Lukas P 650 User Manual
Instruction manual for rescue equipment
Hydraulic units P650
(Translation of the original instruction manual)
175710085 EN
Edition 11.2014
replaces 07.2014
Contents Page
1. Hazard classes 5
2. Product safety 6
3. Intended use 10
4. Labelling of the units 11
5. Functional description 11
5.1 General information 11
5.2 Structure of the units 12
5.3 Motor variants 13
5.4 Valve variants 14
5.5 Pumps 15
5.6 Frame with side parts 15
5.7 Connection to the rescue equipment 15
5.8 Hose reels 16
5.9 Carrying handle 16
5.10 Toolholder 16
6. Connection of the hose lines / devices 17
7. Set-up and start-up 19
7.1 Set-up 19
7.2 Start-up 19
8. Operation 20
8.1 Starting the motor/engine 20
8.2 Stopping the motor/engine 21
8.3 Refuelling (combustion engines only) 22
8.4 Controlling the valves 22
8.5 Hose reels 24
8.6 Telescopic carrying handles 26
8.7 Toolholder 27
9. Removing the device / deactivation following operation 32
10. Tests 33
10.1 Recommended inspection intervals 33
10.2 Hydraulic units with combustion engine 34
10.3 Hydraulic units with electric motor 35
10.4 Hose reels 36
2
11. Maintenance and repair 36
11.1 General information 36
11.2 Maintenance work on the hydraulic unit 37
11.3 Additional maintenance work on units with a combustion engine 39
11.4 Maintenance work on mounted hose reel 43
12. Troubleshooting 46
13. Technical data 53
13.1 Power unit 53
13.2 Noise emissions (Sound pressure level) 61
13.3 Sparking plug 63
13.4 Sparking plug socket 63
13.5 Fuel 63
13.6 Engine oil 64
13.7 Hydraulic fl uid recommendation 64
13.8 Operating and storage temperature range 64
14. EC Declaration of Conformity 65
15. Notes 67
3
4
1. Hazard classes
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 speci¿ c hazard
and possible consequences.
Pictogram
Wear helmet with face protection
Damage /
injury to
People
Objects
- NOTE
Key word Defi nition Consequences
DANGER! Immediate danger
WARNING!
CAUTION!
ATTENTION!
Potentially
dangerous
situation
Less dangerous
situation
Danger of damage
to objects /
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
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 the product design.
Moreover, the operating instructions are intended to help the safe use of LUKAS products.
The generally applicable legal and other binding regulations pertaining to the prevention of
accidents and protection of the environment apply and are to be complied with in addition to
the operating instructions.
The device may only be operated by persons with appropriate training in the safety aspects
of such equipment – otherwise, there is a danger of injury occurring.
We would like to point out to all users that they should carefully read and adhere to the
operating instructions before they use the equipment.
We further recommend that a quali¿ ed 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 the following safety notes 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.
Immediately report any
changes that occur (including
changes in operating
behaviour) to the appropriate
persons/departments! If
necessary, deactivate the
device immediately and secure
against restart!
Inspect the device for visible
defects 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 shut down the
equipment and secure it.
The malfunction is to be
repaired immediately.
Observe all safety and danger
notes 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
deactivated!
Do not carry out any changes
(additions or conversions)
to the equipment without
obtaining prior approval from
LUKAS.
All safety and danger notes
on the device are to be kept
complete and in a legible
condition.
Any mode of operation which
impairs safety and/or stability
of the device is forbidden!
The maximum operating
pressure set on the equipment
must not be changed!
Before the device is switched
on/started up, and during its
operation, it must be ensured
that nobody is endangered by
the operation of the device.
When working in the proximity
of live components and
wires, appropriate steps must
be taken to avoid current
transmission or high-voltage
discharge through the device.
The build-up of static charge
with the potential consequence
of spark formation is to be
avoided when handling the
device.
Motor pumps may not be used
in explosion hazard areas!
If fuel for combustion engines
is spilled, this fuel must be
removed completely before
starting the motor.
Comply with all speci¿ ed
dates or dates speci¿ ed in
the operating instructions
pertaining to regular checks /
inspections of the equipment.
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.
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!
