complete tank of fuel has
been consumed. The battery will then be fully charged.
If the battery is still not charged after the unit consumes a full tank of fuel, the causes may
include the following:

- the contacts (connector) have come loose and must be connected again.

- the battery is defective and must be replaced.

- the generator or engine is damaged. In this case, contact HURST customer service
directly.

5.3.2 Gasoline engine

These hydraulic units are equipped with a combustion engine driven by the fuel "gasoline /
gasoline".
Units can be ¿ tted with both an electric starter and a pull cord starter, or a pull cord starter
only. It is only possible to determine the unit version from the item number and unit name or
the designation printed on the unit.
The integral generator charges the starter battery automatically while the engine is operating.

NOTE:

Using an extremely long electrical connection cable may reduce the output
resistance and the power supply to the motor. The performance of the motor will
be affected as a result.

14

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. A shift lever gives you the option of supplying hydraulic À uid to both connected
devices simultaneously or supplying double the quantity to one device (= TURBO function).
Supplying double the quantity of À uid increases the operating speed of the connected device.

The hoses and devices are always connected to the connecting block via mono-couplings.
On units with a hose reel, only the connection hoses between the hose reel and connecting
block are screwed in position.

CAUTION!

When operating several pieces of rescue equipment with one unit, ensure that
the usable volume of hydraulic À uid in the reservoir is greater than the maximum
possible operating À uid volume of all connected rescue equipment.

5.4.1 "Simultaneous mode" (SIMO) control valve

This valve enables the connection of two dual-acting hydraulic devices. The valve allows
you to operate two devices simultaneously and independently of one another or supply a
larger quantity of hydraulic À uid to one device. Supplying a larger quantity of hydraulic À uid
increases the operating speed of the relevant device.

There are three switches available. The two smaller switches can be used to depressurize the
individual connections. The large switch is responsible for controlling the TURBO function.

5.4.2 "4POWER mode" control valve

This valve enables the connection of four dual-acting hydraulic devices. The valve allows
you to operate four devices simultaneously and independently of one another or supply a
larger quantity of hydraulic À uid to a maximum of two devices. Supplying a larger quantity of
hydraulic À uid increases the operating speed of the relevant devices. The TURBO function
can only be connected between the points either side of the large switch because the device
connections are linked internally.

There are six switches available. The four smaller switches can be used to depressurize
the individual connections. The large switches are responsible for controlling the TURBO
function.
The switches and connections are labelled to make them easier to assign to one another.

15

HURST hydraulic units are equipped with a double-À ow or four-À ow pump depending on the
type. The pumps are permanently connected to the connecting block.

Double-À ow pump for operation with SIMO valve

Four-À ow 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.

Low-pressure level (LP) = up to 14 MPa*

High-pressure level (HP) = up to 70 MPa*

The changeover from low pressure to high pressure is carried out automatically in the pump.
The maximum pressure is limited by a pressure limiting valve.

5.5 Pumps

*) 1 MPa = 10 bar

5.6 Frame with side parts

A surrounding frame is ¿ tted to all the hydraulic units described here, without exception.
The frame and the side parts are designed to protect the unit from external inÀ uences (e.g.
dirt, damage, etc.), to attach accessories (e.g. toolholders) and as a means of transporting
the unit by the frame itself or the optional carrying handles.
The starter equipment and accelerator cable regulator on units with a combustion engine are
mounted on the frame or side parts.

5.7 Connection to the rescue equipment

Connection with the rescue equipment is via extension hose pairs or hose reels. These are
available in various lengths and colored bend protections.
Different colors distinguish the individual hose lines in a hose pair.

(For specifi c details, please consult the HURST range of accessories or contact your
HURST dealer).

WARNING / CAUTION / ATTENTION!

For reasons of safety, the pressure set on this valve must not be adjusted

(without direct authorization from HURST)!

16

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.
The possibility of rolling up and unrolling the hose allows you to adapt the hose length
accordingly and reduce the amount of unnecessary or potentially dangerous excess hose
lying on the ground.
The extension hose pairs are easier to transport and store when fully rolled up.
Moreover, the hose reels on type P650 units are equipped with a hose guide that facilitates
easier rolling up and unrolling.
The unit is connected to the working equipment via couplings.

CAUTION!

In order to avoid potential losses in pressure, the length of the extension hose
lines must not exceed 30 m!

5.9 Carrying handle

Type P650 HURST hydraulic units can be ¿ tted with optional carrying handles. The P650
can be transported more ergonomically using the carrying handles.

NOTE:

Only 2 of the 4 connections can be connected to the hose reel on type
P 650 4G units.
There are 2 coupling connections located between the two reel drums for the
remaining two connections. The lower of the two connections is extendable to
allow easier coupling. It also engages easily in the end positions.
The switches and connections are labelled to make them easier to assign to one
another.

5.10 Toolholder

Type P650 HURST hydraulic units with a hose reel could be ¿ tted with a toolholder.
The toolholder is usually designed to attach a SP310 spreader and a type S5xx cutter.
Needless to say, it is possible to adapt the mount to accommodate all HURST cutters and
spreaders as well as modify it at a later date.
The toolholder allows you to transport a unit with devices still attached.
You no longer have to detach and store devices separately after use. You only have to wind
the hose lines onto the reels and position the devices on the toolholder again.
Devices secured to the unit do not pose a risk during transport.

17

CAUTION!

When connecting the hose lines / devices, always ensure that the connection
components are not soiled. Clean beforehand if necessary!

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 HURST

directly before connecting the equipment!

6. Connection of the hose lines / devices

Male coupling

Female coupling

Dust protection caps

The hose lines / devices are connected to the hydraulic pump or hose reel via mono-coupling
halves (male and female) without any risk of confusion.

18

B

A

C

C

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.

NOTE:

We recommend connecting the coupling halves in a depressurized state

when working in areas with low ambient temperature and using extension hose
assemblies / hose reels, otherwise the coupling may require the application of a
great deal of force.

For dust protection, the supplied dust caps must be re¿ tted.

Fitting the dust protection caps:

The "A" dust protection caps have two external grooves "B". The dust protection caps must
be inserted in the female coupling in such a way that the grooves can be guided over the "C"
pins. Screw the dust protection caps to the limit stop to ¿ x in the female couplings.

19

7. Set-up and start-up

7.1 Set-up

7.2 Start-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 / À at surface / suf¿ cient distance

from vehicles, loads, sources of ignition, etc.).
HURST units work perfectly at an angle of up to 20°. However, in order to guarantee maximum
safety and À uid withdrawal, they should be operated in as level a position as possible.

