Lukas P 600 OE User Manual

Instruction manual for rescue equipment

Hydraulic power unit P 600 OE

(Translation of the original instruction manual

175825085 EN

Edition 11.2014

replaces 01.2014

Contents Page

1. Danger classes 4

2. Product safety 5

3. Proper use 8

4. Functional description 9

4.1 Description 9

4.2 Structure of P600OE 11

5. Connecting the hoses / devices 12

6. Set-up and start-up 14

6.1 Installation 14

6.2 Commissioning 14

7. Operation 17

7.1 Operating the P600OE 17

7.2 Safety instructions 18

8. Dismantling the equipment / deactivation following operation 19

9. Tests 20

9.1 General information 20

9.2 Testing the devices 20

10. Maintenance and repair 22

10.1 General information 22

10.2 Preventive maintenance 22

10.3 Changing the hydraulic ﬂ uid 23

10.4 Checking the ﬁ lters 25

10.5 Changing the signs 25

11. Troubleshooting 26

12. Technical data 32

12.1 P600OE 33

12.1 P600OE 34

12.2 Noise emissions (based on the EN ISO 3744 standard) 35

12.3 Hydraulic ﬂ uid recommendation 35

12.4 Operating and storage temperature ranges 35

12.5 Oscillation / vibration 35

13. EC Declarations of conformity 36

14. Accessories 37

14.1 Batteries 37

14.2 Battery charger 37

14.3 Power supply 38

15. Instructions regarding disposal 39

16. Notes 40

1. Danger classes

We distinguish between various categories of safety instructions. The table below provides an overview of the symbols (pictograms) and signal words assigned to the speciﬁ c danger and also the possible consequences.

Pictogram

Damage /

injury to

Key word Deﬁ nition Consequences

DANGER! Immediate danger

Death or severe

injury

WARNING!

Persons

CAUTION!

ATTENTION!

Property

- NOTE

Wear a helmet with a face guard

Wear protective gloves

Potentially dangerous

situation

Less dangerous

situation

Danger of damage

to property/

environment

Handling tips and

other important/

useful information

and advice

Potential death or

serious injury

Minor or slight

injury

Damage to the

equipment,

damage to the

environment,

damage to

surroundings

No injury/damage

to persons/

environment/

device

Wear safety shoes

Proper recycling

Observe principles of environmental protection

Read and observe operating instructions

2. Product safety

LUKAS products are developed and manufactured to guarantee the best performance and quality when used properly. Operator safety is the most important aspect of the product design. Moreover, the operating instructions are intended to aid the safe use of LUKAS 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 read the operating instructions carefully before using the equipment and fully comply with the instructions therein. We further recommend having a qualiﬁ ed trainer showing you how to use 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 instruction, you should read the following safety instructions again.

WARNING / CAUTION!

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

Make sure that no body parts or clothing get between the openly visible moving parts of the device.

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

Working under loads is prohibited if they are raised exclusively with hydraulic devices. If this work is unavoidable, suitable mechanical supports are also required.

The department responsible must be informed immediately of any apparent changes (including the operating behaviour). If necessary, the equipment is to be deactivated immediately and secured!

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

Inspect all cables, hoses and screwed connections for leaks and externally visible damage! If necessary, repair immediately! Squirting hydraulic ﬂ uid can result in injuries and ﬁ res.

In the event of malfunctions, shut down the device immediately and make it safe. Repair the fault immediately.

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

Do not carry out any changes (additions or conversions) to the equipment without obtaining the approval of LUKAS beforehand.

All safety and danger information on the device must always be complete and in a legible condition.

Make sure that all safety covers are present on the device and in proper working condition.

Safety equipment must never be disabled!

Make sure before switching on/starting up the device and during its operation, that this will put no one in danger.

When working in the vicinity of live components and cables, appropriate measures must be taken to avoid a transfer of current or high-voltage arcing to the device.

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

The maximum permissible operating pressure must not be changed.

Observe all intervals for recurring tests and/or inspections that are prescribed or stated in the operating instructions.

Use only original LUKAS accessories and replacement parts when carrying out 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 and therefore possible sparking must be avoided when handling the device.

All damaged electrical components e.g. scorched cables, etc. are to be replaced immediately!

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

The device is ﬁ lled with hydraulic ﬂ uid. These hydraulic ﬂ uids can be harmful to your health if swallowed or if their vapours are inhaled. Direct contact with the skin must be avoided for the same reason. Please also note that hydraulic ﬂ uids can also adversely affect biological systems.

Ensure adequate lighting when you are working.

Always keep these operating instructions easily accessible at the place of operation.

