Lukas P 630 Lite User Manual
Instruction manual for rescue equipment
Hydraulic power units P 630 lite
P 630 HV lite
P 630 HV lite
P 630 lite
175075085 EN
Edition 11.2013
(Translation of the original instruction manual)
2
Content Page
1. Danger classi¿ cations 5
2. Product safety 6
3. Proper use 10
4. Power unit designation 11
5. Functional description 11
5.1 General information 11
5.2 Installation of the power unit 12
5.3 Motor 13
5.4 Valves in the pump block 14
5.5 Pumps 15
5.6 Connecting the P 630 HV lite power unit with rescue equipment 15
6. Connecting the couplings 17
6.1 Coupling the mono-couplings 17
6.2 Coupling the quick-disconnect couplings 19
7. Set-up and start-up 20
7.1 Set-up 20
7.2 Start-up 20
8. Operation 22
8.1 Starting the engine 22
8.2 Stopping the engine 23
8.3 Refuelling 23
8.4 Controlling the valves 23
9. Dismantling the equipment / deactivation following operation 25
10. Tests 26
10.1 Recommended test intervals 26
10.2 Visual and function check 27
11. Maintenance and repair 28
11.1 General information 28
11.2 Service work on the hydraulic unit 29
11.3 Additional service work 31
12. Fault analysis 36
3
Content Page
13. Technical data 41
13.1 Power unit 41
13.2 Noise emissions 44
13.3 Sparking plug 45
13.4 Sparking plug spanner 45
13.5 Fuel 45
13.6 Engine oil 46
13.7 Hydraulic fl uid recommendation 46
13.8 Operating and storage temperature ranges 46
14. EC Declaration of Conformity 47
15. Notes 48
4
1. Danger classifi cations
We differentiate between various different categories of safety instructions. The table shown
below provides an overview of the assignment of symbols (pictograms) and signal words to
the speci¿ c danger and the possible consequences.
Pictogram
Damage /
injury to
Persons
Property
- NOTE
Key word Defi nition Consequences
DANGER! Immediate danger
Potentially
WARNING!
CAUTION!
ATTENTION!
dangerous
situation
Less dangerous
situation
Danger of damage
to property/
environment
Handling tips and
other important/
useful information
and advice
Death or severe
injury
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 a helmet with a face guard
Wear protective gloves
Wear safety shoes
Proper recycling
Protect the environment
Read and follow operating instructions
5
2. Product safety
LUKAS products are developed and manufactured to ensure the best performance and
quality when used as intended.
The safety of the operator is the most important consideration in product design. Furthermore,
the operating instructions are intended to help in using LUKAS products safely.
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 equipment 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 carefully the operating instructions
and the instructions contained therein before they use the equipment, and that they should
carefully follow such.
We further recommend that you have a quali¿ ed trainer show you how to use the product.
CAUTION!
The operating instructions for the hoses, the accessories and the connected
devices must also be heeded!
Even if you have already received instructions on how to use the equipment, you should still
read through the following safety instructions again.
CAUTION!
Ensure that the accessories and connected equipment are suitable for the
maximum operating pressure!
Please ensure that no body
parts or clothing get stuck
between the visibly moving
parts.
Wear protective clothing, safety
helmet with visor, safety shoes
and protective gloves.
Working under suspended
loads is not permitted where
such loads are being lifted only
by means of hydraulic devices.
If this work is unavoidable,
suitable mechanical supports
are also required.
Immediately report any changes
that occur (including changes
in operating behaviour) to
the appropriate persons/
departments! If necessary, the
equipment is to be shut down
immediately and secured!
Check the equipment for visible
À aws or damage before and
after use.
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.
6
In the event of malfunctions,
immediately deactivate the
device and secure it. Repair the
fault immediately.
Do not carry out any changes
(additions or conversions) to the
equipment without obtaining the
approval of LUKAS beforehand.
Observe all safety and danger
information on the device and in
the operating instructions.
Please ensure that all safety
covers are present on the
equipment and that they are in
proper and adequate condition.
Safety devices 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 close to live
components and cables,
suitable measures must be
taken to avoid current transfers
or high-voltage transfers to the
equipment.
All safety and danger
instructions on the device must
always be complete and in a
legible condition.
Any mode of operation which
compromises the safety and/
or stability of the device is
forbidden!
The maximum operating
pressure set on the equipment
must not be changed!
Observe all intervals for
recurring tests and/or
inspections that are prescribed
or stated in the operating
instructions.
