Lukas P 640 TG User Manual
Operating instructions
for rescue equipment
Hydraulic units
175010085 GB
Issue 12.2009
replaces 03.2009
(Translation of the original operating instructions)
2
Content Page
1. Hazard classes 4
2. Product safety 5
3. Proper use 9
4. Labelling of the units 9
5. Functional description 10
5.1 General information 10
5.2 Motor variants 10
5.3 Valve variants 11
5.4 Pumps 12
5.5 Frames 13
5.6 Connection to the rescue equipment 14
5.7 Connection options 14
6. Assembly of coupling systems 15
6.1 Mono-couplings 15
6.2 Direct connection 15
6.3 Quick-disconnect couplings 16
6.4 Adapter for direct connection to mono-coupling valve block 16
7. Connection of the hoses 17
7.1 Coupling the mono-couplings 18
7.2 Coupling the quick-disconnect couplings 19
7.3 Direct connection 20
8. Set-up and start-up 20
8.1 Set-up 21
8.2 Start-up 21
9. Operation 22
9.1 Starting the motors 22
9.2 Stopping the motors 23
9.3 Controlling the valves 24
10. Dismantling the equipment / deactivation following operation 27
11. Maintenance and service 28
11.1 Recommended testing periods 28
11.2 Hydraulic units with combustion engine 29
11.3 Hydraulic units with electric motor 29
3
12. Repairs 30
12.1 General information 30
12.2 Preventive service 31
12.3 Repairs 33
13. Troubleshooting 40
14. Notes 44
4
Hazard classes1.
We distinguish between various categories of safety instructions. The table below gives you
an overview of the assignment of symbols (pictograms) and key words to the specic hazard
and possible consequences.
Pictogram
Wear helmet with face protection
Damage /
injury to
human
device
- REMARK
Key word Denition Consequences
DANGER! Immediate danger
WARNING!
CAUTION!
CAUTION!
Potentially
dangerous
situation
Less dangerous
situation
Danger of damage
to device /
environment
Advice for
application and
other important /
useful information
and advice
Death or major
injury
Potential death or
major injury
Minor or slight
injury
Damage to the
equipment,
damage to the
environment,
damage to
surrounding
materials
No injury /
damage to
persons /
environment /
equipment
Wear safety gloves
Wear safety shoes
Proper recycling
Observe principles of environmental protection
Read and observe operating instructions
5
Product safety2.
LUKAS products are developed and manufactured in order 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 ensure LUKAS products are used 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 the operating instructions carefully
before using the equipment and comply with the instructions there without restriction.
We further recommend that a qualied instructor train you in the use of 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 instructions on how to use the equipment, you should still
read through the following safety instructions once again.
WARNING / CAUTION!
Ensure that the accessories and connected equipment used 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.
It is prohibited to work under
load if this load is lifted
exclusively by hydraulic
equipment. If this work is
absolutely imperative, additional
mechanical supports must be
used.
In the event of malfunctions,
immediately shut down the
equipment and secure it. The
malfunction is to be repaired
immediately.
The department responsible
is to be informed immediately
of any changes (including to
the operating behaviour). If
necessary, the equipment is to
be shut down immediately and
secured!
Inspect the equipment before
and after use for visible defects
or damage.
Inspect all lines, hoses and
screwed connections for leaks
and externally visible damage. If
necessary, repair immediately!
Squirting hydraulic liquids can
result in injuries and res.
Do not carry out any changes
(additions or conversions) to the
equipment without obtaining the
prior approval of LUKAS.
6
Comply with all the instructions
regarding safety and danger
on the equipment 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.
All the instructions regarding
safety and danger on the
equipment are to be kept
complete and in a legible
condition.
Any method of operation which
impairs safety and/or stability of
the equipment is prohibited!
Safety devices may never be
deactivated!
Before the equipment is
switched on / started up, and
during its operation, it must
be ensured that nobody is
endangered by the operation of
the equipment.
