Lukas P 600 OB User Manual
Operating Instructions
Rescue Tools
Battery Pump P 600 OB
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115001085 GB
Issue 10.2007
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1 Main switch
2 Indicator pin
3 Battery
4 Connection for charger cable
5 Connection for external power supply 24 V DC
6 Charge indication panel
7 Dump valve
8 Carry harness
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Contents page
1 Basic Operation and designated Use of the Machine 3
2 Organizational Methods 3
3 General Safety Instructions 3
4 Instructions for Maintenance and Service 4
5 Safety Instructions for Hydraulic Hoses 5
6 Intended Use 7
7 Description 7
8 Commissioning 9
9 Operation 10
10 Maintenance 13
11 Problems / Trouble Shooting 15
12 Repair 16
13 Battery 16
14 Technical Dat a 17
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1 Basic operation and designated use of the machine
1.1 The machine has been built in accordance with state-of-the-art standards and the recognized
safety rules. Nevertheless, its use may constitute a risk to life and limb of the user or of third parties,
or cause damage to the machine and to other material property.
1.2 The machine must only be used in technically perfect condition in accordance with its
designated use and the instructions set out in the operation manual, and only by safety-conscious
persons who are fully aware of the risks involved in operating the machine. Any functional disorders,
especially those affecting the safety of the machine/plant, should therefore be rectified immediately!
1.3 The machine is exclusively designed for the use described in the operating manual. Using the
machine for purposes other than those mentioned in the manual, such as driving and controlling
other hydraulic systems, is considered contrary to its designated use. The manufacturer/supplier
cannot be held liable for any damage resulting from such use. The risk of such misuse lies entirely
with the user.
Operating the machine within the limits of its designated use also involves observing the instructions
set out in the operating manual and complying with the inspection and maintenance directives.
2 Organizational methods
2.1 The operating manual must always be at hand at the place of use of the machine!
2.2 In addition to the operating instructions, observe and instruct the user in all other generally
applicable legal and other mandatory regulations relevant to accident prevention and environmental
protection.
This also applies for wearing protective clothing, helmet with visor or goggles and protective gloves.
2.3 In order to avoid injuries, the machine must only be operated by a specially trained operator
who has undergone a safety training.
2.4 Observe all safety instructions and warnings attached to the machine. Make sure that safety
instructions and warnings attached to the machine are always complete and perfectly legible.
2.5 Never make any modifications, additions or conversions without the supplier’s approval.
2.6 For repairs only genuine LUKAS spare parts, accessories or system components must be
used.
2.7 Adhere to prescribed intervals or those specified in the operating manual for routine checks
and inspections.
2.8 Make sure to dispose properly of packing material and dismounted parts!
3 General safety instructions
3.1 In the event of malfunctions, stop the machine immediately and lock it. Have any defects
rectified immediately.
3.2 Before starting up or setting the machine in motion and during operation of the machine make
sure that nobody is at risk.
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3.3 Before transporting the machine always check that the accessories have been safely stowed
away.
3.4 Make sure that there is enough lighting during work.
3.5 Avoid any operation that might be a risk to machine stability.
3.6 Check the machine at least after every operation for obvious damage and defects. Report any
changes (incl. changes in the machine’s working behaviour) to the competent organization /person
immediately. If necessary, stop the machine immediately and lock it. All lines, hoses and screwed
connections have to be checked for leaks and obvious damage. Repair damage immediately.
Splashed oil may cause injury and fire.
3.7 All safety equipment has to be checked for completeness and flawless condition:
- instruction markings and warning signs (safety instructions)
- check safety cover (e.g. motor-safety covers, heat protection etc.) if they are available and if
they are in good condition.
3.8 Working under loads is not allowed if they are only lifted by hydraulic cylinders. If the work is
indispensable sufficient mechanical supports are needed additionally.
3.9 The pump is filled with hydraulic fluid. Never swallow or breath in this fluid as this could be
dangerous to your health ! Avoid direct contact between the fluid and your skin !
Be aware that hydraulic fluid may cause negative effects to any kind of biologic systems.
4 Instructions for maintenance and service
4.1 For the execution of maintenance and service work, tools and workshop equipment adapted
to the task on hand are absolutely indispensable.