Please proceed as follows:

1. First of all, check the À uid levels in the unit.

Top off the À uids to the top of the reservoir to reach maximum level. If possible, the

hydraulic unit should be positioned on a level surface when the À uid levels are checked
and the reservoirs ¿ lled.

CAUTION!

Always ¿ ll fuel and hydraulic À uid into the correct reservoir otherwise the unit
may sustain damage!

2. On hydraulic units with an electric motor, connect the plug to the power supply at this

point.

3. Then vent the hydraulic unit. Set all levers on the control valves to the neutral position

(see chapter "Operation"). The actual venting is carried out in the units in a different
manner, depending on the drive motor:

a) Gasoline engine:

- Detach all connectors from the sparking plugs (on the back of the unit).

- Slowly turn the engine over with the starter rope several times.

- Then replace the sparking plug connector.

b) Electric motor (mains power operation):

- Switch the motor on and then off again after approx. 10 seconds, repeat

this procedure several times. (Before switching back on,

the motor must be at a standstill!)

NOTE:

Before commissioning the unit for the ¿ rst time or after longer periods of inactivity,
the starter battery must be connected and the engine oil checked (units with a
combustion engine)! Replenish the engine oil if necessary!
HURST units are delivered without engine oil for reasons of safety!

20

8. Operation

CAUTION!

The control levers on the hydraulic unit must be shifted to neutral position before
the motor/engine is started to prevent connected hydraulic equipment from

moving unexpectedly.
Levers on units with a Toolholder should only be shifted back after you have
removed the devices from the mount and intend to start work.

8.1 Starting the motor/engine

NOTE:

If the engine refuses to start after several attempts, repeat the procedure
described above with the engine switch set to the "ON" position.

3. When the engine starts, keep hold of the handle on the pull cord starter and allow it to

return to its starting position.

4. Allow the engine to warm up for 20 to 30 seconds and then set the engine switch to the

"ON" position (if previously set to "CHOKE").

Starting procedure:

1. Set the engine switch to the "CHOKE" position

( ) (if the engine is already warm or the ambient
temperature is high, start the engine with the
switch in the "ON" position.)

2. Starting with electric starter:

Press the starter button

Starting with pull cord starter:

Slowly pull the handle on the pull cord starter

beyond the compression point (resistance is felt).
Allow to return to the starting position and pull
again quickly all the way out.

8.1.1 Gasoline engines

Before starting the combustion engines, check that the fuel tank is full and that the engine oil
level is within the permitted tolerances. If necessary, top off the relevant À uid.

This procedure means that the pump can slowly draw À uid in and be well vented. The

hydraulic À uid reservoir is equipped with automatic venting, which means no further
venting measures are required.

4. Check the À uid levels in the reservoirs again. If necessary, top off the À uid.

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.

21

8.2 Stopping the motor/engine

WARNING / CAUTION!

Never touch the hot motor / engine parts: this could result in severe burns!

8.2.1 Gasoline engines

The engine on the unit stops automatically when the fuel tank is empty. However, you should
stop the machine and refuel before this happens.
The following procedure stops the engine manually:

Stopping procedure:

1. Make sure that all connected rescue devices are in base position (starting position).

2. Set the levers on the control valves to neutral position (depressurized).

3. Set the engine switch to the "OFF" position.

8.2.2 Electric motors

Set the levers on the control valves to neutral position (depressurized).
Pressing the ON/OFF switch on the side of the unit switches the engine off again. The illuminated
ring around the switch goes out.
When the engine is switched off, the connected hydraulic pump stops delivering.

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. When using a generator,
you should therefore check to see that it can supply the relevant current strength.

The power supply must be protected by a 25 A fuse minimum.

22

8.4 Controlling the valves

8.4.1 "Simultaneous mode" (SIMO) control valve

Three levers are located on the connecting block of this valve.

CAUTION!

The control levers on the hydraulic unit must be shifted to neutral position

(depressurized) before the motor/engine is started to prevent connected

hydraulic equipment from moving unexpectedly.

There is also a large lever that controls the "TURBO"
function. Shifting the lever to the relevant position allows you
to supply double the quantity of hydraulic À uid to one of the
two connections.
In order to activate the "TURBO" function, both connections
must be pressurized. The "TURBO" function is activated by
turning the large lever towards the connection that requires
double the À uid quantity.

Each of the two small levers is assigned to a pressure port. Actuating
the respective lever regulates the pressure in the corresponding pressure
hose (" ") or depressurizes the connection (" ").

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.

8.3 Refuelling (combustion engines only)

3. Replace the ¿ ll cap on the fuel tank again correctly.

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. Make sure you do not burn yourself on hot engine
components! The cloth used to absorb the spilled fuel must then be washed
and disposed of according to applicable regulations and guidelines!

23

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.

There are also two large levers that control the "TURBO"
function. Shifting the lever to the relevant position allows you
to supply double the quantity of hydraulic À uid to one of the
two connections either side of the lever.
In order to activate the "TURBO" function, both connections
must be pressurized. The "TURBO" function is activated by
turning the large lever towards the connection that requires
double the À uid quantity.

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 depressurizes the connection (" ").

NOTE:

All shift levers must always be moved all the way to their end position.

24

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 "A" through 90° to release the locking brake.
To apply the locking brake, turn knob "A" through approx. 90° until it engages automatically.

8.5.3 Unrolling

Pull the extension hose pair until the required length has unrolled from the hose reel.

CAUTION!

Release the locking brake on the hose reel beforehand to avoid damaging the
reel and the pair of hoses!
When unrolling the hoses, make sure that nobody is standing within the
movement range of the crank handle.

The crank handle should make the hose easier to roll up!
To use the crank handle, pull lever "B", fold outwards through 90° and release so that it
engages.
To fold away the crank handle, pull lever "B", fold inwards through 90° and release so that
it engages.

8.5.2 Crank handle

90°

90°

25

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.

Make sure that the direction of rotation is always the same as shown in the illustration!

Direction of rotation
"Rolling up"

Hose

Elbow piece

Make sure that the pair of extension hoses is always rolled up correctly onto the hose

drum.

We recommend guiding the pair of extension hoses with your hand during the rolling

process. You must always guide the pair of hoses in a perpendicular direction to the reel
axis because of the hose guide attached to the hose reel.

- You must then apply the locking brake on the double hose reels.

CAUTION!

The bend protection on the hoses should only rest lightly on the hose guide
when the hose is rolled up completely.
However, if the hose line is rolled up so far that the bend protection is pressed up
against the hose guide, the following could occur:

- The hose material is stretched and the hose damaged, possibly beyond
repair.