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

When working with or storing the device, ensure that the function and the safety is not adversely affected by external extremes of temperature and that the equipment is not damaged. Please note that the device can also heat up over a long period of use.

Before transporting the device, always check to see that the accessories are positioned securely to prevent the possibility of an accident.

Make sure you properly dispose of all removed parts, leftover hydraulic ﬂ uid, leftover oil and packing materials.

The generally applicable, legal and other binding national and international regulations pertaining to the prevention of accidents and protection of the environment apply and are to be implemented in addition to the operating instructions.

WARNING / CAUTION / ATTENTION!

If you still injure yourself on the hydraulic unit, clean the wound immediately and consult a doctor to have it attended to! If you get hydraulic ﬂ uid in your eye, rinse it immediately several times with clear , clean water and consult a doctor! Also, if you swallow hydraulic ﬂ uid you should consult a doctor!

WARNING / CAUTION / ATTENTION!

The device is intended exclusively for the purpose stated in the operating instructions (see chapter "Proper Use"). Any other use is not in accordance with its designated use.

The manufacturer/supplier cannot be held liable for any damage resulting from such use. The risk of such misuse lies entirely with the user. Proper use includes observance of the operating instructions and compliance with the inspection and maintenance conditions.

Never work when you are overtired or intoxicated!

3. Proper use

The P600OE hydraulic unit is designed specially to supply hydraulic ﬂ uid to a double-acting LUKAS rescue unit. The special feature of the P600OE is its compact lightweight construction. This means that it is possible to work with hose-bound rescue equipment even in difﬁ cult to reach locations. When working with this hydraulic unit, you must also observe all the regulations and directives for safe and proper deployment of the connected rescue equipment. The P600OE is NOT suitable for underwater deployment.

WARNING / CAUTION / ATTENTION!

The P600OE hydraulic unit is not explosion protected! When using the equipment in explosion risk areas you must make sure that operation of the unit does not trigger an explosion! The responsibility for explosion prevention or for ruling out work with the P600OE rests with the operator of the device or with the person responsible at the place of use.

When working in areas at risk of explosion, all applicable legal, national and international regulations, standards and safety rules for preventing explosions must be observed without exception!

The equipment should not come into contact with acids or alkalis. If this is unavoidable, clean the equipment immediately afterwards with a suitable cleaning agent.

Y ou can order replacement parts and accessories for LUKAS equipment from your authorised LUKAS dealer!

4. Functional description

4.1 Description

The P600OE is a compact lightweight electrically driven hydraulic pump. It is designed for supplying hydraulic power to a double-acting LUKAS rescue unit. Their use for supplying pressure / ﬂ uid to rescue equipment of other manufacturers is possible, yet requires the technical inspection and approval by LUKAS in each individual case.

CAUTION!

When selecting the units to connect to the unit, bear in mind that the maximum possible useable volume of hydraulic ﬂ uid is limited. The max. required operating volume (hydraulic ﬂ uid) of the connected unit must not exceed the maximum possible useable volume of the hydraulic pump!

The volume of the tank on the P600OE is designed so that all LUKAS cutters, spreaders, combi tools and the R410 and R412 rescue cylinders that are ﬁ tted with Streamline can be operated. The energy source for the P600OE can be either a mains power unit or an accumulator battery. The mains power units and accumulator batteries that ﬁ r into this hydraulic unit can also be used for the LUKAS eDRAULIC units. When working with the P600OE you can choose which energy source to use. Both the accumulator battery and the mains power unit can be inserted in the opening provided in the body of the tool. Both will lock in place automatically.

NOTE:

When connecting to the mains, if a very long connecting cable is used, the power supply to the motor may be reduced as a result of the resistance in the cable. This will reduce the power of the motor.

The hydraulic unit operates in two modes, the WORKING mode and the ECO mode. It switches to mode required automatically. In the WORKING mode, the P600OE provides the rescue unit with maximum volume ﬂ ow of the hydraulic ﬂ uid at maximum pressure. In the ECO mode, we employ a special speed drop facility. This mode facilitates a very long pump running time with the battery charge. The speed drop facility reduces the volume ﬂ ow of hydraulic ﬂ uid to a minimum. The P600OE automatically switches to the ECO mode after 2-3 seconds if the control valve on the connected rescue unit is not being operated, in other words, when it is in neutral setting. As soon as the control valve on the rescue unit is actuated, the pump switches automatically to the WORKING mode. You now have the maximum power of the P600OE available. The response time of the switchover from ECo to WORKING mode is less than 0.5 s and is therefore hardly noticeable. The noise of the motor tells you which mode the hydraulic unit is using. At reduced temperatures (from approx. 5 °C) it switches to the ECO mode. The P600OE then runs permanently in working mode. As soon as the oil has heated up, the normal function is available again.

