Lukas P 660 SG User Manual
Operating instructions
Rescue equipment
P660SG SUPER SILENT
175325085 GB
Edition 07.2010
replaces 06.2008
(Translation of the original Operating Instructions)
Contents Page
1. Danger classes 3
2. Product safety 4
3. Proper use 7
4. Unit labelling 7
5. Functional description 8
5.1 General 8
5.2 Motor 9
5.3 Control valve 9
5.4 Pumps 9
5.5 Connection to rescue devices 9
5.6 Connection options 10
6. Connection of the hose lines 10
7. Installation and commissioning 11
7.1 Installation 11
7.2 Commissioning 11
8. Operation 14
8.1 Starting motors 14
8.2 Stopping motors 16
8.3 Controlling the valves 17
8.4 Opening the side parts 17
9. Removal of the device / Shutdown after operation 17
10. Care and maintenance 18
11. Repairs 20
11.1 General 20
11.2 Preventative service 20
11.3 Repairs 24
12. Troubleshooting 25
13. Technical data 28
13.1 Unit 28
13.2 Noise emissions 29
13.3 Spark plug 29
13.4 Fuel 29
13.5 Motor oil 29
13.6 Hydraulic uid recommendation 30
13.7 Operating and storage temperature ranges 30
14. Notes 31
2
1. Danger classes
We distinguish between various categories of safety instructions. The table shown below
shows you the overview via the assignment of symbols (pictograms) and signal words the
concrete danger and the possible consequences.
Pictogram
Wear helmet with face guard
Damage /
injury to
human
device
- NOTE
Key word De nition 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 protective gloves
Wear safety shoes
Proper recycling
Protect the environment
Read and follow operating instructions
3
2. Product safety
LUKAS products are developed and produced in order to ensure the best performance and
quality with proper use.
The safety of the operator is the most important consideration of the product design.
In addition, the operating instructions are to help use the LUKAS products safely.
In addition to the operating instructions, all generally applicable, statutory and other
binding rules for accident prevention and for environmental protection must be heeded and
disseminated.
The device must only be operated by educated persons who are trained in safety technology,
because otherwise there is a risk of injury.
We advise all users before using the device to carefully read through the operating instructions
and to follow the instructions contained therein without exception.
We also recommend that you get instructed by a quali ed trainer in the use of the product.
WARNING / CAUTION!
The operating instructions for the hoses, the accessories and the connected
devices must also be heeded!
Even if you have already received instruction, you should read the following safety instructions
again.
WARNING / CAUTION!
Make sure that the accessories used and the connected devices are suitable
for the max. operating pressure!
Make sure that no body parts
or clothing get between the
openly visible moving parts of
the device.
Wear protective clothing,
protective helm with visor,
safety shoes and protective
gloves.
Working under loads is
prohibited if they are raised
exclusively with hydraulic
devices. If this work is
unavoidable, suf cient
mechanical supports are
additionally required.
In the event of malfunctions,
shut down the device
immediately and secure it. You
should have the malfunction
repaired immediately.
Immediately report changes
that occur (including changes
in operating behavior) to
the appropriate persons/
departments! If necessary,
immediately shut down and
secure the device!
Check the device for visible
defects or damage before and
after use.
Check all lines, hoses and
screwed connections for leaks
and externally visible damages
and repair immediately!
Escaping hydraulic uid can
lead to injuries and res.
Do not make any changes
(add-ons or conversions) on the
device without the approval of
LUKAS.
4
Heed all safety instructions
and hazard warnings on the
device and in the operating
instructions.
All safety instructions and
hazard warnings on the device
are to be kept intact and in a
legible condition.
Make sure that all safety covers
are present on the device and
in proper working condition.
Safety equipment must never
be disabled!
Before switching on/engaging
the device or while operating
the device, it must be ensured
that no one is endangered by
operating the device.
When working in the vicinity
of live components and lines,
take appropriate measures for
preventing current transfers or
high voltage ashovers to the
device.
The source of electrostatic
discharge with the possible
consequence of spark formation
when handling the device
should be prevented.
Motor pumps must not be
operated in areas at risk for
explosion!
Any work procedure that
detracts from the safety and/or
stability of the device should be
abandoned!
The maximum permissible
operating pressure must not be
changed.
Observe all intervals that
are prescribed or speci ed
in the operating instructions
for recurring tests and/or
inspections.
For repairs only original LUKAS
accessories and replacement
parts are to be used.
Make sure that you do not
get caught in the hose loops
and trip when working with or
transporting the device.
Do not come in contact with
the motor and exhaust system
because of the risk of burns.
Combustion engines must not
be operated in closed rooms
due to risk of poisoning and/or
suffocation.
If fuel is spilled on combustion
engines, it must be completely
removed before starting the
motor.
Keep combustion engines and
their fuel away from ignition
sources due to danger of
explosion.
Refuelling during operation of
a combustion engine is strictly
prohibited!
All damaged electrical
components (e.g. smouldered
cables etc.) must be promptly
replaced!
5
In order to prevent re hazard,
ensure suf cient ventilation
when operating combustion
engines and maintain a safety
distance of at least 1 m (39.4
in.) to walls and other shields.
Ensure that the combustion
engine motor pumps always
sit on a largely level horizontal
surface, so that no fuel can
leak.
The device is lled with
hydraulic uid. These hydraulic
uids can be detrimental to
health if they are swallowed or
the vapors thereof are inhaled.
Direct contact with the skin
should be avoided for the same
reasons. Also, when handling
hydraulic uids, note that they
can negatively affect biological
systems.
Make sure there is adequate
lighting while working.
Always keep these operating
instructions easily accessible
at the site where the device is
used.
Damage to electrical
components may only be
eliminated by a trained quali ed
electrician, in compliance with
all applicable national and
international safety guidelines
and regulations.