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 suf¿ cient
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 À at a
surface as possible in order to
prevent fuel from leaking.
The device is ¿ lled with
hydraulic À uid. These hydraulic
À 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
À 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 device is used.
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, it
must be ensured that they are
not impaired by the inÀ uences
of extreme temperatures.
When working with or storing
the device, ensure that the
function and the safety of the
device are not impaired by the
effects of extreme external
temperatures or that the
device is damaged in any way.
Please note that the device
can also heat up over a long
period of use.
Before transporting the
device, always ensure that the
accessories are positioned
such that they cannot cause
an accident.
Ensure the proper disposal of
all removed parts, leftover oil,
hydraulic À 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 / CAUTION / ATTENTION!
The device is to be used exclusively for the purpose stated in the operating instructions
(see chapter "Intended Use"). Any form of use beyond this is not considered intended
use. The manufacturer / supplier is not liable for any resulting damages. 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 de¿ nition of intended use.
Never work when you are overtired or intoxicated!
WARNING / CAUTION / ATTENTION!
Should you sustain an injury while working with the hydraulic unit, clean the
wound immediately and seek medical attention!
If hydraulic À uid enters your eye, rinse immediately several times with clear, clean
water and seek medical attention!
You should also seek medical attention after ingesting hydraulic À uid!
9
3. Intended 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 power units were not
(operating time < 15 minutes).
WARNING / CAUTION / ATTENTION!
Always observe the safety notes of these operating instructions with regard to
place of installation and type of installation!
Type P 650 units manufactured by LUKAS are not explosion-proof!
You can obtain accessories and replacement parts for the rescue apparatus from your
authorised LUKAS dealer!
CAUTION!
When selecting a device for connection, remember that the maximum possible
useable volume of the hydraulic À uid is limited.
The maximum total volume of hydraulic À uid required by all connected devices
must not exceed the maximum possible useable volume of the unit!
Due to the limited useable volume, a maximum of 2 rescue rams can be
connected for reasons of safety (only at maximum ¿ ll quantity).
Type R424 cylinders are an exception to the rule, however.
Two of these cylinders should never be coupled and operated
simultaneously!
developed for being operated without hoses or devices
NOTE:
Always register your hydraulic unit on the LUKAS Hydraulik GmbH website.
This is the only way to guarantee your extended warranty cover.
Y ou must always contact LUKAS or an authorised dealer before using couplings
from another manufacturer.
10
4. Labelling of the units
P
Coding for
hydraulic units
650 4 G
Type group
Valve variants
Valve variants:
S = Simultaneous mode
4 = 4POWER mode
Motor variants:
E = Electric motor (operation via mains supply)
G = Gasoline engine
Motor variants
-
ES
with electric starter
-
DHR
Speci¿ cations
(e.g. DHR = with
integral reels)
5. Functional description
5.1 General information
The hydraulic pump on all LUKAS hydraulic units is always operated by a combustion
engine or electric motor. The pump conveys À uid from the reservoir and builds up hydraulic
pressure. The distribution of the À uid is controlled by mounted valves.
Two versions of type P650 unit are available:
1. small frame without reel
2. large frame with mounted reel, Toolholder and carrying handles
The telescopic carrying handles are an optional accessory for the ¿ rst version and can
always be retro¿ tted.
NOTE:
A hose reel is only included with the second version and cannot be retro¿ tted
at a later date!
11
5.2 Structure of the units
8
11 12
1
13
7
10
9
17
10
21
15
18
14
21
10
22
18
4
20
11 17
19
12
15
16
2
3
6
5
14
1 Hydraulic À uid reservoir
2 Gasoline tank
3 Engine with hydraulic
pump
4 Connecting block with
control valves
5 Engine switch
6 Electric starter button
7 Pull cord starter
8 Valve control lever
9 "TURBO" control lever
10 Mono-couplings
1 1 Hydraulic À uid ¿ ll cap
17
12 Gasoline ¿ ll cap
13 Frame
3
14 Side panel
15 Rubber buffer
16 ON/OFF switch for
electric motor
17 T elescopic carrying
handle
(also optionally available
for retro¿ tting)
18 Hose reel
19 Crank handle (hose reel)
20 Lock (hose reel)
21 Hose guide
22 T oolholder
5.3 Motor variants
WARNING / CAUTION / ATTENTION!
