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
6. Connecting the couplings
ATTENTION!
When connecting the hose assemblies / units, always ensure that the connection
components are not contaminated with dirt. Clean prior to use if necessary!
WARNING/CAUTION!
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!
6.1 Coupling the mono-couplings
The hose lines / units are connected via quick-disconnect coupling halves (female and male)
to the hydraulic pump or hose reel in such a way that they cannot be reversed.
Dust protection caps
Mono-coupling
halve (male)
Mono-coupling
halve (female)
17
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 been made and locked. Decoupling is
accomplished by turning the locking sleeve in direction "0".
Coupling of the hose assemblies when under pressure is also possible, assuming the
connected equipment is not turned on.
NOTE:
We recommend connecting the coupling halves in a depressurised state
when working in areas with low ambient temperature and using extension hose
assemblies / hose reels, as otherwise the coupling may require the application
of a great deal of force.
For dust protection, the supplied dust caps must be re¿ tted.
Using 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 ¿ x in the female couplings.
A
B
C
18
C
6.2 Coupling the quick-disconnect couplings
The device is connected to the hydraulic pump without risk of misconnection using
monocoupling halves (female and male coupling).
X
Y
Before coupling, remove dust caps and then pull back and hold the locking sleeve of the
female coupling half (position X). Connect the male and female couplings and release the
locking sleeve. Then turn the locking sleeve to position Y. The connection has been made
and locked. Uncoupling is done in the reverse order.
ATTENTION!
Always connect the return pressure line ¿ rst and then the supply line!
NOTE:
Coupling of the devices is only possible, when the hoses are depressurized.
For dust protection, the supplied dust caps must be re¿ tted.
WARNING/CAUTION!
Some quick-disconnect couplings have special functions.Therefore, you must
not unscrew them from the hoses or swap them over!
19
7. Set-up and start-up
7.1 Set-up
WARNING/CAUTION!
Because of possible spark formation, combustion engine units and electrical
equipment must not be used in an explosion-risk area. 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.).
LUKAS 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 horizontal a position as possible.
7.2 Start-up
NOTE:
The engine oil level must be inspected before the ¿ rst commissioning or after
longer periods of storage. First ¿ ll the engine or top with engine oil!
For safety reasons, LUKAS power units do not contain engine oil upon delivery!
ATTENTION!
Never mix up the fuel and hydraulic À uid tanks when ¿ lling the tank; this can
damage the power unit!
7.2.1 First commissioning - Power unit without engine oil, hydraulic fl uid and petrol.
1. Pour engine oil in according to the instructions included
with the separate manufacturer operating instructions
regarding the ¿ lling opening (engine oil ¿ ller cap, see
chapter "Installation of the power unit").
2. Pour hydraulic oil into the hydraulic À uid tank until the ¿ ll
level indicator in the viewing window is between MIN/
MAX (see illustration on the right). The upper mark
shows the absolute ¿ ll level when connecting additional
equipment with increased usable volume. The resulting
¿ ll quantity is up to 3.0 l.
3. Pour fuel (petrol) into the tank until the ¿ ll level is just
below the ¿ lling opening. If the power unit is resting on
an inclined surface, do not ¿ ll the tank to its maximum
capacity .
20
Hydraulic oil ¿ ll
level indicator
4. Now bleed the hydraulic power unit:
5. Open and remove the tank cap so that air enters the tank.
6. Open the venting plug on the pump block, tilt the power unit backwards by approx. 45°
(see illustration) and wait until oil comes out next to the bolt.
Pump block P 630 lite
7. If oil comes out at the venting plug, the air has escaped out of the pump. First close the
venting plug and then return the power unit to level.
8. Check the À uid levels again. Top up if necessary.
9. Now connect the connection hoses (if they have not already been connected to the power
unit).
Venting plug
21
7.2.3 Commissioning (after the fi rst fi lling or prior to use)
1. Check the À uid level of the engine oil, the hydraulic À uid and the fuel reservoir. Top up if
necessary. For precise reading of the À uid levels and for ¿ lling, the hydraulic unit should
be as level as possible.