- The couplings, bend protection and hoses may be damaged during
transportation or storage.

26

Always fully extend and secure the carrying handles before using them to transport the unit.
When not in use, always insert and secure the carrying handles to prevent them from
restricting your movement when operating the unit. The handles should also be inserted and
secured when stored to reduce the risk of accident.

Procedure (fi tting the telescopic carrying handles to units without a reel):

1. Remove protective covers "A" using a screwdriver.

2. Insert telescopic carrying handle "B" in the frame and screw in guide sleeve "C".

3. Then slide the telescopic carrying handle all the way in and lock in position.

A

B

C

8.6 Telescopic carrying handles

The hydraulic units could 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. Turn the handles counterclockwise (approx. 1
revolution) to unlock them.

27

8.7 Toolholder

A device must ¿ rst be detached from retaining clip "D" 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.

D

28

Procedure (fi tting and adjusting the toolholder):

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

B

C

D

E

F

G

F

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.

29

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".

One exception is the retainer for type S700 cutters. Bracket "J" must be installed on

mounting block "R" using screws "N" and "O" because of the size of the cutters. Mounting
block "R" is then secured to mounting plate "K" using screws "S".

H

J

K

L

M

N

O

P

Q

R

S

P

Q

N

NOTE:

For type SP 510 and SP 512
spreaders, the lugs on bracket "H"
must be cut off with a knife.

30

4. Mounting plates "G" and "K" are secured to the frame of the unit using screws "T" as
shown in the illustration below.

T

T

T

T

K

G

31

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.

32

On units with a combustion engine, you should drain the fuel from the tank and disconnect
and/or remove the starter battery.
Avoid storing the hydraulic units in a damp environment.

Please observe the regulations in the separate operating instructions for the hose lines.

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.

9. Removing the device / deactivation following operation

CAUTION!

Depending on the size and the weight of the hydraulic unit, it should be transported
to the storage site by one person or several people.

Mono-couplings:

If the connected hose lines have to be dismantled during shut-down, decouple the mono­couplings as described in chapter "Connection of the hose lines". Ensure that you replace
the dust protection caps onto the mono-coupling halves.
Give the hydraulic unit a general clean before placing in storage. If you intend to store
the unit for longer, clean the outside thoroughly and lubricate all mechanical moving parts.

ATTENTION when using units with a combustion engine!

Check that the engine switch is set to "OFF" and remains in that position to
prevent anyone from starting the unit unintentionally!

NOTE:

If your unit is equipped with a hose reel, the hoses must be rolled onto the reels
correctly!

33

10. T ests

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. Also check regularly that all the securing screws are
tightened (if applicable, comply with prescribed tightening torques)

CAUTION!

Clean off any dirt before checking the equipment!

WARNING / CAUTION / ATTENTION!

In order to carry out testing, maintenance and repair work, tools appropriate for
the job and personal protecting equipment are essential. (use protective shields
if required).

HURST offers a suitable test kit for the functional check of the hydraulic units.

(For specifi c details, please consult the HURST range of accessories or contact your
HURST dealer).

10.1 Recommended inspection intervals

10.1.1 Visual inspection

A visual inspection is to be carried out after every use or every six months.

34

Visual inspection

Hydraulic units

• All hydraulic connections are still tightened

• General tightness, no leakage (sweated oils do not have any inÀ uence on the function)

• Obvious damage on the motor/engine, connecting blocks or frame

• Obvious damage to the hydraulic system and/or gasoline tank,

• Side panels present and securely ¿ tted

• Type plate, all activation plates, signs, identi¿ cation marks and warning labels are present

and legible

• All covers (e.g. exhaust deÀ ector) are present and undamaged

• All heat protection mats on the reservoirs are present and undamaged,

• Minimum gap of 10 mm between the reservoirs and hot motor/engine components

• Liquid levels are within the speci¿ ed tolerances

• Starters are in proper working order and undamaged

• Electric cables are fully functional and undamaged

• Electric starter battery is fully functional and undamaged

• Couplings must be easy to couple

• Dust protection caps must be available

• All necessary accessories (such as sparking plugs, plug spanner and fuel canister) must

be present.

• Toolholder (if available) is undamaged and fully functional

• Carrying handles (if available) are undamaged and fully functional

10.2 Hydraulic units with combustion engine

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.

Should either of the above occur several times within a month or the maximum pressure
is not reached during the functional check, contact HURST customer service immediately.
See the chapter "Troubleshooting" for contact details.

10.1.2 Functional check

35

Functional check

• No suspicious noises

• Starter fully functional

• Engine switch fully functional

• Test for maximum load

(Recommendation: use the HURST test kit, including testing instructions, for the functional

check).

10.3 Hydraulic units with electric motor

Visual inspection

Hydraulic units

• All hydraulic connections are tightened

• General tightness, no leakage (sweated oils do not have any inÀ uence on the function)

• Obvious damage to the motor/engine, valve blocks or casing

• Side panels present and securely ¿ tted

• Type plate, all activation plates, signs, identi¿ cation marks and warning labels are present

and legible

• All covers (e.g. fan cover) are present and undamaged

• Liquid levels are within the speci¿ ed tolerances

• ON/OFF switch in proper working order, undamaged

• Couplings must be easy to couple

• Dust protection caps must be available

• All electrical attachments (such as cables and plugs) must be present and undamaged

• Toolholder (if available) is undamaged and fully functional

• Carrying handles (if available) are undamaged and fully functional

Functional check

• No suspicious noises

• Test for maximum load

(Recommendation: use the HURST test kit, including testing instructions, for the functional

check).

36

11. Maintenance and repair

11.1 General information

10.4 Hose reels

Visual inspection

Hose reel

• General tightness (no leaks)

• Hose drums rotate easily

• All ¿ xing screws are present and tightened

• Frame and drum undamaged

• Crank handle present, undamaged and fully functional

• Locking brake on double hose reel present and fully functional

• All signs present and legible

Hoses

• Visual inspection for visible damage and leaks

• Check age of hose (replace after 10 years at the latest)

• Hose connection on mounted reel secure and not leaking

• Couplings must be easy to couple

• Dust caps ¿ tted

Functional check

• Extension hose pairs unroll and roll up smoothly.

• No suspicious noises

HURST type P 650 hydraulic units have an extremely complex design but require minimal

maintenance work. Maintenance work does not require special training, but knowledge

on operating the unit, statutory safety regulations and handling all the necessary tools are
basic requirements.

CAUTION!

