Lukas P 630 SG User Manual
Operating instructions for rescue equipment
Hydraulic power unit P 630 SG
(Translation of the original operating instructions)
175070085 EN
Edition 11.2013
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 14
5.5 Pumps 15
5.6 Frame with side sections 15
5.7 Connection to the rescue equipment 15
6. Connecting the hoses / devices 16
6.1 Coupling the mono-couplings 16
7. Erection and start-up 18
7.1 Set-up 18
7.2 Start-up 18
8. Operation 20
8.1 Starting the engine 20
8.2 Turning the engine off 21
8.3 Refuelling 21
8.4 Controlling the valves 22
9. Dismantling the equipment / deactivation following operation 23
10. Tests 24
10.1 Recommended test intervals 24
10.2 Visual and function check 25
11. Maintenance and repair 26
11.1 General information 26
11.2 Service work on the hydraulic unit 27
11.3 Additional service work 29
12. Fault analysis 34
3
Content Page
13. Technical data 39
13.1 Power unit 39
13.2 Noise emissions 41
13.3 Sparking plug 42
13.4 Sparking plug spanner 42
13.5 Fuel 42
13.6 Engine oil 43
13.7 Hydraulic fl uid recommendation 43
13.8 Operating and storage temperature range 43
14. EC Declaration of Conformity 44
15. Notes 45
4
1. Danger classifi cations
We differentiate between various different categories of safety instructions. The table shown
below shows you 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 must only be operated by persons with appropriate training in the safety
aspects of such equipment – otherwise, there is a danger of injury.
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 you have a quali¿ ed trainer show you how to use the product.
CAUTION!
The operating instructions for the hoses, accessories and the connected
devices must also be heeded!
Even if you have already received instruction 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
information 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 original 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. are to 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 must 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 make sure 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 damages 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!
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 limitation!
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
Valve variants:
S = Simultaneous operation
Motor variants:
G = Petrol engine
630 S G
Type group
Valve variants
Motor variants
5. Functional description
5.1 General information
In the case of all LUKAS hydraulic power units, the hydraulic pump is operated with a motor.
The pump conveys the À uid from the hydraulic oil tank and builds up the pressure in the tool.
Fluid is distributed to the connected equipment through control valves.
The P 630 SG is a power unit with frame and with a petrol engine and simultaneous operation.
11
5.2 Installation of the power unit
11
3
4
9
1
13
16
5
7
10
12
2
Equipment back
23
14
15
1 Petrol tank
2 Hydraulic À uid tank
3 Engine with hydraulic pump
4 Connecting block with
control valves
5 Speed adjusting lever
6 Carrying handle
7 Cable-pull starter
8 Valve control lever
9 "TURBO" control lever
10 Mono-coupling (female)
11 Fuel tank cap
12 Filler cap hydraulic À uid
13 Frame
14 Rubber buffer
15 Side panel
16 Air ¿ lter
17 Choke
18 Fuel tap
19 ON/OFF switch (engine
switch)
22 Engine oil ¿ ller cap/dipstick
23 Fill level indicator
17
18
19
22
12
5.3 Motor
WARNING/CAUTION!
See also the separate operating instructions of each engine manufacturer
accompanying the delivery.
5.3.1 Petrol engine
These hydraulic units are equipped with a combustion engine driven by the fuel "petrol".
The power units are equipped with a cable-pull starter with which the engine is started.
(For specifi c details, please consult the separate operating instructions of the engine
manufacturer!)
HONDA motors have a main switch that must be activated to switch the power unit on and
off. The speed adjusting lever on these power units has two switch positions.
Switch position 1 (standard): Speed 3000 1/min " " and
Switch position 2: Speed 3800 1/min " ".
The setting is adjusted by moving the speed adjusting lever.
NOTE:
The engine installed in the 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
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.
The connecting block of the P 630 SG also has a TURBO function.
With a switching lever, either both connected devices can be supplied simultaneously with
hydraulic À uid, or a single device can be supplied with double the volume (= TURBO function).
By supplying at double the feed rate, the speed of the connected device is increased.
The hoses are connected with the connecting block via mono-couplings.
5.4.1 Control valve "simultaneous operation" (SIMO)
This valve enables the connection of two pressure hoses and two return hoses. It has two
switching options, each of which controls the pressure application of the pressure hose
that is marked accordingly. This means that two devices can be supplied with pressure
simultaneously and independently of each other. Without impairing the work output, it
enables work with two devices simultaneously and independently of each other.
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 hydraulic power units model P 630 are equipped with a SIMO connecting block.
The pump is rigidly connected to the connecting block.
Double-À ow pump for operating with 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*
High-pressure level (HP) = up to 70 MPa*
The changeover from low pressure to high pressure is carried out automatically by 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)!
*) 1 MPa = 10 bar)
5.6 Frame with side sections
The P 630 hydraulic power unit is mounted within a frame.
The frame and side panels are also used, despite the robust design, to protect the power unit
from external inÀ uences, such as for example, dirt or damage.
5.7 Connection to the rescue equipment
Connection to the rescue equipment is via extension hose pairs or via hose reels. They are
supplied in various lengths.
(For specifi c details, please consult the LUKAS range of accessories or contact your
LUKAS dealer.)
15
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