2. Now connect the extension hoses and/or hose reels (unless already connected to the unit)
and/or couple the rescue equipment.
8. Operation
ATTENTION!
The control lever of the hydraulic power unit should always be switched to the
neutral position (depressurized) prior to starting the engine in order to prevent
unwanted movements of connected hydraulic equipment and starting the power
unit without hydraulic load.
8.1 Starting the engine
Before starting the combustion engine, check that the fuel tank is full and that the engine oil
level is within the permitted tolerances. If necessary, top up the relevant À uid.
1. Open petrol tap
2. Set the ON/OFF switch to the ON position.
3. Move lever from switching position A to switching
position B (choke) when starting from cold
4. Pull starter cable.
5. When the engine is running, switch the lever back to
position A.
For the detailed procedure for starting the
combustion engine, please see the
separate operating instructions of the engine manufacturer!
22
A
B
8.2 Stopping the engine
1. Set the ON / OFF switch to the OFF position.
2. When the engine has come to a standstill, close the
fuel tap.
For more details on switching the engine off, please refer to the separate operating
instructions of the engine manufacturer!
CAUTION!
Never touch hot engine parts: this could result in severe burns!
8.3 Refuelling
The engine must be switched off for refueling!
Procedure:
1. Open the fuel tank cap.
2. Fill the tank with fuel until the ¿ ll level is just below the ¿ lling opening.
WARNING/CAUTION!
Be sure not to spill fuel. In particular, hot engine parts must not come into
contact with fuel; danger of ¿ re otherwise!
If fuel is spilled, it must be cleaned up immediately with a suitable absorbent
cloth. In doing so, be careful not to burn yourself on one of the hot engine
parts! The used cloth must then be cleaned or disposed of according to the
relevant provisions and guidelines.
3. Close the fuel tank again with the fuel tank cap.
8.4 Controlling the valves
ATTENTION!
The control level of the hydraulic power unit should always be switched to the
neutral position (depressurized) prior to starting the engine in order to prevent
unwanted movements of connected hydraulic equipment.
23
8.4.1 "Simultaneous operation" control valve (SIMO) P 630 lite
Two switching levers that control the valves (see the illustration at the top)
are located on the pump block.
Each of the two levers is assigned to the pressure connection below.
The pressure application of the corresponding pressure hose is controlled
( ) or the connection is switched depressurised ( ) by moving the lever.
NOTE:
All switching levers must always be moved completely up to the stop.
24
9. Dismantling the equipment /
deactivation following operation
Once work has been completed, all connected equipment is to be reset to its neutral position
(storage position) before the unit is shut down. Subsequently , you can switch the engine of f.
ATTENTION!
Check that the engine switch is set to the “OFF“ position and remains there to
prevent the unwanted starting of the power unit!
Quick-disconnect couplings:
If the connected hose assemblies are to be removed during deactivation,
uncouple the quick-disconnect couplings as
described in the chapter "Coupling quick-disconnect couplings". Ensure that you replace the
dust protection caps onto the
quick-disconnect couplings.
Mono-couplings:
If the connected hose assemblies are to be dismantled during shut-down, decouple as
described in chapter "Coupling the mono-couplings". Ensure that you replace the dust
protection caps onto the mono-coupling halves.
Direct connection:
This connection should only be disconnected if it is absolutely necessary, for example, for
extended storage periods, de-commissioning, maintenance, etc
If the connected hose assemblies are to be removed during deactivation, the hydraulic À uid
tank cap must ¿ rst be removed. Equal pressure is thus enabled. First remove the pressure
hose and then the return hose. Then mount the union nuts with the steel ball to the screw-in
nipples on the pump block (M = 40 Nm). Clean the hydraulic power unit of any stubborn dirt
prior to storage.
Clean the hydraulic power unit of any stubborn dirt accumulated through use
prior to storage.