For all motor variants, also comply with the separate operating instructions of
each motor manufacturer.
5.3.1 Electric motor
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 À uctuations do not occur, as these have a
direct inÀ uence 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 chapter entitled „Technical data".
NOTE:
Using an extremely long electrical connection cable may reduce the output
resistance and the power supply to the motor. The performance of the motor will
be affected as a result.
5.3.2 Gasoline engine
These hydraulic units are equipped with a combustion engine driven by the fuel "gasoline /
gasoline".
Units can be ¿ tted with both an electric starter and a pull cord starter, or a pull cord starter
only. It is only possible to determine the unit version from the item number and unit name or
the designation printed on the unit.
The integral generator charges the starter battery automatically while the engine is operating.
NOTE:
Not all the technical details of the engine installed in LUKAS units correspond
to the engine described in the separate operating instructions provided by the
manufacturer. Components such as the gasoline tank have been modi¿ ed to
guarantee the safety of the overall hydraulic unit because the unit is used for
rescue operations.
However, it is important that you observe all safety regulations and operating,
maintenance and storage instructions included in the separate manual
accompanying the engine without fail because they are unaffected by any
adaptations made by LUKAS.
If the battery discharges completely after a period of inactivity, you must start the unit using
the cord pull starter and allow the unit to operate until almost a complete tank of fuel has
been consumed. The battery will then be fully charged.
If the battery is still not charged after the unit consumes a full tank of fuel, the causes may
include the following:
- the contacts (connector) have come loose and must be connected again.
- the battery is defective and must be replaced.
- the generator or engine is damaged. In this case, contact LUKAS customer service
directly .
13
5.4 Valve variants
The valves are always permanently installed in a connecting block. This block is integrated
directly in the hydraulic unit. Both hose lines (pressure and return) are always connected to
the connecting block. The units are ¿ tted either with a SIMO or a 4POWER connecting block.
Both connecting blocks also have a TURBO function.
More speci¿ cally, this means that there are always 2 device connections linked internally to
one another. A shift lever gives you the option of supplying hydraulic À uid to both connected
devices simultaneously or supplying double the quantity to one device (= TURBO function).
Supplying double the quantity of À uid increases the operating speed of the connected device.
The hoses and devices are always connected to the connecting block via mono-couplings.
On units with a hose reel, only the connection hoses between the hose reel and connecting
block are screwed in position.
CAUTION!
When operating several pieces of rescue equipment with one unit, ensure that
the usable volume of hydraulic À uid in the reservoir is greater than the maximum
possible operating À uid volume of all connected rescue equipment.
5.4.1 "Simultaneous mode" (SIMO) control valve
This valve enables the connection of two dual-acting hydraulic devices. The valve allows
you to operate two devices simultaneously and independently of one another or supply a
larger quantity of hydraulic À uid to one device. Supplying a larger quantity of hydraulic À uid
increases the operating speed of the relevant device.
There are three switches available. The two smaller switches can be used to depressurise the
individual connections. The large switch is responsible for controlling the TURBO function.
5.4.2 "4POWER mode" control valve
This valve enables the connection of four dual-acting hydraulic devices. The valve allows
you to operate four devices simultaneously and independently of one another or supply a
larger quantity of hydraulic À uid to a maximum of two devices. Supplying a larger quantity of
hydraulic À uid increases the operating speed of the relevant devices. The TURBO function
can only be connected between the points either side of the large switch because the device
connections are linked internally.
There are six switches available. The four smaller switches can be used to depressurise
the individual connections. The large switches are responsible for controlling the TURBO
function.
The switches and connections are labelled to make them easier to assign to one another.
14
5.5 Pumps
LUKAS hydraulic units are equipped with a double-À ow or four-À ow pump depending on the
type. The pumps are permanently connected to the connecting block.
Double-À ow pump for operation with SIMO valve
Four-À ow pump for operation with 4POWER valve
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 (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 in the pump.
The maximum pressure is limited by a pressure limiting valve.
WARNING / CAUTION / ATTENTION!