Do not exert excess force when performing maintenance work on the unit as this
may damage components or compromise the operational safety of the unit

Due to the complex design, repair work on the actual hydraulic unit must always

be performed by the equipment manufacturer, personnel trained by the equipment
manufacturer or authorized HURST dealers.

WARNING / CAUTION / ATTENTION!

During maintenance and repair work, it is essential to wear protective clothing
since equipment can still be pressurized even when it is not in operation.

During the work, ensure that all components are particularly clean, since dirt
can damage the unit!

37

CAUTION!

Since HURST 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 HURST service training,

- you have the express permission of HURST Customer Service (after request,
veri¿ cation that permission may be granted. Veri¿ cation required in each
individual case!)

When cleaning units and equipment, note that no cleaning agent may be used
that has a pH value outside the range 5 - 8!

CAUTION!

Attention must be paid to ensuring that no operating À uids can escape from
units with combustion engines during repair work!

11.2 Maintenance work on the hydraulic unit

11.2.1 Cleaning instructions

The outside of the device must be cleaned from time to time (not the electrical contacts)
and the metallic surfaces (not the electrical contacts) treated with a suitable agent to

protect against corrosion.

(In case of doubt, contact your authorized HURST dealer or HURST directly!)

11.2.2 Function and load test

If there is any doubt regarding the safety or reliability of the equipment, a function and load
test must also be performed.
HURST offers appropriate test equipment.

11.2.3 Replacing the hydraulic fl uid

- Replace the hydraulic À uid once a year at the latest

- The À uid should be replaced when it is warmed up.

- The motor must be switched off!

- The old hydraulic À uid must be disposed of properly.

38

A

B

C

4. Re¿ t components "A" and "C" in the reverse order.

5. Fill fresh hydraulic À uid into the reservoir through the ¿ ller neck and then close off the
neck with ¿ ll cap "B".

6. Finally, the unit must be vented as described in the chapter entitled "Start-up".

Procedure:

1. Place the unit on a slightly raised base so that the drain screw for the hydraulic À uid is
easy to access.

2. Place a suitable container under drain screw "A".

3. Open reservoir ¿ ll cap "B", remove drain screw "A" and seal ring "C", and allow the
hydraulic À uid to drain into the container provided.

11.2.4 Replacing signs

All damaged and/or illegible signs (safety notices, type plate etc.) must be replaced.

Procedure:

1. Remove damaged and/or illegible labels.

2. Clean surfaces with industrial alcohol.

3. Af¿ x new signs.

Ensure that you attach the signs in the correct position. If this is no longer known, you should
ask your authorized HURST dealer or contact HURST directly.

39

NOTE:

The ¿ rst oil change must take place after 20 operating hours and the next oil
change after 100 hours.

Use a standard articulated sparking plug socket spanner (21 mm) to remove the
sparking plug.
A straight / ¿ xed sparking plug socket would damage or break off the sparking
plug!

(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. Change more frequently when operating the unit in a dirty or
dusty environment.

Perform the following maintenance work every 200 operating hours:

• Adjust the electrode gap on the sparking plug

• Clean the fuel ¿ lter

Perform the following maintenance work every 500 operating hours:

• Replace the sparking plug and ¿ lter element

• Clean or adjust the carburetor, valve clearance, valve seat and cylinder head.

Perform the following maintenance work every 1000 operating hours or every 2 years:

• Check the starter

• Inspect the engine/motor for damage

• Replace the fuel line.

11.3 Additional maintenance work on units with a combustion
engine

40

Air ¿ lter

11.3.1 Changing and cleaning the air fi lter

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. Paper insert:

To clean, tap gently to loosen the dirt and then blow off the dust. Never use oil! Clean the

paper insert every 50 operating hours and replace every 200 hours or once a year.

4. Urethane foam:

Wash out the insert with fresh water. Squeeze out the water and dry the insert. (DO NOT

WRING OUT!!)

5. Then re¿ t the ¿ lter.

41

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.

3. Remove the sparking plug from the engine using a 21 mm articulated sparking plug socket

for sparking plugs.

4. Remove any soot on the sparking plug using a sparking plug cleaning agent or a brush.

If the sparking plug is damaged beyond repair (e.g. electrodes burnt), it must be replaced
with a new one.

5. Set the gap between the electrodes to 0.6 - 0.7 mm.

6. Then re¿ t the sparking plug.

0.6 - 0.7 mm

Sparking plug

Sparking plug
connector

11.3.3 Changing the engine oil and engine fi lter

Please refer to the separate operating instructions provided by the engine manufacturer for
information on changing the engine oil and the engine ¿ lter.

42

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.

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.

Loosen attachment belt "D" and remove the
battery. When replacing the battery, make sure
that you insert the new battery as shown in the
illustration.

The unit is assembled in reverse order.

B

A

CD

43

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.
Hose lines will age over time and must be replaced according to statutory regulations.
If there are no applicable statutory regulations, the hoses must be replaced after 10 years

at the latest. (Read the separate operating instructions for the hoses.)

11.4.1 Replacing the extension hose lines

Procedure:

1. First of all, empty the hydraulic reservoir
as described in the chapter "Replacing the
hydraulic À uid".

2. Unroll extension hoses "A". Slide protective
hoses "B" over elbow piece "C", leaving
the screwed connection uncovered.
Then unscrew the hoses.

C

A

B

44

3. Screw the new extension hoses onto the elbow
pieces with a torque of

M

A

= 40 Nm. Do not forget to slide protective hoses

"B" back over the screwed connections.

The protective hose set must be
fi tted to the reel!

B

4. Roll up the extension hose again.

5. The hydraulic À uid reservoir must then be ¿ lled and the unit vented.

11.4.2 Mono-couplings

The mono-couplings must be replaced if:

- there is external damage,

- the lock does not function correctly,

- hydraulic À uid continues to leak in a coupled/uncoupled state.

WARNING / CAUTION / ATTENTION!

Never repair couplings: they must be replaced with genuine HURST parts!

Procedure for couplings on the valve block:

1. First of all, empty the hydraulic reservoir as described in the chapter "Replacing the

hydraulic À uid".

2. Remove the screwed connections on the coupling.

3. Remove the couplings and seals underneath

4. Place the new coupling on the valve block together with the seals.

5.

Secure the couplings again using the screws and tighten these to a torque of MA = 40 Nm.

6. The hydraulic À uid reservoir must then be ¿ lled and the unit vented.

45

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. Position the new coupling and tighten the union nuts on the hose lines to a torque of

M

A

= 40 Nm and push the cover back over the couplings.