If the equipment is to be stored for a longer period of time, the exterior is to be cleaned
completely and the mechanically mobile parts are to be lubricated. If storing a unit with
combustion engine, you should also remove the fuel from the fuel tank.
Avoid storing the hydraulic power units in a damp environment.
Observe the additional regulations in the separate operating instructions for the hoses.
CAUTION!
Depending on the size and weight of the hydraulic power unit it should be
transported to the storage location by one or more persons.
25
10. T ests
The hydraulic power units are subject to very high levels of stress. A visual inspection must
therefore be carried out after every use and at least one visual inspection must 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)
Every 3 years or when there might be doubts regarding the safety or reliability of the unit, an
additional function check is to be carried out (in this connection, comply with the applicable
national and international regulations with regard to the maintenance intervals of rescue
equipment). Operating time per day In the Federal Republic of Germany, regular safety
inspections according to the regulations of the Gesetzlichen Unfallversicherung (GUV;
connoted ‘Legal accident insurance’) are mandatory.
ATTENTION!
Clean off any dirt before checking the equipment!
WARNING/CAUTION!
To perform inspections, maintenance and repairs, personal safety equipment
appropriate for the work is an absolute requirement. (when necessary also use
screens).
LUKAS offers a suitable test kit for the function test of the hydraulic units.
(For specifi c details, please consult the LUKAS range of accessories or contact your
LUKAS dealer.)
10.1 Recommended test intervals
10.1.1 General visual inspection
A visual inspection must be carried out after every use, but at least once every six months.
26
10.1.2 Function check
Operating time per day Functional test
up to 1 hour 1 x annually
up to 8 hours 1 x per quarter
up to 24 hours 1 x per month
In addition to these test intervals you need to carry out a function test if:
- the unit makes suspicious noises,
- there is a justifi ed suspicion of internal damage to the unit.
If the noises and suspicions referred to above arise several times in a month, or if maximum
pressure cannot be achieved during the function test, you need to contact LUKAS customer
service immediately. The contact details are given in the Chapter "Fault analysis".
10.2 Visual and function check
Visual Inspection
• Tightness of all hydraulic connections,
• General tightness, no leakage (sweated oil does not have any inÀ uence on the function),
• Is there any sign of damage to the engine or pump block,
• Is there any sign of damage to the hydraulics or fuel tank,
• Presence and legibility of the identi¿ cation plate, all actuation signs, instruction signs,
markings and warnings,
• The presence and perfect condition of all covers (e.g. exhaust deÀ ector),
• All À uid levels are within the speci¿ ed tolerances,
• Are the rotary switches and switching levers in proper working order and undamaged,
• Couplings must be easy to couple,
• Dust protection caps must be available,
• All required accessory parts (e.g. sparking plug, sparking plug spanner and fuel can) are
present.
• Check for leaks.
Functional test
• Unconventional or noticeable noises heard during operation
• Cable starter fully functional,
• Engine switch fully functional,
• Test for maximum load.
NOTE:
use the LUKAS test kit, including testing instructions, for the function test.
27
11. Maintenance and repair
11.1 General information
LUKAS hydraulic units model P 630 require only limited maintenance. For service work,
special training is not required; however, knowledge about the function of the power unit,
the statutory safety instructions and dealing with the required tools are basic prerequisites.
ATTENTION!
Never use unnecessary force during maintenance work that could damage the
components of the power unit or compromise operational safety.
Due to the complex design, service work on the hydraulic power unit may only
be executed by the equipment manufacturer, personnel trained by the equipment
manufacturer or authorised LUKAS dealers.
WARNING/CAUTION!
Protective clothes must be worn when maintenance and repairs are being
carried out, since the devices may also be pressurised when not in operation.
During work, ensure that all components are particularly clean, since dirt can
damage the rescue equipment!
28
ATTENTION!
Since LUKAS hydraulic units are designed for top performance, only those
components in the replacement parts lists for the relevant unit can be replaced.
Further components in the unit may only be replaced if:
- You have participated in an appropriate LUKAS service training course.