For reasons of safety, the pressure set on this valve must not be adjusted
(without direct authorisation from LUKAS)!
*) 1 MPa = 10 bar
5.6 Frame with side parts
A surrounding frame is ¿ tted to all the hydraulic units described here, without exception.
The frame and the side parts are designed to protect the unit from external inÀ uences (e.g.
dirt, damage, etc.), to attach accessories (e.g. Toolholders) and as a means of transporting
the unit by the frame itself or the optional carrying handles.
The starter equipment and accelerator cable regulator on units with a combustion engine are
mounted on the frame or side parts.
5.7 Connection to the rescue equipment
Connection with the rescue equipment is via extension hose pairs or hose reels. These are
available in various lengths and coloured bend protections.
Different colours distinguish the individual hose lines in a hose pair.
(For specifi c details, please consult the LUKAS range of accessories or contact your
LUKAS dealer).
15
5.8 Hose reels
The hose reels were designed to store extension hose pairs leading between the hydraulic
supply and the working equipment (hose pairs are included in the delivery as standard).
The extension hose pairs are connected to the hose reels and rolled onto the drums.
A hose reel with extension hose pairs can cover long distances between the hydraulic supply
and the working equipment, allowing you to keep the hydraulic unit on a vehicle, for example.
The possibility of rolling up and unrolling the hose allows you to adapt the hose length
accordingly and reduce the amount of unnecessary or potentially dangerous excess hose
lying on the ground.
The extension hose pairs are easier to transport and store when fully rolled up.
Moreover, the hose reels on type P650 units are equipped with a hose guide that facilitates
easier rolling up and unrolling.
The unit is connected to the working equipment via couplings.
CAUTION!
In order to avoid potential losses in pressure, the length of the extension hose
lines must not exceed 30 m!
NOTE:
Only 2 of the 4 connections can be connected to the hose reel on type
P 650 4G units.
There are 2 coupling connections located between the two reel drums for the
remaining two connections. The lower of the two connections is extendable to
allow easier coupling. It also engages easily in the end positions.
The switches and connections are labelled to make them easier to assign to one
another.
5.9 Carrying handle
Type P650 LUKAS hydraulic units without a hose reel can be ¿ tted with optional carrying
handles. The scope of delivery of units with a hose reel already includes handles.
The P650 can be transported more ergonomically using the carrying handles.
5.10 Toolholder
Type P650 LUKAS hydraulic units with a hose reel are ¿ tted with a Toolholder.
The Toolholder is usually designed to attach a spreader and a type S700 cutter.
Needless to say, it is possible to adapt the mount to accommodate all LUKAS cutters and
spreaders as well as modify it at a later date.
The Toolholder allows you to transport a unit with devices still attached.
You no longer have to detach and store devices separately after use. You only have to wind
the hose lines onto the reels and position the devices on the Toolholder again.
Devices secured to the unit do not pose a risk during transport.
16
6. Connection of the hose lines / devices
CAUTION!
When connecting the hose lines / devices, always ensure that the connection
components are not soiled. Clean beforehand if necessary!
WARNING / CAUTION / ATTENTION!
Before connecting equipment, make sure that all the components
used are suitable for the maximum operating pressure of the
hydraulic unit! In cases of doubt, you must consult LUKAS
directly before connecting the equipment!
The hose lines / devices are connected to the hydraulic pump or hose reel via mono-coupling
halves (male and female) without any risk of confusion.
Dust protection caps
Male coupling
Female coupling
17
Before coupling, remove the dust protection caps, then connect male and female couplings
and turn the locking sleeve of the female coupling in direction "1" until the locking sleeve
latches. The connection has now been made and locked. Decoupling is accomplished by
turning the locking sleeve in direction "0".
Coupling of the hose lines 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, otherwise the coupling may require the application of a
great deal of force.
For dust protection, the supplied dust caps must be re¿ tted.
Fitting the dust protection caps:
The "A" dust protection caps 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 "C"
pins. Screw the dust protection caps to the limit stop to ¿ x in the female couplings.
A
B
C
18
C
7. Set-up and start-up
7.1 Set-up
WARNING / CAUTION / ATTENTION!