Only genuine LUKAS
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
and therefore possible sparking
must be avoided when handling
the device.
Motorised pumps must not be
operated in areas at risk of
explosion!
Do not touch the engine and
exhaust system when running
with combustion engine pumps
because of the danger of
burning.
Combustion engines must not
be operated in enclosed spaces
because of the danger of
poisoning and / or smothering.
7
If you spill any fuel when using combustion engines, you
must remove the spilled fuel
completely before starting the
engine.
Keep combustion engines and
their fuels away from sources
of ignition since otherwise there
will be a danger of explosion.
Refuelling whilst the engine is
running is strictly prohibited!
All damaged electrical
components e.g. scorched
cables, etc. must be replaced
immediately!
In order to prevent the danger
of ¿ re, you should ensure
adequate ventilation when
operating combustion engines
and you must keep a safety
distance of at least 1m (39.4 in.)
to walls and other screens.
Make sure that the combustion
engines are always standing on
as À at and horizontal a surface
as possible to prevent fuel from
leaking out.
The equipment is ¿ lled with
hydraulic À uid. This hydraulic
À uid can be detrimental to
health if it is swallowed or its
vapour is inhaled. Direct contact
with the skin must be avoided
for the same reason. Also,
when handling hydraulic À uid,
note that it can negatively affect
biological systems.
Make sure there is adequate
lighting while working.
Always keep these operating
instructions easily accessible at
the place of operation.
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.
When setting up the units, you
must ensure that they are not
impaired by the inÀ uences of
extreme temperatures.
When working with or storing
the equipment, ensure that the
function and the safety of the
equipment are not impaired
by the effects of severe
external temperatures or that
the equipment is damaged in
any way. Please note that the
equipment can also heat up
over a long period of use.
Before transporting the
equipment, always ensure that
the accessories are positioned
in such a way that they cannot
cause an accident.
Ensure the proper disposal of
all removed parts, leftover oil,
hydraulic À uid and packaging
materials.
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.
WARNING/CAUTION!
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 is not liable for any damage resulting from improper use.
The user bears sole responsibility for such use.
Proper use includes observance of the operating instructions and compliance with the
inspection and maintenance conditions.
Never work in a fatigued or intoxicated state!
WARNING/CAUTION!
However, 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 À uid in your eye, rinse it immediately several times with clear,
clean water and consult a doctor!
Also, if you swallow hydraulic À uid you should consult a doctor!
9
3. Proper use
LUKAS hydraulic units are specially designed to supply LUKAS 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 LUKAS in each individual
case.
The equipment is not designed to operate without hoses or equipment (operating time
without hoses or equipment < 15 minutes).
WARNING/CAUTION!
The safety instructions in this operating instruction manual concerning the site of
erection and type of erection must always be observed!
LUKAS P 630 units are 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 P 630
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 avoiding explosions must be observed without restriction!
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.
You can obtain accessories and replacement parts for the rescue apparatus from your
authorised LUKAS dealer!
ATTENTION!
When selecting the units to connect to the unit, bear in mind that the maximum
possible useable volume of hydraulic À uid is limited.
The sum of the max. required operating volume (hydraulic À uid) of all connected
equipment must not exceed the maximum possible usable volume of the power
unit!
NOTE:
Always register your hydraulic unit on the LUKAS Hydraulik GmbH internet site.
This is the only way to guarantee your extended warranty cover.
Before you use couplings from a different company , you must contact LUKAS or
an authorised dealer.
10
4. Power unit designation
P
Coding for hydraulic
power units
630
Type group
Model versions
HV lite = hose version
lite = version with quick-disconnect
couplings
5. Functional description
5.1 General information
On all LUKAS hydraulic power units, the hydraulic pump is operated with a motor. The pump
conveys À uid from the hydraulic oil tank and builds up the pressure in the tool. Fluid is
distributed to the connected equipment through valves.
The P 630 lite is a power unit without frame and with a petrol engine and simultaneous
operation.
The hydraulic power unit is available in two models:
1) P 630 HV lite -> without couplings for direct hose connection
2) P 630 lite -> with quick-disconnect couplings
11
5.2 Installation of the power unit
P 630 lite
6
10
1
8
9
19
18
11
2
Equipment rear
21
13
12
7
1 Petrol tank
3
2 Hydraulic À uid tank
3 Engine
4 Hydraulic pump with
14
control valve
5
5 Speed adjusting lever
6 Carrying handle, swivelling
7 Cable starter
8 Valve control lever
9 Coupling connection
10 Fuel tank cover
11 Filler cover hydraulic À uid
20
4
12 Base
13 Rubber buffer
14 Air ¿ lter
15 Choke
16 Fuel tap
17 ON/OFF switch (engine
switch)
18 Connection pressure line
19 Connection tank line
20 Engine oil ¿ lling cap/
dipstick
21 Fill level indicator
15
16
17
12
P 630 HV lite
9
19
9 Hose connection
18 Connection pressure line
19 Connection tank line
18
5.3 Motor
WARNING/CAUTION!