- You have the express permission of LUKAS customer service (upon request
a check is carried out for the grant of permission. An examination in each
individual case necessary!)
When cleaning units and equipment, note that no cleaning agent may be used
that has a pH value outside the range 5 - 8!
ATTENTION!
Attention must be paid to ensuring that no operating À uids can escape from
units with combustion engines during repair work!
11.2 Service work on the hydraulic unit
11.2.1 Care instructions
The exterior of the device must be cleaned from time to time (not the electrical contacts)
and the metallic surfaces (not the electrical contacts) must be treated with a suitable agent
to protect against corrosion.
(In case of doubt, contact your authorised LUKAS dealer or LUKAS directly!)
11.2.2 Function and load test
If there is any doubt regarding the safety or reliability of the equipment, a function and stress
test must also be performed.
LUKAS offers appropriate testing equipment for this.
11.2.3 Replacing the hydraulic fl uid
- After approx. 200 deployments, but after three years at the latest, replace the hydraulic
À uid.
- The À uid should be replaced after it has warmed up.
- The engine must be switched off!
- The used hydraulic À uid must be disposed of properly.
29
Replacing the hydraulic fl uid - procedure:
1. Place the power unit on a slightly elevated base so that the drain plug for the hydraulic
À uid can be easily reached.
2. Place a suitable collection container under the "A" drain plug.
3. Open the "B" ¿ ller cap, remove the "A" drain plug and let the hydraulic À uid run into the
provided collection container.
4. Screw the "A" drain plug in again (tightening torque max. 5 Nm).
B
A
5. Pour the new hydraulic À uid through the ¿ ller neck into the hydraulic tank and close the
neck again with ¿ ller cap "B".
6. The unit then has to be bled again as described in the Chapter "Commissioning".
11.2.4 Changing decals
All damaged and/or illegible decals (safety notices, type plate etc.) must be replaced.
Procedure:
1. Remove damaged and/or illegible decals.
2. Clean surfaces with industrial alcohol.
3. Af¿ x new decals.
Take care to af¿ x the decals in the correct positions. If this is no longer known, you should
ask your authorised LUKAS dealer or contact LUKAS directly.
30
11.3 Additional service work
NOTE:
Non-observance of the maintenance plan can lead to malfunctions that are not
covered by the warranty.
For removing the sparking plug, use a commercially-available sparking plug
spanner with universal joint and wrench size 16 mm (5/8 inch).
A straight/rigid sparking plug spanner would damage or break off the sparking
plug!
(also observe the separate instructions from the engine manufacturer)
First month or after the fi rst 20 hours (fi rst time):
• Change engine oil (see operating instructions of the engine manufacturer).
You must conduct the following service measures every 50 operating hours:
• Clean the air ¿ lter element.
• After using in a dusty environment, inspect the air ¿ lter element and clean immediately ,
if necessary.
You must conduct the following service measures every 100 operating hours:
• Change engine oil.
• Check the sparking plug, clean if necessary / set the electrode gap of the sparking plug
You must conduct the following service measures every 200 operating hours:
• Replace the sparking plug
• Replace air ¿ lter
(The following service work should be executed by an authorised dealer, LUKAS directly or
the engine manufacturer.)
You must conduct the following service measures every 300 operating hours:
• Replace the sparking plug and ¿ lter element
• Clean and set the carburettor, valve clearance, valve seat and cylinder head.
You must conduct the following service measures every 1000 operating hours or every
2 years:
• Check the starter
• Inspect the engine for damage
• Check the fuel line and replace, if necessary.
31
11.3.1 Replacing and cleaning the air fi lter
NOTE:
Keeping the air ¿ lter in good condition is extremely important. Penetrating
dirt leads to damage and wear in the engine in case of incorrect installation,
incorrect damage or unsuitable ¿ lter inserts.
Always keep the air ¿ lter insert clean.