Procedure for couplings on hose pairs:

1. First of all, empty the hydraulic reservoir as described in the chapter "Replacing the

hydraulic À uid".

2. Pull the cover back from the couplings.

5. The hydraulic À uid reservoir must then be ¿ lled and the unit vented.

46

12. T roubleshooting

In the case of defects which directly affect the motor / engine, please consult the separate
operating instructions of the motor / engine manufacturer.

Trouble Check Cause Solution

Electric motor
does not operate
when the switch is
actuated or does
not operate at full
power

Check the
connection cable
on the electric
motor

Power cable not
connected

Connect power cable
correctly

Defect on connection
cable

Shut down immediately
and have repaired by
authorized dealer, motor
/ engine manufacturer or
directly by HURST

Extension cable
or cable drum
used?

Cable not completely
uncoiled

Uncoil the power cable
completely

Cable losses in
extension cable or
cable drums too great
(electrical resistance)

Use a different suitable
extension cable or cable
drum.

Electric motor
connected
to a suitable
accumulator?

Battery À at Charge battery
Electric motor

not suitable for
accumulator operation

Connect the motor to a
different suitable power
supply

Electric safety
device in power
supply has
triggered

Power supply not
suitable for electric
motor

Connect the motor to a
different suitable power
supply

Electric safety device
in power supply has
triggered although it is
suitable for operation
of the motor.

Safety device too low,
use a different fuse.

Are all valves
depressurized
(base position)?

Electric motor
defective or
overloaded due to
another defect in the
unit

Shut down immediately
and have repaired by
authorized dealer, motor
/ engine manufacturer or
directly by HURST

47

Trouble Check Cause Solution

Combustion
engine will not
start

Check fuel level
in tank

Fuel tank empty Top off fuel

Electric starter
present?

Electric starter battery
À at

Charge electric starter
battery or use pull cord
starter

Check fuel line Fault in the fuel line Shut down immediately

and have repaired by
authorized dealer, motor
/ engine manufacturer or
directly by HURST

Check the starter
button and
engine switch

Starter button or pull
cord starter not
actuated

Actuate starter button or
pull cord starter

Engine switch not set
to “Choke”

Set engine switch to
“Choke”

Hydraulic unit or
motor / engine
not suitable
for the working
environment

Ambient temperature
too low

For the solution,
consult the separate
operating instructions
of the engine / motor
manufacturer.

Use a different hydraulic
or operating À uid that
is suitable for the
corresponding ambient
temperatures (see
chapter “Technical data”)

Not enough oxygen in
the air because of the
altitude of application
location of the
hydraulic motor

Use a different more
suitable hydraulic unit.

Have the engine set to
the altitude of application
by an authorized
dealer, motor / engine
manufacturer or HURST
directly (only if the unit is
to be used frequently at
this altitude).

Check air ¿ lter Air ¿ lter contaminated Clean or replace the air

¿ lter.

Are all valves
depressurized
(base position)?

Combustion
engine defective or
overloaded due to
another defect in the
unit

Have repaired by
authorized dealer, motor
/ engine manufacturer or
directly by HURST

48

Trouble Check Cause Solution

The motor / engine
is running, but
the connected
rescue equipment
does not move
when the valve is
actuated.

Check hose line Hose line not

connected properly or
is damaged

Inspect the connection
of the hose line and,
if necessary, reconnect

Check the
position of the
valve lever on the
pump block of the
hydraulic unit

Valve not switched to
pressurize the supply
line.

Switch valve to
pressurize the supply
line.

Defective pump unit Have repaired by

authorized dealer or
directly by HURST

Connect another
device and
check whether it
functions when
the valve is
actuated

The previously
connected device is
defective.

For the solution,
consult the operating
instructions for the
connected device

Mono-coupling
(female) defective

Replace mono-coupling
(female)

The connected
rescue equipment
does not move on
activation of the
valve, or moves
only very slowly or
unevenly.

Connect another
device and
check whether it
functions when
the valve is
actuated

The previously
connected device is
defective.

For the solution,
consult the operating
instructions for the
connected device

Check the
position of the
valve lever on the
pump block of the
hydraulic unit

Pressure relief on
the unit is still active
(circulation at static
pressure)

Check the switching
positions of the
valve lever(s) and,
if necessary, reset
(as far as the ¿ nal
position)

Defective pump unit Have repaired by

authorized dealer or
directly by HURST

Air in hydraulic system Vent the hydraulic

system

Mono-coupling
(female) defective

Replace mono-coupling
(female)

49

Trouble Check Cause Solution

Connected rescue
device does not
reach its ¿ nal
position

Check hydraulic
À uid volume
in hydraulic
reservoir

Insuf¿ cient À uid in the
hydraulic reservoir

Top off hydraulic À uid to
the maximum ¿ lling level

Caution! Before
topping off fl uid the
rescue equipment
must be returned to
the base position!

Usable hydraulic À uid
volume of the unit is
insuf¿ cient

Use a different rescue
device with a required
quantity below the
maximum usable
quantity of the unit

Connected rescue
device does not
reach its speci¿ c
performance data

Maximum permitted
operating pressure
of the pump is not
reached

Have the pressure
limiting valve reset or
repaired by authorized
dealer or directly by
HURST

Defective pump block Have repaired by

authorized dealer or
directly by HURST

Connected device is
defective

For the solution,
consult the operating
instructions for the
connected device

During the
functional check:
A pressure gauge
installed between
the rescue
equipment and
the hydraulic
power pack does
not indicate
the maximum
operating pressure
of the equipment.

Check the details
of the rescue
device

The operating pressure
of the connected
rescue device is
locked internally

No repair or fault
recti¿ cation required

Connected rescue
device is defective

Consult the separate
operating manual for
the connected rescue
device

Hydraulic unit
defective

Have repaired by
authorized dealer or
directly by HURST

50

Trouble Check Cause Solution

Fluid escaping
from the hydraulic
À uid reservoir

Connected
device is not yet
in base position
and À uid is
escaping from the
¿ ller screw?

Return of the hydraulic
À uid from the rescue
device exceeds the
reservoir’s maximum
quantity when ¿ lled.

Reduce the ¿ ll level
in the hydraulic
À uid reservoir to the
"minimum" mark, move
the device to base
position and then ¿ ll
the À uid back up to
"maximum"

Fluid leaking from
a different place?