In addition, the P600OE is ﬁ tted with LED lighting as standard in order to make working under reduced visibility conditions easier. The light-emitting diodes attached on the connection side light up the coupling area. The main switch has also been provided with a light, so that you can see at a glance whether the device is switched on. The hydraulic tank is also lit. This allows you to see the ﬁ ll level at any time if the lighting conditions are poor.

The P600OE is ﬁ tted with a single ﬂ ow pump with two pressure stages, a low pressure stage and a high pressure stage.

Low pressure stage (ND) = up to 14 MPa* High pressure stage (HD) = 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.

Connection with the rescue equipment is via extension hose pairs or a hose reel. They are supplied in various lengths and kink-protection colours. The individual hoses in a pair of hoses can be distinguished by their different colours.

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

Lukas recommends that you do not use more than 10 m of total hose length between the hydraulic pump and the rescue unit.

NOTE:

Always register your hydraulic unit on the LUKAS Hydraulik GmbH internet site. Only then are you entitled to the extended guarantee.

Before you use couplings from a different company , you must contact LUKAS or an authorised dealer.

You can order replacement parts and accessories for the P600OE from your authorised LUKAS dealer!

*) 1 MPa = 10 bar)

4.2 Structure of P600OE

2 9

881

1 Casing 2 Filler cover 3 Filler cap 4 Mono-coupling sleeve

with dust cap 5 ON / OFF switch 6 LED lighting 7 Battery or mains power

unit 8 Rubber buffer 9 Fill level display

(illuminated)

5. Connecting the hoses / devices

CAUTION!

When connecting the hose assemblies / units, always ensure that the connection components are not soiled. If necessary, clean immediately!

WARNING / CAUTION / ATTENTION!

Before connecting equipment, make sure that all the components used are suitable for the maximum operating pressure of the hydraulic unit! In cases of doubt, you must consult LUKAS

directly before connecting the equipment!

The hose lines / units are connected via quick-disconnect coupling halves (female and male) to the hydraulic pump in such a way that they cannot be reversed.

Dust protection caps

Male coupling

Remove the dust caps before coupling together. Then push the male and female parts together and turn the locking sleeve on the female coupling in the direction "1" until the locking sleeve clicks in place. The connection has now been made and locked. Uncoupling is accomplished by turning the locking sleeve in direction "0".

Female coupling

NOTE:

Couple together only when in ECO mode, or when the P600OE is switched off!

For dust protection, the supplied dust protection caps must be reﬁ tted.

Fitting the dust protection caps:

The dust protection caps "A" 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 pins "C". Screw in the dust protection caps to the limit stop to ﬁ x in the female couplings.

6. Set-up and start-up

6.1 Installation

WARNING / CAUTION / ATTENTION!

The LUKAS Mini electric pump is not explosion protected! When using the equipment in explosion risk areas you must make sure that operation of the unit does not trigger an explosion!

The unit is to be set up in a suitable location (safe location / ﬂ at surface / sufﬁ cient distance from vehicles, loads, sources of ignition, etc.). LUKAS units work perfectly at an angle of up to 20°. However, in order to guarantee maximum safety and ﬂ uid withdrawal, they should be operated in as horizontal a position as possible. The P600OE is designed in such a way that, when deactivated and with correctly ﬁ tted ﬁ ller cap, no hydraulic ﬂ uid can leak out, even if the pump were to tip over.

6.2 Commissioning

NOTE:

When delivered the hydraulic ﬂ uid in the P600OE has a special High-Tech running in additive mixed in. This can be seen with the different colour of the hydraulic ﬂ uid when the pump is delivered. The additive optimises the running-in behaviour and the hydraulic function of the pump. When topping up or ﬁ lling with hydraulic ﬂ uid, you should always observe Item 12.3 in this manual.

Before starting up for the ﬁ rst time, the battery (if ﬁ tted) must be fully charged in an external charger.

Commissioning procedure:

1. First check the condition of the pump.

- The casing should not be damaged.

- Hydraulic ﬂ uid should not be coming out in an uncontrolled manner.

- The coupling should not be damaged

- The battery connection slot should not exhibit any function-inhibiting damage.

2. Then check the level of hydraulic ﬂ uid in the in the pump. The ﬂ uid levels can be read off on the ﬁ ll level indicator on the side of the unit. There are

3 marks on the ﬁ ll level indicator. For precise reading off of the ﬂ uid levels and for ﬁ lling, the hydraulic unit should be as level as possible.

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