Procedure:
1. Unscrew both bolts from the air ¿ lter cover and remove the cover.
2. Remove the foam air ¿ lter insert from the cover.
3. Take the paper air ¿ lter insert from the air ¿ lter housing.
4. Check both air ¿ lter inserts and replace if damaged. The paper air ¿ lter set must always
be replaced in planned intervals.
5. Clean the air ¿ lter inserts when reusing.
Paper air fi lter insert: Tap out the paper air ¿ lter insert a few times on a hard surface to
remove dirt or blow compressed air [not more than 207 kPa (2.1 kg/cm )] from the air ¿ lter
housing side through the ¿ lter insert. Never attempt to brush out dirt because it would be
pressed in by the bristles. Replace the paper air ¿ lter insert if it is exceedingly dirty.
Foam air fi lter insert: Clean in warm soapy water, rinse and let dry thoroughly . Or clean in
non-À ammable solvent and let dry. Do not introduce any oil to the foam air ¿ lter insert.
6. Wipe away dirt from the inside of the air ¿ lter housing with a damp cloth. Ensure that dirt
does not penetrate the air duct leading to the carburettor.
7. Then, re¿ t the ¿ lter.
Bolts
Air ¿ lter housing
Paper air ¿ lter insert:
Foam air ¿ lter insert
Air ¿ lter cover
32
11.3.2 Replacing, cleaning and setting the sparking plug
Procedure:
In order to delivery good performance, the sparking plug must have a correct electrode gap
and be free from deposits.
1. Detach the sparking plug connector and remove any dirt near the sparking plug.
2. Unscrew the sparking plug using a 16 mm (5/8 inch) sparking plug spanner.
3. Inspect the sparking plug. Replace the sparking plug if it is damaged, extremely dirty , if the
sealing washer is in poor condition or if the electrodes are worn.
4. Measure the electrode gap of the sparking plug with a wire feeler gauge. Correct the
electrode gap, if required, by carefully bending the side electrode. Target electrode gap:
0.6 - 0.7 mm (0.024 - 0.028 in)
5. Carefully screw in the sparking plug by hand in order to avoid stripping the thread.
6. Tighten the sparking plug after mounting with a 5/8-inch sparking plug spanner in order to
compress the washer.
7. A new sparking plug should be tightened by an additional 1/2 turn after mounting in order
to compress the washer.
8. A used sparking plug should be tightened by an additional 1/8 to 1/4 turn after mounting
in order to compress the washer.
9. Place the sparking plug connector onto the spark plug.
NOTE:
A loose sparking plug can overheat and damage the engine.
A sparking plug that is too tight can damage the thread in the cylinder head.
Side electrode
0.6 - 0.7 mm
(0.024 - 0.028 in)
Sparking plug connector
Gasket
Sparking plug
spanner
11.3.3 Replacing the engine oil and the engine oil fi lter
For the procedure for replacing the engine oil and engine oil ¿ lter, please refer to the separate
operating instructions of the engine manufacturer!
33
11.3.4 Mono-couplings
The mono-couplings must be replaced if:
- there is external damage,
- the locking does not function,
- hydraulic À uid continues to leak in the coupled/uncoupled state.
WARNING/CAUTION!
Never repair couplings: they must be replaced by genuine LUKAS parts!
Procedure for coupling to hose pairs:
1. First empty the hydraulic tank as described in the chapter "Replacing the hydraulic À uid".
2. Pull the cover back from the couplings.
3. Release the union nuts on the hose lines and remove the coupling.
34
ATTENTION!
Ensure that connection “T1”/"T2" on the pump block is always connected to
connection “T” on the mono-coupling.
4. Position the new coupling and tighten the union nuts on the hose assemblies to a torque
of M
= 40 Nm and push the cover of the couplings back.
A
5. The hydraulic À uid reservoir must then be re¿ lled and the power unit vented.
11.3.5 Quick-disconnect couplings
The quick-disconnect couplings must be replaced if:
- there is external damage,
- the locking does not function,
- hydraulic À uid continues to leak in the coupled/uncoupled state.
WARNING/CAUTION!