Leak on reservoir,
lines or seals

Replace defective
components or have
repaired by authorized
dealer or directly by
HURST

Leaking À uid
between engine
and À ange bearing

Radial shaft seal
on the drive shaft is
defective

Have repaired by
authorized dealer or
directly by HURST

Hydraulic À uid
milky and cloudy

Water / condensation
in the system

Immediately replace
hydraulic À uid

Hose line cannot
be coupled

Pressure too high (e.g.
caused by excessive
ambient temperature)

Switch valve block to
circulation at static
pressure

Coupling defective Coupling must be

replaced immediately

Impossible to
retract or extend
carrying handles.

Carrying handles are
still locked

Unlock carrying handles
and extend.

Carrying handles or
frame defective

Replace the carrying
handles or frame.

Impossible to lock
or unlock carrying
handles

Carrying handles or
frame defective

Replace the carrying
handles or frame.

Hose reel does
not turn

Locking brake still
applied

Release locking brake

Hose reel defective Have repaired by

authorized dealer or
directly by HURST

Impossible to
attach equipment
to the toolholder

Toolholder set
incorrectly

Adjust the toolholder
to accommodate the
device.

Toolholder defective Replace toolholder.

51

Trouble Check Cause Solution

It is frequently not
possible to couple
hose lines

Hydraulic À uid not
adapted to the
application situation

Hydraulic À uid must be
replaced (see chapter
"Recommended
hydraulic À uids")

Coupling defective Coupling must be

replaced immediately

Leak in the
couplings

Coupling defective Coupling must be

replaced immediately

Fluid escaping
from hoses or
joints

Leak, possible damage Replace hoses

Surface of the
hoses damaged

Mechanical damage
or contact with
aggressive agents

Replace hoses

Hydraulic À uid
escaping from
inside the hose
drum.

Extension hose
pairs damaged?

Hose lines defective. Replace hoses

Screwed
connection on the
hose lines tight?

Connection between
hose lines and elbow
pieces not tight
enough.

Tighten the screwed
connections between
the hose lines and elbow
pieces.

Screwed
connection
between elbow
piece and shaft
leaking?

Defective elbow piece
or seal

Replace the elbow piece
or seal

Defective shaft Repair of fault by

authorized dealer,
specially trained HURST
staff or directly by
HURST

Hydraulic À uid
escaping from
the connections
between the
connection hoses
and reel shaft

Connection
hoses damaged?

Hose lines defective. Replace hoses

Screwed
connection on the
hose lines tight?

Hose lines or male
couplings not tight
enough.

Tighten the screwed
connections on the hose
lines or male couplings.

Leak between
male coupling
and shaft?

Male coupling not tight
enough

Tighten screwed
connection.

Seal between male
coupling and shaft
defective?

Replace seal.

Male coupling
defective

Replace male coupling

Connection
between hub and
shaft leaking

Seal between hub and
shaft defective.

Repair of fault by
authorized dealer,
specially trained HURST
staff or directly by
HURST

52

If it isn’t possible to rectify the malfunctions, inform an authorized HURST dealer or the
HURST customer service department immediately!
The address for the HURST customer service department is:

HURST

JAWS OF LIFE, INC

A Unit of IDEX Corporation

711 N. Post Road
Shelby, NC 28150 USA

Phone: [phone]
Fax: [phone]
e-mail: [email protected]

53

13. T echnical data

NOTE:

The following tables contain only the technical data required for standard
acceptance.
Additional data concerning your unit can be obtained from HURST on request.
The restriction for the maximum ¿ ll quantity of the hydraulic reservoir is calculated
from the "operability in inclined position" speci¿ cations in the relevant standards.

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.

13.1 Unit

13.1.1 Basic unit dimensions

Units without hose reel:

Units with hose reel:

445 mm

17.5 in.

485 mm

19.1 in.

440 mm

17.3 in.

mm [in.]

54

1)

HP

= High pressure

2)

LP = Low pressure

3)

1MPa = 10 bar

13.1.2 Type series P 650 SE and P 650 SE - DHR

Device type P 650 SE P 650 SE - DHR
Ref. number 275750000 275752000
Motor type 230V / 60 Hz ; Electric motor

Power

[kW] 2.65

[HP] 3.55

Speed

[min

-1

]

3540

[rpm.]

Max. operating
pressure

(HP)

1)

[MPa]

3)

70

[psi.] 10000

Max. operating
pressure

(LP)

2)

[MPa]

3)

14

[psi.] 2000

Flow rate

(HP)

1)

[l/min] 2 x 0.8

[gal.-US/min] 2 x 0.2

Flow rate

(LP)

2)

[l/min] 2 x 3.0

[gal.-US/min] 2 x 0.8

Max. fi ll quantity

Hydraulic fl uid

[l] 5.5

[gal.-US] 1.45

Max. usable
quantity

Hydraulic fl uid

[l] 4.8

[gal.-US] 1.27

Weight (incl. 4.3 l
hydraulic fl uid)

[kg] 41.0 76

[lbs.] 90.4 167.6

Starting current [A] 32
Valve typ Simultaneous operation
Hose reel NO YES

Max. number of device
connections

2

55

1)

HP

= High pressure

2)

LP = Low pressure

3)

1MPa = 10 bar

13.1.3 Type series P 650 SG

Device type P 650 SG P 650 SG - ES
Ref. number 275710000 275720000
Motor type 4-stroke gasoline engine

Power

[kW] 4.2

[HP] 5.63

Speed

[min

-1

]

3300

[rpm.]

Max. operating
pressure

(HP)

1)

[MPa]

3)

70

[psi.] 10000

Max. operating
pressure

(LP)

2)

[MPa]

3)

14

[psi.] 2000

Flow rate

(HP)

1)

[l/min] 2 x 0.9

[gal.-US/min] 2 x 0.24

Flow rate

(LP)

2)

[l/min] 2 x 3.1

[gal.-US/min] 2 x 0.82

Max. fi ll quantity

Hydraulic fl uid

[l] 5.5

[gal.-US] 1.45

Max. usable quantity

Hydraulic fl uid

[l] 4.8

[gal.-US] 1.27

Max. fi ll quantity

gasoline

[l] 1.65

[gal.-US] 0.44

Weight (incl. gasoline
and 4.3 l hydraulic fl uid)

[kg] 38 43.5

[lbs.] 83.8 95.9

Valve typ Simultaneous operation
Max. number of device connections 2
Additional series equipment Electric starter

56

1)

HP

= High pressure

2)

LP = Low pressure

3)

1MPa = 10 bar

13.1.4 Type series P 650 SG - DHR

Device type P 650 SG - DHR P 650 SG - ES - DHR
Ref. number 275712000 275722000
Motor type 4-stroke gasoline engine

Power

[kW] 4.2

[HP] 5.63

Speed

[min

-1

]

3300

[rpm.]