Work on the hydraulic system must be carried out only by personnel having special knowledge and
experience with hydraulic equipment.
4.2 Before putting into operation clean the machine, especially connections and threaded unions,
of any traces of oil, fuel or preservatives before carrying out maintenance/repair. Never use
aggressive detergents. Use lint-free cleaning rags and pay attention that the components are
meticulously clean during reassembling after repair.
4.3 During dismantling of machines it is necessary to collect the outrunning hydraulic liquids
completely, so that they cannot reach the ground. They have to be disposed properly according to
the instructions.
4.4 Always tighten any screwed and thread connections that have been loosened during
maintenance and repair. Observe the stipulated torques.
4.5 Work on the electrical system or equipment may only be carried out by a skilled electrician
himself or by specially instructed personnel under the control and supervision of such electrician and
in accordance with the applicable electrical engineering rules.
4.6 The electrical equipment of machines is to be inspected and checked at regular intervals.
Defects such as loose connections or scorched cables must be rectified immediately.
4.7 Aggressive material (acid, lye, solvent, vapour) can damage the machine. It is necessary to
clean the whole machine if it must be exceptionally operated under such conditions or gets into touch
with these materials. Additionally, the machine must be checked as described under 3.6.
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4.8 Should you observe a loss of speed of the rescue tool during operation the battery must be
recharged. Do not continue with the operation until the motor stops. Otherwise there is the risk of
the battery becoming deep discharged which would reduce its lifetime.
5 Safety Instructions for Hydraulic Hoses
A T T E N T I O N !
- by no means the hose must be exposed to brake fluid as this fluid will destroy outer
layer of hose
- do not expose the hose to any of the following aggressive fluids:
• acid, lye or solvent
• alcohol and fuel
• battery and automatic transmission fluid
• phosphate ester
Clean hose immediately with water and detergent when it was exposed to such fluids.
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5.1 Handling of hoses
- never exceed the permissible working pressure as stated on hose and/or literature
- avoid any tension (see figure 1) and do not hang any load onto the hose
- never exceed the minimum bend radius as resulting kink will cause failure of hose (see figure
2)
- do not allow hose to contact sharp edges or rough objects (see figure 3)
- avoid any twisting of hose (see figure 4)
- do not run over hose with any vehicle or equipment ! Hoses which are put on the surface of
sidewalk or street have to be suitably protected (see figure 5)
- do not allow hose to contact areas of high temperature such as mufflers, exhaust manifold,
heaters or burners. Protect the hose as shown in figure 6 or install it in sufficient distance
from the source of heat.
- it is not allowed to attach weights to the hoses
- make sure that no objects fall on the hoses.
5.2 Protection of the working area in case of breakdown of hoses
Hoses have to be installed or protected in such a way that dangers are prevented, if possible, in
case of breakdown of the hoses.
Danger can be caused by:
- Uncontrolled hose movement after a hose rupture caused e.g. by external influence.
- Emerging of the pressure medium under pressure.
- Inflammation of pressure medium near igniting sources
Dangers can be prevented by e.g. protective coverings or shieldings
5.2.1 Do not go near leaks!
- High pressure oil easily punctures skin causing serious injury,
gangrene or death!
- If injured, seek emergency medical help! Immediate surgery is
required to remove oil!
- Do not use finger or skin to check for leaks!
- Lower load or relieve hydraulic pressure befor loosening finttings!
5.3 Storage of hoses
- Hoses are subject to a natural aging even if they are stored correctly. Therefore, their storage
and service time is limited.
When storing the hoses please observe the following:
- Store them cool, dry and dustless (eventually wrapped with plastics sheeting); prevent direct
solar radiation and UV rays; shield heat sources which are near the hoses.
- Do not use any ozone producing lamps (e.g. fluorescent light sources, mercury-vapor lamp)
or electrical devices next to the hoses.
- Hoses have to be stored freely of tension and in a horizontal position. If they are stored in
rings the smallest bending radius determined by the manufacturer must not fall below.
5.4 Marking of hoses
- The hose is marked with the manufacturer's name and quarter/year of production.
- The max. allowable pressure and month/year of production is indicated on the hose end fitting.
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