Never repair couplings: they must be replaced by genuine LUKAS parts!
During assembly, tighten the union nuts on the hose line to a torque of M
= 35 Nm.
A
Procedure:
1. Release the union nuts on the hose line and remove the coupling.
2. Position the new coupling and tighten the union nut on the hose assemblies to a torque of
= 35 Nm.
M
A
ATTENTION!
The return hose, which is screwed onto the port “T” of the rescue tool, must
always be equipped with a quick-disconnect-coupling (male).
However, the supply hose line must be equipped with a quick-disconnectcoupling (female).
35
12. Fault analysis
Fault Check Cause Solution
Combustion engine
will not start
NOTE:
In case of faults
which directly affect
the combustion
engine, please
also observe
the separate
instructions in
the operating
instructions
of the engine
manufacturer.
Check fuel level
in tank
Check fuel line Fault in the fuel line Shut down immediately
Check engine
switch
Hydraulic unit
or engine not
suitable for
the working
environment
Check air ¿ lter Air ¿ lter contaminated Clean or replace the air
Are all valves
set to pressurefree(rest setting)?
Fuel tank empty Top up with fuel
Cable starter not
actuated
Engine switch not set to
Choke
Ambient temperature
too low
Not enough oxygen in
the air because of the
altitude of application
location of the hydraulic
motor
Combustion engine
defective or overloaded
due to a different defect
in the unit
and have it repaired by
an authorised dealer,
engine manufacturer or
directly by LUKAS
Actuate the cable
starter
Set engine switch to
Choke
For the solution,
consult the separate
operating instructions
of the engine
manufacturer.
Use a different
hydraulic À uid or
operating À uid that is
suitable for the relevant
ambient temperature
(see Chapter I
"Technical Data")
Use a different more
suitable hydraulic unit.
Have the engine
set to the altitude
of application of the
hydraulic power unit by
an authorised dealer,
engine manufacturer
or LUKAS directly
(only if the unit is to be
used frequently at this
altitude).
¿ lter.
Have repaired by
authorised dealer,
engine manufacturer or
directly by LUKAS
36
Fault Check Cause Solution
The engine is
running, but the
connected rescue
equipment is not
moving / moving
very slowly upon
activation of the
valve.
The connected
rescue equipment
does not move on
activation of the
valve, or moves
only very slowly or
unevenly.
Check hose Hose assembly not
connected properly or
damaged
Check the switch
position of the
valve lever on the
pump block of the
hydraulic unit
Connect a
different unit and
check whether
it works when
actuated
Connect a
different unit and
check whether
it works when
actuated
Check the switch
position of the
valve lever on the
pump block of the
hydraulic unit
Valve not switched
to supply line
pressurisation.
Defective pump unit Have it repaired by
The previously
connected unit is
defective.
Mono-coupling (female)
defective
The previously
connected unit is
defective.
Pressure relief on
the unit is still active
(circulation at static
pressure)
Defective pump unit Have it repaired by
Air in hydraulic system Vent the hydraulic
Plug-in coupling
(female) defective
Mono-coupling (female)
defective
Check connection of
hose and reconnect if
necessary .
Switch valve to
pressure load of the
supply line.
authorised dealer or
directly by LUKAS
Recti¿ cation see
operating instructions
of the connected unit
Replace mono-coupling
(female)
Recti¿ cation see
operating instructions
of the connected unit
Check the switching
positions of the
valve lever(s) and, if
necessary, reset (as far
as the end position)
authorised dealer or
directly by LUKAS
system
Replace plug-in
coupling (female)
Replace mono-coupling
(female)
37
Fault Check Cause Solution
Connected rescue
device does not
reach its end
position
Check hydraulic
À uid volume in
hydraulic reservoir
Insuf¿ cient À uid in the
hydraulic reservoir
Top up hydraulic À uid to
the maximum ¿ ll level
Caution! Before
topping up the rescue
equipment, return to
the rest position!