Max. operating pressure

(HP)

1)

[MPa]

3)

70

[psi.] 10000

Max. operating pressure

(LP)

2)

[MPa]

3)

14

[psi.] 2000

Flow rate

(HP)

1)

[l/min] 2 x 0.9

[gal.-US/min] 2 x 0.24

Flow rate

(LP)

2)

[l/min] 2 x 3.1

[gal.-US/min] 2 x 0.82

Max. fi ll quantity

Hydraulic fl uid

[l] 5.5

[gal.-US] 1.45

Max. usable quantity

Hydraulic fl uid

[l] 4.8

[gal.-US] 1.27

Max. fi ll quantity

gasoline

[l] 1.65

[gal.-US] 0.44

Weight (incl. gasoline
and 4.3 l hydraulic fl uid)

[kg] 73 78.5

[lbs.] 161 173

Valve typ Simultaneous operation
Max. number of device connections 2
Additional series

equipment

- Electric starter

57

13.1.5 Type series P 650 4E

1)

HP

= High pressure

2)

LP = Low pressure

3)

1MPa = 10 bar

Device type P 650 4E
Ref. number 275780000
Motor type 240V / 60 Hz ; Electric motor

Power

[kW] 4

[HP] 5.36

Speed

[min

-1

]

3540

[rpm.]

Max. operating pressure (HP)

1)

[MPa]

3)

70

[psi.] 10000

Max. operating pressure (LP)

2)

[MPa]

3)

14

[psi.] 2000

Flow rate (HP)

1)

[l/min] 4 x 0.75

[gal.-US/min] 4 x 0.2

Flow rate (LP)

2)

[l/min] 4 x 2.6

[gal.-US/min] 4 x 0.69

Max. fi ll quantity

Hydraulic fl uid

[l] 5.5

[gal.-US] 1.45

Max. usable quantity

Hydraulic fl uid

[l] 4.8

[gal.-US] 1.27

Weight

(incl. 5.5 l hydraulic fl uid)

[kg] 58.0

[lbs.] 128

Starting current [A] 60
Valve typ 4POWER
Max. number of device connections 4

58

13.1.5 Type series P 650 4G

1)

HP

= High pressure

2)

LP = Low pressure

3)

1MPa = 10 bar

Device type P 650 4G P 650 4G - ES
Ref. number 275730000 275740000
Motor type 4-stroke gasoline engine

Power

[kW] 5.1

[HP] 6.84

Speed

[min

-1

]

3600

[rpm.]

Max. operating
pressure

(HP)

1)

[MPa]

3)

70

[psi.] 10000

Max. operating
pressure

(LP)

2)

[MPa]

3)

14

[psi.] 2000

Flow rate

(HP)

1)

[l/min] 4 x 0.7

[gal.-US/min] 4 x 0.18

Flow rate

(LP)

2)

[l/min] 4 x 2.55

[gal.-US/min] 4 x 0.67

Max. fi ll quantity

Hydraulic fl uid

[l] 5,5

[gal.-US] 1.45

Max. usable quantity

Hydraulic fl uid

[l] 4.8

[gal.-US] 1.27

Max. fi ll quantity

gasoline

[l] 1.65

[gal.-US] 0.44

Weight (incl. gasoline
and 5.5 l hydraulic fl uid)

[kg] 45 50.5

[lbs.] 99.2 111

Valve typ 4POWER
Max. number of

device connections

4

Additional series
equipment

Electric starter

59

13.1.6 Type series P 650 4G - DHR

1)

HP

= High pressure

2)

LP = Low pressure

3)

1MPa = 10 bar

Device type P 650 4G - DHR P 650 4G - ES - DHR
Ref. number 275732000 275742000
Motor type 4-stroke gasoline engine

Power

[kW] 5.1

[HP] 6.84

Speed

[min

-1

]

3600

[rpm.]

Max. operating
pressure

(HP)

1)

[MPa]

3)

70

[psi.] 10000

Max. operating
pressure

(LP)

2)

[MPa]

3)

14

[psi.] 2000

Flow rate

(HP)

1)

[l/min] 4 x 0.7

[gal.-US/min] 4 x 0.18

Flow rate

(LP)

2)

[l/min] 4 x 2.55

[gal.-US/min] 4 x 0.69

Max. fi ll quantity

Hydraulic fl uid

[l] 5.5

[gal.-US] 1.45

Max. usable
quantity

Hydraulic fl uid

[l] 4.8

[gal.-US] 1.27

Max. fi ll quantity

gasoline

[l] 1.65

[gal.-US] 0.44

Weight (incl.
gasoline and 5.5 l
hydraulic fl uid)

[kg] 83.5 89

[lbs.] 184.1 196.2

Valve typ 4POWER
Max. number of device

connections

4

Additional series equipment Electric starter

60

13.2 Noise emissions

13.3 Sparking plug

13.5 Fuel

Sparking plug type: BR6HS (NGK)

Fuel: Lead-free gasoline

ROZ 91 to ROZ 98
Max. permissible bioethanol
content: 10%

Device type

P 650 S E P 650 S G P 650 4 G P 650 4 E

and and and

P 650 S E -

DHR

P 650 S G -

DHR

P 650 4 G -

DHR

No-load operation

(measuring distance 1 m)

[dB(A)] 80 82 83 78

Full-load operation

(measuring distance 1 m)

[dB(A)] 83 87 87 83

No-load operation

(measuring distance 4 m)

[dB(A)] 72 76 76 72

Full-load operation

(measuring distance 4 m)

[dB(A)] 78 81 81 74

13.4 Sparking plug socket

Articulated sparking plug socket, size 21 mm

61

13.7 Hydraulic fl uid recommendation

13.8 Operating and storage temperature range

Mineral oil DIN ISO 6743-4 for HURST 10K hydraulic equipment and others

Oil temperature range Oil code Viscosity rating Remarks

A -20 .... +55°C HM 10 VG 10

Oil temperature range Oil code Viscosity rating Remarks

A

-4.0 .... +131°F HM 10 VG 10

recommended viscosity range: 10...200 mm²/s (10…200 cSt.)

Supplied with HM 10 DIN ISO 6743-4.

CAUTION!

You must always contact your local authorized HURST dealer or HURST directly
before using hydraulic À uid from other manufacturers.

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

not in operation)

[°C] /

[°F] -30 … +60 -22 … +140

13.6 Engine oil

62

14. EP A Warranty

Emission Control Warranty Statement

FEDERAL EVAPORATIVE EMISSIONS COMPONENT
DEFECT WARRANTY

EMISSIONS COMPONENT DEFECT WARRANTY COVERAGE - This emission warranty is

applicable in all States, except the State of California.