Combustion engine units and electrical units must not be used in a potentially
explosive situation (danger of the formation of sparks). 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:
Before commissioning the unit for the ¿ rst time or after longer periods of inactivity,
the starter battery must be connected and the engine oil checked (units with a
combustion engine)! Replenish the engine oil if necessary!
LUKAS units are delivered without engine oil for reasons of safety!
Please proceed as follows:
1. First of all, check the À uid levels in the unit.
The translucent reservoirs provide a good view of the À uid levels in the unit. The reservoirs
have marks that indicate the minimum and maximum levels. If possible, the hydraulic unit
should be positioned on a level surface when the À uid levels are read and the reservoirs
¿ lled.
CAUTION!
Always ¿ ll fuel and hydraulic À uid into the correct reservoir otherwise the unit
may sustain damage!
2. On hydraulic units with an electric motor, connect the plug to the power supply at this
point.
3. Then vent the hydraulic unit. Set all levers on the control valves to the neutral position
(see chapter "Operation"). The actual venting is carried out in the units in a different
manner, depending on the drive motor:
a) Gasoline engine:
- Detach all connectors from the sparking plugs (on the back of the unit).
- Slowly turn the engine over with the starter rope several times.
- Then replace the sparking plug connector.
b) Electric motor (mains power operation):
- Switch the motor on and then off again after approx. 10 seconds, repeat
this procedure several times. (Before switching back on,
the motor must be at a standstill!)
19
This procedure means that the pump can slowly draw À uid in and be well vented. The
hydraulic À uid reservoir is equipped with automatic venting, which means no further
venting measures are required.
4. Check the À uid levels in the reservoirs again. If necessary, top up the À uid.
5. To conclude, you can now connect the extension hoses and/or hose reels (unless already
connected to the unit) and/or couple the rescue equipment.
8. Operation
CAUTION!
The control levers on the hydraulic unit must be shifted to neutral position before
the motor/engine is started to prevent connected hydraulic equipment from
moving unexpectedly.
Levers on units with a Toolholder should only be shifted back after you have
removed the devices from the mount and intend to start work.
8.1 Starting the motor/engine
8.1.1 Gasoline engines
Before starting the combustion engines, 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.
Starting procedure:
1. Set the engine switch to the "CHOKE" position
( ) (if the engine is already warm or the ambient
temperature is high, start the engine with the
switch in the "ON" position.)
2. Starting with electric starter:
Press the starter button
Starting with pull cord starter:
Slowly pull the handle on the pull cord starter
beyond the compression point (resistance is felt).
Allow to return to the starting position and pull
again quickly all the way out.
NOTE:
If the engine refuses to start after several attempts, repeat the procedure
described above with the engine switch set to the "ON" position.
3. When the engine starts, keep hold of the handle on the pull cord starter and allow it to
return to its starting position.
4. Allow the engine to warm up for 20 to 30 seconds and then set the engine switch to the
"ON" position (if previously set to "CHOKE").
20
8.1.2 Electric motors
Before starting the electric motors, check that all electrical connections and cables are in
proper order. First of all, connect the power cable (for motors with power supply) to the
supply socket.
The motor is started by pressing the ON/OFF switch on the side of the unit. The ring around
the switch lights up when the unit is switched on.
CAUTION!
Electric motors draw a brief, very high starting current. When using a generator,
you should therefore check to see that it can supply the relevant current strength.
The power supply must be protected by a 25 A fuse at least.
8.2 Stopping the motor/engine
8.2.1 Gasoline engines
The engine on the unit stops automatically when the fuel tank is empty. However, you should
stop the machine and refuel before this happens.
The following procedure stops the engine manually:
Stopping procedure:
1. Make sure that all connected rescue devices are in base position (starting position).
2. Set the levers on the control valves to neutral position (depressurised).
3. Set the engine switch to the "OFF" position.
WARNING / CAUTION!
Never touch the hot motor / engine parts: this could result in severe burns!
8.2.2 Electric motors
Set the levers on the control valves to neutral position (depressurised).
Pressing the ON/OFF switch on the side of the unit switches the engine off again. The illuminated
ring around the switch goes out.
When the engine is switched off, the connected hydraulic pump stops delivering.
21
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