Connected rescue
device does not
reach its speci¿ c
performance data
During function test:
A pressure gauge
installed between the
rescue equipment
and the hydraulic
power unit does
not indicate the
maximum operating
pressure of the
equipment.
Check the details
of the rescue
device
Usable hydraulic À uid
volume of the unit is
insuf¿ cient
Maximum permitted
operating pressure
of the pump is not
reached
Pump block defective Have it repaired by
Connected unit
defective
The operating pressure
of the connected
rescue device is locked
internally
Connected rescue
device is defective
Hydraulic unit defective Have it repaired by
Use a different rescue
device with a demand
quantity below the
maximum usable
quantity of the unit
Have the pressure
limiting valve reset or
repaired by authorised
dealer or directly by
LUKAS
authorised dealer or
directly by LUKAS
Recti¿ cation see
operating instructions of
the connected unit
No repair or fault
recti¿ cation required
Consult the separate
operating manual for
the connected rescue
device
authorised dealer or
directly by LUKAS
38
Fault Check Cause Solution
Fluid coming out of
hydraulic À uid tank
Leaking À uid
between engine and
À ange bearing
Hydraulic À uid milky
and cloudy
Connected unit
not in rest position
yet and À uid
coming out of ¿ ller
cap?
Fluid leaks from a
different location?
Return of the hydraulic
À uid from the rescue
device exceeds the
reservoir’s maximum
quantity when ¿ lled.
Leak from tank, lines or
seals
Radial shaft seal on the
drive shaft is defective
Water / condensation in
the system
Reduce À uid level in
the hydraulic tank to
“Minimum” mark, move
the unit to the rest
position and then ¿ ll
back up with hydraulic
À uid to the “Maximum”
level
Replace defective
components or repair
by authorised dealer or
Lukas directly
Have it repaired by
authorised dealer or
directly by LUKAS
Replace the hydraulic
À uid immediately
Hoses cannot be
coupled
Pressure too high (e.g.
caused by ambient
temperature too high)
Coupling defective Coupling must be
Switch valve block to
circulation at static
pressure
replaced immediately
39
Fault Check Cause Solution
It is frequently not
possible to couple
hose assemblies
Hydraulic À uid not
adapted to the
application situation
Coupling defective Coupling must be
Hydraulic À uid must be
replaced (see chapter
"Recommended
hydraulic À uids")
replaced immediately
Leak from the
couplings
Leakage at the drive
shaft of the hydraulic
pump
NOTE:
In case of faults which affect the combustion engine, please also observe the instructions
in the separate operating instructions of the engine manufacturer.
Contact an authorised LUKAS dealer or the LUKAS Customer Service Department directly
if the malfunctions cannot be recti¿ ed.
The address for the LUKAS Customer Service department is:
LUKAS
A Unit of IDEX Corporation
Weinstraße 39, D-91058 Erlangen
Tel.: (+49) 09131 / 698 - 348
Fax.: (+49) 09131 / 698 - 353
Hydraulik GmbH
Coupling defective Coupling must be
replaced immediately
Shaft seal defective. Repair by an
authorised dealer, by
personnel specially
trained by LUKAS, or
by LUKAS direct.
40
13. Technical data
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.
NOTE:
The following tables contain only the technical data required for standard
acceptance.
Additional data concerning your unit can be obtained from LUKAS on request.
The limitation of the max. ¿ ll quantity of the hydraulic tank results from the
"operability at a slant" prescribed in the standards.
13.1 Power unit
13.1.1 Basic dimensions in mm [inch]
Dimensions of the power unit P 630 lite:
41
Dimensions of the power unit P 630 HV lite:
42
13.1.2 Technical data power unit
Device type P 630 lite
P 630 HV lite
Article number 81-53-25 81-53-26
Engine type
Engine power rating
Engine speed
Feed rate
1)
(HD)
Feed rate
2)
(ND)
Max. operating pressure
1)
(HD)
Max. operating pressure
2)
(ND)
max. fi ll quantity and
usable quantity
Hydraulic fl uid
Max. fi ll volume
Petrol
Weight (with petrol and
hydraulic fl uid)
[kW] 2.2
[HP] 3.0
-1
] 3000 / 3800
[min
[rpm.]