When working close to live
components and cables,
suitable measures must be
taken to avoid current transfers
or high-voltage transfers to the
equipment.
The build-up of static charge
with the potential consequence
of spark formation is to be
avoided when handling the
equipment.
Motor pumps may not be used
in explosion hazard areas!
The maximum operating
pressure set on the equipment
must not be changed!
Comply with all specied
dates or dates specied in the
operating instructions pertaining
to regular checks / inspections
of the equipment.
Only original LUKAS
accessories and spare parts
may 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.
When working with combustion
engine pumps, never touch
the motor and exhaust system,
since there is a risk of burning.
Combustion engines must not
be used in enclosed spaces, as
there is a danger of poisoning
and/or asphyxiation!
If fuel for combustion engines
is spilled, this fuel must be
removed completely before
starting the motor.
Filling up during operation of
the combustion engine is strictly
prohibited!
7
Keep combustion engines and
their fuel away from ignition
sources, as otherwise there is
the danger of an explosion.
All damaged electrical
components e.g. scorched
cables, etc. are to be replaced
immediately!
To avoid the danger of re
when using combustion
engines, ensure sufcient
ventilation and maintain a
safety distance of at least 1 m
(39.4 in.) to the walls and other
screens.
Please ensure that the
combustion engine pumps
are always placed on as at a
surface as possible in order to
prevent fuel from leaking.
The equipment is lled with
hydraulic uid. These hydraulic
uids can be harmful to your
health if swallowed or if their
vapours inhaled. Direct contact
with the skin is to be avoided
for the same reason. Please
also note that hydraulic uids
can also have a negative effect
on biological systems.
Ensure adequate lighting when
you are working.
Always keep these operating
instructions within reach where
the equipment is used.
Damage to electrical
components may only be
repaired by a qualied
electrician in compliance with
all applicable national and
international safety guidelines
and regulations.
When setting up the units, it
must be ensured that they are
not impaired by the inuences
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 extreme external
temperatures and that the
equipment is not 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 uid and packaging
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!
8
WARNING / DANGER / CAUTION!
The equipment is to be used exclusively for the purpose stated in the operating
instructions (see chapter "Proper use"). Any form of use beyond this is not considered
proper use. The manufacturer / supplier is not liable for any damages resulting from improper
use. The user bears sole responsibility for such use.
Observance of the operating instructions and compliance with the inspection and maintenance
conditions are covered by the denition of proper use.
Never work when you are overtired or intoxicated!
9
Proper use3.
LUKAS hydraulic units are specially designed to supply LUKAS rescue equipment with
hydraulic uid so that this equipment can be used to rescue victims of road, rail or air trafc
accidents as well as from buildings.
Their use for supplying pressure / uid to rescue equipment of other manufacturers is
possible, yet requires the technical inspection and approval by LUKAS in each individual
case.
WARNING / DANGER / CAUTION!
Always observe the safety notes of these operating instructions with regard to
place of installation and type of installation! The units must not be used in all
atmospheres, since there could be a danger of explosion!
Spare parts and accessories for the rescue equipment can be ordered from your authorised
LUKAS dealer!
Labelling of the units4.
P 640 I G D
Coding for
hydraulic units
Type group
Valve variants
Valve variants:
O = Single operation
A = Alternative operation
I = Automatic operation (ISV valve)
S = Simultaneous operation
T = Triple-ow operation (TRIMO)
Motor variants:
E = Electric motor (operation via mains
supply)
B = Electric motor (operation via battery)
G = Gasoline / petrol engine
D = Diesel engine
Frame variants:
(no entry) = Standard frame
D = D frame
U = U frame
S = Frame for rescue sets
F = F frame
Motor variants
-
Frame variants
HR-
Specications
(e.g. HR = with
mounted reels)
10
Functional description5.
