Lukas P 650 Series User Manual

175710085 ENHydraulic units P650(Translation of the original instruction manual)replaces 07.2014Instruction manual for rescue equipmentEdition 11.2014

103. Intended useYou can obtain accessories and replacement parts for the rescue apparatus from your authorised LUKAS dealer!WARNING / CAUTION / ATTEN

11-4. Labelling of the unitsP650 4 GCoding for hydraulic unitsType groupValve variantsMotor variantsDHRSpeci¿ cations(e.g. DHR = with integral reels)V

12 5.2 Structure of the units 1 Hydraulic À uid reservoir 2 Gasoline tank 3 Engine with hydraulic pump 4 Connecting block with control valves

13 5.3 Motor variants WARNING / CAUTION / ATTENTION! For all motor variants, also comply with the separate operating instructions of each motor manu

14 5.4 Valve variantsThe valves are always permanently installed in a connecting block. This block is integrated directly in the hydraulic unit. Both

15LUKAS 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

16 5.8 Hose reelsThe hose reels were designed to store extension hose pairs leading between the hydraulic supply and the working equipment (hose pairs

17CAUTION!When connecting the hose lines / devices, always ensure that the connection components are not soiled. Clean beforehand if necessary!WARNING

18BACCBefore coupling, remove the dust protection caps, then connect male and female couplings and turn the locking sleeve of the female coupling in d

197. Set-up and start-up 7.1 Set-up 7.2 Start-upWARNING / CAUTION / ATTENTION!Combustion engine units and electrical units must not be used in a poten

2 Contents Page1. Hazard classes 52. Product safety 63. Intended use 104. Labelling of the units 115. Functional description 11 5.1 General

208. OperationCAUTION!The control levers on the hydraulic unit must be shifted to neutral position beforethe motor/engine is started to prevent connec

21 8.2 Stopping the motor/engineWARNING / CAUTION!Never touch the hot motor / engine parts: this could result in severe burns! 8.2.1 Gasoline engine

22 8.4 Controlling the valves 8.4.1 "Simultaneous mode" (SIMO) control valveThree levers are located on the connecting block of this val

23NOTE:All shift levers must always be moved all the way to their end position. 8.4.2 "4POWER mode" control valveSix levers are located on

24 8.5 Hose reels8.5.1 Locking brakeThe locking brake is designed to prevent extension hose pairs from unrolling during transportation! Pull and turn

258.5.4 Rolling upNOTE:We recommend using the crank handle to roll up the hoses!- Fold out the crank handle.- Check that the locking brake on the do

26Always fully extend and secure the carrying handles before using them to transport the unit.When not in use, always insert and secure the carrying h

27 8.7 ToolholderA device must ¿ rst be detached from retaining clip before it can be removed from the toolholder.The device is then easy to remove.Th

28Procedure (fi tting and adjusting the Toolholder): 1. Mount the retaining clip "A" on block "C" and secure using the screws "

29 3. Then mount bracket "H" for the spreader and combi tool as well as bracket "J" for the cutters to mounting plate "K&quo

311. Maintenance and repair 36 11.1 General information 36 11.2 Maintenance work on the hydraulic unit 37 11.3 Additional maintenance work on

30 4. Mounting plates "G" and "K" are secured to the frame of the unit using screws "T" as shown in the illustratio

31 5. Now adapt the brackets to the respective devices. Loosen the ¿ xing screws "F" and "S" or nuts "Q" slightly so th

32On units with a combustion engine, you should drain the fuel from the tank and disconnect and/or remove the starter battery.Avoid storing the hydrau

3310. TestsThe hydraulic units are subject to very high mechanical loads. A visual inspection is therefore to be carried out after every use, however

34Visual inspectionHydraulic units• All hydraulic connections are still tightened• General tightness, no leakage (sweated oils do not have any inÀ u

35Functional check• No suspicious noises• Starter fully functional• Engine switch fully functional• Test for maximum load (Recommendation: use th

3611. Maintenance and repair 11.1 General information 10.4 Hose reelsVisual inspectionHose reel• General tightness (no leaks)• Hose drums rotate

37CAUTION!Since LUKAS hydraulic units are designed for top performance, only those components in the spare parts lists of the relevant unit may be rep

38ABC4. Re¿ t components "A" and "C" in the reverse order.5. Fill fresh hydraulic À uid into the reservoir through the ¿ ller nec

39NOTE:The ¿ rst oil change must take place after 20 operating hours and the next oil change after 100 hours.Use a standard articulated sparking plug

4

40Air ¿ lter 11.3.1 Changing and cleaning the air fi lterMaintaining the air ¿ lter in good condition is essential.The ingress of dirt due to incorre

41 11.3.2 Changing, cleaning and adjusting the sparking plugProcedure:1. Remove the right side panel on the hydraulic unit by detaching the mounting