[l/min] 2 x 0.55 / 2 x 0.7
[gal.-US/min] 2 x 0.15 / 2 x 0.18
[l/min] 2 x 2.4 / 2 x 3.0
[gal.-US/min] 2 x 0.63 / 2 x 0.79
3)
[MPa]
[psi.] 10000
3)
[MPa]
[psi.] 2000
[l] 2.2
[gal.-US] 0.58
[l] 0.77
[gal.-US] 0.17
[kg] 22.4
[lbs.] 49.4 47.8
4-stroke petrol engine
70
14
21.7
Valve variants Simultaneous operation
max. number of
connectible devices
2
1)
HD = High pressure 2) ND = Low pressure
43
3)
1MPa = 10 bar
13.2 Noise emissions
Device type P 630 HV lite / P 630 lite
Speed 3000 [1/min] /
Idle run (according to EN) [dB(A)] 80 84
Full load (according to EN) [dB(A)] 84 88
Idle run (according to NFPA) [dB(A)] 73 77
Full load (according to NFPA) [dB(A)] 77 80
Explanation of dual number noise emission values according to DIN EN 13204:2012-09
Serial number of the machine, operating conditions and other characteristic properties:
Model ...P 630 lite, type ...81-53-25, maximum working pressure ...700 bar, engine
speed ....3800 [1/min] / [rpm]
INDICATED DUAL NUMBER NOISE EMISSION VALUES according to EN ISO 4871
Measured A-valued emission sound pressure level
LpA, in dB, with regard to 20 ȝPa ....88
Measurement uncertainty, KpA, in dB .....4
Measured A-valued emission sound power level (if required)
LWA, in dB, with regard to 1 pW ....101
Measurement uncertainty, KpA, in dB .....4
Determine values according to EN 13204, Appendix B, using basic standards
EN ISO 3744 and EN ISO 11201.
NOTE! The sum of the measured noise emission values and the associated measurement uncertainty that can occur during the measurement represent the upper limit of the
measured values.
[rpm] 3800 [1/min] / [rpm]
44
13.3 Sparking plug
Sparking plug type: CR5HSB (NGK)
U16FSR-UB (DENSO)
13.4 Sparking plug spanner
Universal joint sparking plug spanner with spanner size 16 mm
(5/8 inch)
13.5 Fuel
Lead-free petrol
Fuel:
ROZ 91 to ROZ 98
45
13.6 Engine oil
13.7 Hydraulic fl uid recommendation
Mineral oil DIN ISO 6743-4 for LUKAS 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
recommended range of viscosity: 10...200 mm²/s (10…200 cSt.)
Supplied with HM 10 DIN ISO 6743-4.
-4.0 .... +131°F HM 10 VG 10
ATTENTION!
Before you use hydraulic À uids from a different manufacturer, you must contact
LUKAS or an authorised dealer.
13.8 Operating and storage temperature ranges
Operating temperature [°C] / [°F] -20 … +55 -4 … +131
Environmental temperature
(device in operation)
Storage temperature
(device not in operation)
[°C] / [°F] -25 … +45 -13 … +113
[°F] -30 … +60 -22 … +140
[°C] /
46
14. EC Declaration of Conformity
47
15. Notes
48
495051
WARNING/CAUTION!
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!
Please dispose of all packaging materials and
removed items properly.
LUKAS
A Unit of IDEX Corporation
Weinstraße 39, D-91058 Erlangen
Tel.: (+49) 0 91 31 / 698 - 0
Fax.: (+49) 0 91 31 / 698 - 394
e-mail: lukas.info@idexcorp.com
www.lukas.com
Hydraulik GmbH
Made in GERMANY
© Copyright 2013 LUKAS Hydraulik GmbHP630_lite_manual_175075085_en.indd
Subject to changes
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