See also the separate operating instructions of each engine manufacturer
accompanying the delivery.
5.3.1 Petrol motor
These hydraulic units are equipped with a combustion engine driven by the fuel "petrol".
The power units are equipped with a cable starter with which the engine is started.
(For specifi c details, please consult the separate operating instructions of the engine
manufacturer!)
The HONDA engines have a main switch that must be activated to switch the power unit on
and off. The speed adjusting lever on these power units have two positions.
Switch position 1: Speed 3000 1/min " " and
Switch position 2: Speed 3800 1/min " " .
The setting is changed by moving the speed adjusting lever, which is infi nitely variable.
NOTE:
The engine installed in LUKAS power units does not match every detail of the
engine described in the manufacturer's separate operating instructions.
Nevertheless, it is important that you follow all safety rules and operating,
maintenance and storage instructions in the separate engine instructions as
absolute since they are not affected by adjustments made by LUKAS.
13
5.4 Valves in the pump block
Both valves of the power unit in the pump block are ¿ xed in place. The pump block is fully
integrated into the hydraulic power unit. The hose assemblies (pressure line (grey) and
return (blue)) must be connected to the pump block. The rescue equipment is connected to
the hose assemblies. Model P 630 units are equipped with a SIMO connecting block.
5.4.1 Control valves in the pump block "simultaneous operation" (SIMO)
The control valves are located in the pump block of the P 630 lite. Two pressure hoses and
two return hoses can be connected. Each valve has two switching options, each of which
controls the pressure application of the corresponding pressure hose. This means that two
devices can be supplied with pressure simultaneously and independently of each
another. Without impairing the work output, it enables work with two devices simultaneously
and independently of each another.
ATTENTION!
When operating several pieces of rescue equipment with one unit, ensure
that the usable volume of hydraulic À uid in the power unit is greater than the
maximum possible operating À uid volume of all connected rescue equipment.
14
5.5 Pumps
The LUKAS model P 630 lite hydraulic power pump is equipped with a double-À ow pump for
operation with the SIMO valve.
The pump used always has two pressure stages per pump feed À ow, one low pressure and
one high pressure.
Low-pressure level (LP) = up to 14 MPa*
Low-pressure level (HP) = up to 70 MPa* *) 1 MPa = 1 0 bar )
The changeover from low pressure to high pressure is carried out automatically in the pump.
This system is secured with a pressure limiting valve. Therefore, the maximum permissible
system pressure cannot be exceeded.
WARNING/CAUTION!
For safety reasons, the pressure set on this valve must not be adjusted (without
the approval of LUKAS directly)!
5.6 Connecting the P 630 HV lite power unit with rescue equipment
Connection with the rescue equipment is via extension hose pairs of the following models:
- 5.0 m long - kink-protection, blue - order number: 81-62-05
- 10.0 m long - kink-protection, blue - order number: 81-62-10
5.6.1 Direct connection
The hydraulic hoses are screw-connected to the pump block of the hydraulic unit. Screw-in
nipples are mounted in the pump block. The hoses are connected to these screw-in nipples
directly using union nuts. You must ¿ rst remove the dust protection caps from the hoses and
remove the stopper screws and the steel balls underneath on the pump block of the power
unit. Subsequently, connect the corresponding hydraulic hose with the union nuts to the
screw-in nipples. Please observe the tightening torque of 35 Nm.
ATTENTION!
Always connect the return line (blue / T1 or T2) ¿ rst and then the supply line
(grey / P1 or P2)! Raise the blind plugs consisting of union nuts and steel ball.
If a hose pair is not connected, the hoses must always be connected to the
pump with balls and union nuts.
15
Connecting hose assemblies:
Remove blind plug consisting of union nut
and steel ball.
Connection labelled with T1 or T2:
Return line (blue)
Connection labelled with P1 or P2:
Supply line (grey)
Fit the corresponding hose line and tighten
the union nuts to a torque of 40 Nm.
Connect equipment using mono or quickdisconnect couplings to mounted hoses.
16
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