When the units are installed,
care needs to be taken that they
are not impaired by extremely
strong temperature effects.
When operating and/or storing
the device, make sure that the
function and the safety of the
device are not impaired by
strong external temperature
effects or that the device is
damaged. Consider that the
device can also heat up when it
is continuously used.
Before transporting the device,
always check to see that the
accessories are positioned
securely against the possibility
of an accident.
Make sure you properly dispose
of all removed parts, leftover
hydraulic uid, leftover oil and
packing materials.
In addition to the safety instructions of these operating instructions, all generally applicable,
statutory and otherwise binding national and international rules for accident prevention need
to be heeded and disseminated!
WARNING / CAUTION / ATTENTION!
The device is speci ed exclusively for the purpose represented in the operating
instructions (see Chapter "Proper use"). Any use that differs or goes beyond this is
considered improper. The manufacturer/supplier shall not be held liable for damages
resulting from improper use. The risk shall be borne solely by the user.
Proper use also includes heeding the operating instructions and complying with the inspection
and maintenance requirements.
Never work in a fatigued or intoxicated state!
6
3. Proper use
LUKAS hydraulic units are speci cally designed to supply LUKAS rescue equipment with
hydraulic uid so that they can be used to rescue victims in the event of accidents in road,
rail and air travel as well as in building rescues.
The use for the supply of pressure or uid to rescue equipment of other manufacturers
is possible, but requires the technical testing and approval of LUKAS on a case-by-case
basis.
WARNING / CAUTION / ATTENTION!
Make sure you always heed the safety tips contained in these operating
instructions with regard to the installation location and type! The units also may
not be operated in all atmospheres due to a possible danger of explosion!
Accessories and spare parts for the rescue equipment can be obtained from your authorized
LUKAS dealer!
4. Unit labelling
P 660 S G
Type group
Codes for
hydraulic units
Valve variant:
S = Simultaneous operation
Motor variant:
G = Petrol-operated motor
Valve variant
7
Motor variant
5. Functional description
5.1 General
The main components (see image) of each LUKAS hydraulic unit are:
6
5
8
10
11
7
1 Recoil starter
2 Motor switch
3 Control switch 1 for
hydraulic supply
4 Control switch 2 for
hydraulic supply
5 Exhaust
6 Tank ller (fuel)
7 Air lter
8 Filler neck for
hydraulic uid
1
left
device
side
13
right
device
side
3
9 Motor oil ller neck with oil dipstick
10 Spark plug socket
11 Motor oil drain plug
12 Drain plug for
hydraulic uid and
hydraulic uid lter
13 Carrying handle
14 Female monocoupling
12
14
9
2
4
8
In all LUKAS hydraulic units, a motor typically operates a hydraulic pump, which delivers
uid from the tank and builds the pressure. The distribution of the uid is then controlled by
integrated valves.
5.2 Motor
These hydraulic units are equipped with a 4-cycle combustion engine, which is operated with
petrol. (refer to chapter "Fuel")
5.3 Control valve
ATTENTION!
In the operation of multiple rescue devices with a unit, make sure that the usable
amount of hydraulic uid in the uid tank is greater than the maximum possible
amount of operating uid of all connected rescue devices together!
The installed valve makes it possible to supply two devices simultaneously with pressure.
The pressure supply of both hydraulic connections, and consequently the pressure supply of
the connected rescue devices, can be controlled by way of the two control switches.
5.4 Pumps
LUKAS SUPER SILENT units are equipped with a dual ow pump.
Dual ow pump 2 pump delivery ows
The pumps used are always equipped with two pressure circuits per pump delivery ow,
a low-pressure and a high-pressure circuit.
Low-pressure circuit (ND) = up to 14 MPa*
High-pressure circuit (HD) = up to 70 MPa*
The switch from low pressure to high pressure is automatic in the pump.
The maximum pressure is limited by a pressure control valve.
WARNING / CAUTION / ATTENTION!
For safety reasons, the pressure set at this valve must not be changed (without
the direct consent of LUKAS)!
*(1 MPa = 10 bar)
5.5 Connection to rescue devices
The connection to the rescue devices is created by extension hose pairs or hose reels. They
are offered in different lengths, anti-kink colours and different connection options.
The standard hose pairs from the LUKAS line of accessories are always equipped with
monocouplings on at least one end in order to connect them to LUKAS rescue devices. The
individual hose lines of a hose pair can be differentiated by the different colours in order to
avoid confusion of the pressure and return lines.
(For more details, please refer to the LUKAS line of accessories or contact your LUKAS
dealer.)
9
5.6 Connection options
The connections for the hydraulic hoses are always provided on the unit.
The unit is provided exclusively with monocouplings.
6. Connection of the hose lines
ATTENTION!
When connecting the hose lines, make sure that the connection components are
not dirty and if necessary clean immediately beforehand!
ATTENTION!
Only devices in the basic position may be connected to the unit in order to avoid
that an amount of hydraulic uid greater than the maximum ll quantity can enter
the tank of the unit!
WARNING / CAUTION / ATTENTION!
Before connecting devices, make sure that all components
used are suitable for the maximum operating pressure of the
hydraulic unit! In case of doubts, LUKAS must be consulted
directly before connecting the devices!
The hydraulic hoses are connected via quick-disconnect coupling halves (female and male)
to the hydraulic pump in such a way that they cannot be reversed.
Dust caps
Male coupling
Before coupling, remove dust caps, then connect male and female couplings and turn
locking sleeve of the female coupling in direction "1" until the locking sleeve engages. The
connection is then made and secured. The decoupling is accomplished by turning the locking
sleeve in direction "0".
The coupling of the devices under pressure is also possible, assuming the connected
equipment is not turned on.
10
Female coupling
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