5.1 General information
The main components (see sample illustration) of all LUKAS hydraulic units are:
1 Fluid reservoir
2 Motor
3 Pump
4 Frame
5 Connecting block with control valve
6 Carrying handle
6
6
3
5
4
5
3
2
1
1
As a general principle on all LUKAS hydraulic units, a hydraulic pump is operated with a
motor (combustion engine or electric motor) that feeds the uid from the reservoir and builds
up the pressure. The distribution of the uid is controlled by mounted valves.
The mounted frame serves as a simple protective cage and as a mounting base for
accessories that can be tted. The hydraulic unit can also be carried by the frame or using
carrying handles mounted on it.
2
1
5
5.2 Motor variants
WARNING / DANGER / CAUTION!
For all motor variants, also comply with the separate operating instructions of
each motor manufacturer.
5.2.1 Electrical
These hydraulic units are equipped with an electric motor. The electric motor is driven by
electricity from the mains supply or by electricity produced by generators. In the case of
operation with generators, make sure that voltage uctuations do not occur, as these have a
direct inuence on the pumping capacity and stability of the hydraulic unit.
The possible operating voltage, the current frequency and the required intensity of current
can be found in the separate instructions for your unit in the chapter entitled "Technical
data".
11
5.2.2 Gasoline / petrol
These hydraulic units are equipped with a combustion engine driven by the fuel "gasoline /
petrol".
(For specic details, please consult the separate operating instructions of the engine
manufacturer!)
The engines of type Briggs & Stratton have a main switch, which must be actuated for
switching the aggregate on and off. The accelerator cable of these engines does not have to
be readjusted and is xed in the position „ “. Nevertheless, if it is necessary in exceptional
cases to switch the engine into idle running, the accelerator lever can be lifted over the
adjusting plate and be switched into the position „ “.
5.2.4 Diesel
These hydraulic units are equipped with a combustion engine driven by the fuel "diesel".
(For specic details, please consult the separate operating instructions of the engine
manufacturer!)
5.3 Valve variants
In all cases, the valves are designed as connecting blocks. This block is rmly integrated into
the hydraulic unit. Both hoses (pressure and return) are always connected to the connecting
block. There are various connection blocks with different valve variants available for the
different requirements of operators and the various areas of application.
REMARK:
For certain regions, the selection of the control valves is limited due to applicable
standards and legal regulations.
Bear in mind that only the variants that are ofcially approved for your region will
be deployed!
CAUTION!
When operating several pieces of rescue equipment with one unit, ensure that
the usable volume of hydraulic uid in the reservoir is greater than the maximum
possible operating uid volume of all connected rescue equipment.
As a general principle, there are two different connection blocks for each connection block
variant. A block is conceived for screwing in mono-couplings directly and for screwing on
hoses. On the mono-coupling variants, an adapter can be used to screw on hoses directly.
On the hose connection variant, the built-in connection nipples can be replaced by quickdisconnect coupling halves.
It goes without saying that LUKAS can also provide adapter sets to connect mono-couplings
to a hose connection block. These adapter sets consist of a supply and return hose with a
mono-coupling tted on one end.
5.3.1 Control valve "single operation"
This variant only enables the connection of one pressure hose and one return hose. Turning
a lever / switch controls the pressure application to the pressure hose, i.e. the pressure on
the pressure hose is switched on or off.
5.3.2 Control valve "alternative operation"
This valve enables the connection of two pressure hoses and two return hoses. Turning a
lever / switch controls the pressure application to the pressure hoses. However, only one
device can be provided with pressure at any one time.
12
5.3.3 Control valve "automatic operation (ISV valve)"
This valve enables the connection of two pressure hoses and two return hoses. The
patented LUKAS ISV valve provides one device at each connecting block with pressure
without a manual switching procedure. Changeover between the two pressure hoses is
automatic. With this control valve, the rst driven and pressure-operated connected device
is always provided with hydraulic uid. The second connected device, on the other hand, is
automatically disconnected from uid supply.
5.3.4 Control valve "simultaneous operation"
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 two devices can be supplied with pressure
simultaneously and independently of one another. Without impairing the work output, it
enables work with two devices simultaneously and independently of one another.