Hurst Jaws of Life at 711 North Post Rd. Shelby, NC. 28150, warrant(s) to the initial retail

purchaser and each subsequent owner, that this Nonroad engine (herein “engine”) has been
designed, built, and equipped to conform at the time of initial sale to all applicable regulations
of the U.S. Environmental Protection Agency (EPA), and that the engine is free of defects
in materials and workmanship which would cause this engine to fail to conform with EPA
regulations during its warranty period.

For the components listed under PARTS COVERED, the service dealer authorized by Hurst
Jaws of Life will, at no cost to you, make the necessary diagnosis, repair, or replacement

necessary to ensure that the engine complies with applicable U.S. EPA regulations.

EVAPORATIVE EMISSISON COMPONENT DEFECT WARRANTY PERIOD

The warranty period for this engine begins on the date of sale to the initial purchaser and

continues for a period of 2 years.

EVAPORATIVE PARTS COVERED

Listed below are the parts covered by the Emission Components Defect Warranty. Some of
the parts listed below may require scheduled maintenance and are warranted up to the ¿ rst
scheduled replacement point for that part.

(1) Fuel Line
(2) Fuel Line Fittings
(3) Clamps
(4) Fuel Tank
(5) Fuel Cap

REPLACEMENT PARTS DISTRIBUTION CENTER

Replacement parts are provided to the market upon request by the customers. Replace-

ment parts distribution center is located at Hurst Jaws of Life at 711 North Post Rd. Shel-

by, NC. 28150. If you have a question regarding your replacement part, you should contact

Customer Service. at (800.537.2659)

([email protected])

OBTAINING WARRANTY SERVICE

To obtain warranty service take your engine to the nearest authorized Hurst Jaws of Life

63

service dealer. Bring your sales receipts indicating date of purchase for this engine. The

service dealer authorized by Hurst Jaws of Life will perform the necessary repairs or

adjustments within a reasonable amount of time and furnish you with a copy of the repair

order. All parts and accessories replaced under this warranty become the property of Hurst

Jaws of Life.

Hurst Jaws of Life HONOR WARRANTY CLAIMING

For owners located more than 100 miles from an authorized service center, the following

will be provided to those applicable owners. (excluding the states with high-altitude areas)

* Hurst Jaws of Life will either pay for the shipping costs of replacement parts to

and from an authorized service center.

* Or Hurst Jaws of Life will provide for a service technician to come to the owner to

make the warranty repair.

* Or Hurst Jaws of Life will pay for the repair to be made at a local non-authorized

service center.

WHAT IS NOT COVERED

* Conditions resulting from tampering, misuse, improper adjustment (unless they were

made by the service dealer authorized by Hurst Jaws of Life during a warranty

repair), alteration, accident, failure to use the recommended fuel or not performing

required maintenance services.
* The replacement parts used for required maintenance services.
* Consequential damages such as loss of time, inconvenience, loss of use of the engine
or equipment, etc.
* Diagnosis and inspection charges that do not result in warranty-eligible service being
performed.
* or malfunction of authorized parts due to use of non-authorized parts.

OWNER’S WARRANTY RESPONSIBILITIES

As the engine owner, you are responsible for the performance of the required maintenance

listed in your owner’s manual. Hurst Jaws of Life recommends that you retain all receipts
covering maintenance on your engine, but Hurst Jaws of Life cannot deny warranty solely

for the lack of receipts or for your failure to ensure the performance of all scheduled main­tenance.

As the engine owner, you should however be aware that Hurst Jaws of Life may deny

warranty coverage if your engine or a part has failed due to abuse, neglect, improper main­tenance or unapproved modi¿ cations.

You are responsible for presenting your engine to the nearest service dealer authorized by

Hurst Jaws of Life when a problem exists.

If you have any questions regarding your warranty rights and responsibilities, you should

contact the Hurst Jaws of Life customer service department at (800.537.2659)

www.jawsoÀ ife.com. ([email protected]) for the information.

64

THINGS YOU SHOULD KNOW ABOUT THE
EMISSION CONTROL SYSTEM WARRANTY

MAINTENANCE AND REPAIRS

You are responsible for the proper maintenance of the engine. You should keep all receipts
and maintenance records covering the performance of regular maintenance in the event
questions arise. These receipts and maintenance records should be transferred to each

subsequent owner of the engine. Hurst Jaws of Life reserves the right to deny warranty

coverage if the engine has not been properly maintained. Warranty claims will not be denied,
however, solely because of the lack of required maintenance or failure to keep maintenance
records.

MAINTENANCE, REPLACEMENT OR REPAIR OF EMISSION CONTROL DEVICES AND
SYSTEMS MAY BE PERFORMED BY ANY REPAIR ESTABLISHMENT OR INDIVIDUAL;
HOWEVER, WARRANTY REPAIRS MUST BE PERFORMED BY A SERVICE DEALER AU-

THORIZED BY Hurst Jaws of Life. THE USE OF PARTS THAT ARE NOT EQUIVALENT

IN PERFORMANCE AND DURABILITY TO AUTHORIZED PARTS MAY IMPAIR THE EF­FECTIVENESS OF THE EMISSION CONTROL SYSTEM AND MAY HAVE A BEARING ON
THE OUTCOME OF A WARRANTY CLAIM.

If other than the parts authorized by Hurst Jaws of Life are used for maintenance replace-

ments or for the repair of components affecting emission control, you should assure yourself
that such parts are warranted by their manufacturer to be equivalent to the parts authorized

by Hurst Jaws of Life in their performance and durability.

HOW TO MAKE A CLAIM

All repairs qualifying under this limited warranty must be performed by a service dealer au-

thorized by Hurst Jaws of Life. In the event that any emission-related part is found to be
defective during the warranty period, you shall notify Hurst Jaws of Life customer service
department at (800.537.2659)

www.jawsoÀ ife.com. ([email protected]) and you will be advised of the appropri-

ate warranty service dealer or service providers where the warranty repair can be performed.

65

15. Notes

66

67

Made in USA

P650_power_units_manual_275710085_en.indd

Subject to revision

Please dispose of all packaging materials and
dismantled parts properly.

© Copyright 2014 Hurst Jaws of Life, INC

HURST

JAWS OF LIFE, INC

A Unit of IDEX Corporation

711 N. Post Road
Shelby, NC 28150 USA

Phone: [phone]
Fax: [phone]
e-mail: [email protected]

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 HURST directly before

connecting the equipment!