42 11.3.4 Externally charging and replacing the starter batteryProcedure:1. Remove the left side panel "A" on the hydraulic unit by detach

43 11.4 Maintenance work on mounted hose reel A visual inspection of the ¿ tted hoses and couplings is to be carried out after every use or every six

44 3. Screw the new extension hoses onto the elbow pieces with a torque of MA = 40 Nm. Do not forget to slide protective hoses "B" back o

453. Loosen the union nuts on the hose lines and remove the coupling.CAUTION!As the case may be, make sure that port 'T' / 'T1' of

4612. TroubleshootingIn the case of defects which directly affect the motor / engine, please consult the separate operating instructions of the motor

47Trouble Check Cause SolutionCombustion engine will not startCheck fuel level in tankFuel tank empty Top up fuelElectric starter present?Electric sta

48Trouble Check Cause SolutionThe motor / engine is running, but the connected rescue equipment does not move when the valve is actuated.Check hose li

49Trouble Check Cause SolutionConnected rescue device does not reach its ¿ nal positionCheck hydraulic À uid volume in hydraulic reservoirInsuf¿ cient

5 Wear helmet with face protection Wear safety gloves Wear safety shoes Proper recycling Observe principles of environmental protection Read an

50Trouble Check Cause SolutionFluid escaping from the hydraulic À uid reservoirConnected device is not yet in base position and À uid is escaping from

51Trouble Check Cause SolutionIt is frequently not possible to couple hose linesHydraulic À uid not adapted to the application situationHydraulic À ui

52If it is not possible to rectify the malfunctions, inform an authorised LUKAS dealer or the LUKAS Customer Service department immediately!The addres

5313. Technical dataNOTE:The following tables contain only the technical data required for standard acceptance. Additional data concerning your unit c

54 1) HP = High pressure 2) LP = Low pressure 3) 1MPa = 10 bar 13.1.2 Type series P 650 SE and P 650 SE - DHR, 230 V / 50 HzDevice type P 650 SE P

55 1) HP = High pressure 2) LP = Low pressure 3) 1MPa = 10 bar 13.1.3 Type series P 650 4E and P 650 4E - DHRDevice type P 650 4E P 650 4E - DHRRe

56 1) HP = High pressure 2) LP = Low pressure 3) 1MPa = 10 bar 13.1.4 Type series P 650 SGDevice type P 650 SG P 650 SG - ESRef. number 81-53-51 (

57 1) HP = High pressure 2) LP = Low pressure 3) 1MPa = 10 bar 13.1.5 Type series P 650 SG - DHRDevice type P 650 SG - DHR P 650 SG - ES - DHRRef.

58 13.1.6 Type series P 650 4G 1) HP = High pressure 2) LP = Low pressure 3) 1MPa = 10 barDevice type P 650 4G P 650 4G - ESRef. number 81-53-57 (

59 13.1.7 Type series P 650 4G - DHR 1) HP = High pressure 2) LP = Low pressure 3) 1MPa = 10 barDevice type P 650 4G - DHR P 650 4G - ES - DHRRef.

62. Product safetyLUKAS products are developed and manufactured to ensure the best performance and quality when used as intended.The safety of the ope

60 1) HP = High pressure 2) LP = Low pressure 3) 1MPa = 10 bar 13.1.8 Type series P 650 SE and P 650 SE - DHR, 230 V / 60 HzDevice type P 650 SE P

61 13.2 Noise emissions (Sound pressure level)Device typeP 650 SE P 650 SE P 650 SG P 650 4G P 650 4Eund und und und undP 650 SE - DHR (50Hz)P 650 SE

62Explanation of dual number noise emission values according to DIN EN 13204:2012-09Serial number of the machine, operating conditions and other chara

63 13.3 Sparking plug 13.5 FuelSparking plug type: BR6HS (NGK)Fuel: Lead-free gasoline ROZ 91 to ROZ 98 Max. permissible bioethanol content:

64 13.7 Hydraulic fl uid recommendation 13.8 Operating and storage temperature rangeMineral oil DIN ISO 6743-4 for LUKAS hydraulic equipment and oth

6514. EC Declaration of Conformity

66

6715. Notes

LUKAS Hydraulik GmbHA unit of the IDEX CorporationWeinstrasse 39, D-91058 ErlangenPhone: (+49) 0 91 31 / 698 - 0Fax.: (+49) 0 91 31 / 698 - 394e-ma

7In the event of malfunctions, immediately shut down the equipment and secure it. The malfunction is to be repaired immediately.Do not carry out any c

8The generally applicable, legal and other binding national and international regulations pertaining to the prevention of accidents and protection of

9WARNING / CAUTION / ATTENTION!The device is to be used exclusively for the purpose stated in the operating instructions (see chapter "Intended U