5.3.5 Controlvalve"triple-owoperation"
This valve enables the connection of three pressure hoses and three return hoses. It has
three switching options, each of which controls the pressure application of the pressure hose
that is marked accordingly. This means three devices can be supplied with pressure
simultaneously and independently of one another. Without impairing the work output, it
enables work with three devices simultaneously and independently of one another.
5.4 Pumps
Depending on the type, a single-ow, double-ow or triple-ow pump is built into LUKAS
hydraulic units.
Single-ow pump 1 pump capacity
Double-ow pump 2 pump capacities
Triple-ow pump 3 pump capacities
The pumps used are always equipped with two pressure levels for each pump capacity, one
low-pressure and one high-pressure level.
Low-pressure level (ND) = up to 16 MPa*
High-pressure level (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.
WARNING / DANGER / CAUTION!
For reasons of safety, the pressure set on this valve must not be adjusted
(without direct authorisation from LUKAS)!
*) 1 MPa = 10 bar)
13
5.5 Frames
As a general principle, all hydraulic units from the rescue equipment range come with a
frame to make them easier to transport.
5.5.1 Standard frame
The standard frames vary depending on the type of hydraulic unit. They range from simple
handles through to bow-type handles all the way to a frame adapted according to the unit.
It therefore cannot be guaranteed that the entire unit can t inside the exterior dimensions of
the frame of standard frames.
5.5.2 D frame
As a general principle, the D frame dimensions are 500 mm x 440 mm x 480 mm.
On D frames, all parts of the unit are located within the frame.
In addition, there are mounting possibilities for connection hose reels (one double and two
single hose reels).
The dimensions mean that this frame ts into in the standard xing devices of rescue service
vehicles.
5.5.3 U frame
The U frame differs from the D frame with regard to outer dimensions and shape. There are
currently no mounting possibilities for hose reels on this frame.
14
5.5.4 Frame for rescue sets
The frame for rescue sets is specically designed for the motor / engine and all the
components included in a rescue set. In some cases, these frames have additional mounting
options or special attachment parts.
(For specic information, please contact your authorised LUKAS dealer or LUKAS directly.)
5.5.5 F frames
The F frame is currently the largest frame in the LUKAS range. This frame is deployed if
the size of the motor and mounted parts makes other frame variants too small. The special
shape of this frame enables mounting of connection hose reels (one double and two single
hose reels).
This frame is mainly used for combustion engine units with triple-ow control valves (TRIMO
units).
5.6 Connection to the rescue equipment
Connection with the rescue equipment is via extension hose pairs or hose reels. These
are available in various lengths, coloured bend protections and with various connection
options.
The individual hoses of a hose pair are to be differentiated by colour to prevent confusion of
the pressure and return hoses.
(For specic details, please consult the LUKAS range of accessories or contact your
LUKAS dealer).
5.7 Connection options
The connections for the hydraulic hoses are always on the valve block.
In the standard range, only mono-couplings or alternatively direct connections, or quickdisconnect couplings or alternatively direct connections are envisaged. Depending on the
coupling variant, an autonomous connecting block is tted on the unit.
In order to be able to use the direct connection as an alternative possible connection, an
adapter or connection nipple (male) must be tted in the connecting block beforehand.
(Fitting the adapter, see chapter "Assembly of coupling systems")
15
Assembly of coupling systems6.
6.1 Mono-couplings
Only female mono-coupling halves are mounted
on the connecting block of the hydraulic unit.
The female coupling is screwed into the valve
block with a tightening torque of M
6.2 Direct connection
On the connecting block of the hydraulic unit, the connection nipple (male) is screwed into the
valve block with a tightening torque of M
Subsequently, suitable locking elements (e.g. locking ball with nut) must be screwed onto the
connection nipples or the hoses must be connected immediately.
= 40 Nm.
A
= 40 Nm.
A
Loading...