Instruction manual for rescue equipment Hydraulic power units P … · 2019-11-04 · 13.echnical T...
Transcript of Instruction manual for rescue equipment Hydraulic power units P … · 2019-11-04 · 13.echnical T...
![Page 1: Instruction manual for rescue equipment Hydraulic power units P … · 2019-11-04 · 13.echnical T data 53. 13.1 Power Unit 53 13.2 Noise emissions (Sound pressure level) 64 13.3](https://reader033.fdocuments.us/reader033/viewer/2022060502/5f1c3887265cd533e715f19b/html5/thumbnails/1.jpg)
175635085 EN
(Translation of the original instruction manual)
replaces 05.2017Edition 07.2017
Instruction manual for rescue equipment
Hydraulic power units P 635
P 635 SEP 635 SG
![Page 2: Instruction manual for rescue equipment Hydraulic power units P … · 2019-11-04 · 13.echnical T data 53. 13.1 Power Unit 53 13.2 Noise emissions (Sound pressure level) 64 13.3](https://reader033.fdocuments.us/reader033/viewer/2022060502/5f1c3887265cd533e715f19b/html5/thumbnails/2.jpg)
2
Content Page1. Dangerclassifications 4
2. Productsafety 5
3. Intendeduse 9
4. Powerunitdesignation 10
5. Functionaldescription 10 5.1 General information 10 5.2 Installation of the power unit 11 5.3 Motor variants 14 5.4 Valves 15 5.5 Pumps 16 5.6 Frame with side sections 16 5.7 Connection to the rescue equipment 16 5.8 Hose reels 17 5.9 Carrying handle 17 5.10 Toolholder 17
6. Connectingthehoses/devices 18
7. Set-upandcommissioning 20 7.1 Set-up 20 7.2 Commissioning 20
8. Operation 22 8.1 Starting the engine 22 8.2 Turningtheengineoff 23 8.3 Refuelling (petrol engines only) 23 8.4 Controlling the valves 24 8.5 Hose reels 25 8.6 Telescopic carrying handles 27 8.7 Toolholder 28
9. Dismantlingtheequipment/deactivationfollowingoperation 31
![Page 3: Instruction manual for rescue equipment Hydraulic power units P … · 2019-11-04 · 13.echnical T data 53. 13.1 Power Unit 53 13.2 Noise emissions (Sound pressure level) 64 13.3](https://reader033.fdocuments.us/reader033/viewer/2022060502/5f1c3887265cd533e715f19b/html5/thumbnails/3.jpg)
3
Content Page10.Tests 32 10.1 Recommended test intervals 32 10.2 Hydraulic unit with petrol engine 33 10.3 Hydraulic unit with electric motor 34 10.4 Hose reels 35
11.Maintenanceandrepair 36 11.1 General information 36 11.2 Service work on the hydraulic unit 37 11.3 Additional service work on unit with a petrol engine 39 11.4 Maintenance work on mounted hose reel 42
12.Faultanalysis 46
13.Technicaldata 53 13.1 Power Unit 53 13.2 Noise emissions (Sound pressure level) 64 13.3 Sparking plug 66 13.4 Sparking plug spanner 66 13.5 Fuel 66 13.6 Engine oil 67 13.7 Hydraulicfluidrecommendation 67 13.8 Operating and storage temperature range 67
14.ECDeclarationofConformity 68
15.Notes 69
![Page 4: Instruction manual for rescue equipment Hydraulic power units P … · 2019-11-04 · 13.echnical T data 53. 13.1 Power Unit 53 13.2 Noise emissions (Sound pressure level) 64 13.3](https://reader033.fdocuments.us/reader033/viewer/2022060502/5f1c3887265cd533e715f19b/html5/thumbnails/4.jpg)
4
Wearahelmetwithafaceguard
Wearprotectivegloves
Wearsafetyshoes
Properrecycling
Protecttheenvironment
Readandfollowoperatinginstructions
Wedifferentiatebetweenvariousdifferentcategoriesofsafetyinstructions.Thetableshownbelowshowsyouanoverviewoftheassignmentofsymbols(pictograms)andsignalwordstothespecificdangerandthepossibleconsequences.
1. Danger classifications
Pictogram Damage / injury to Key word Definition Consequences
Persons
DANGER! Immediatedanger Deathorsevereinjury
WARNING!Potentiallydangeroussituation
Potentialdeathorseriousinjury
CAUTION! Lessdangeroussituation
Minororslightinjury
Property
ATTENTION!Dangerofdamage
toproperty/environment
Damagetotheequipment,
damagetotheenvironment,damagetosurroundings
- NOTE
Handlingtipsandotherimportant/usefulinformation
andadvice
Noinjury/damagetopersons/environment/
device
![Page 5: Instruction manual for rescue equipment Hydraulic power units P … · 2019-11-04 · 13.echnical T data 53. 13.1 Power Unit 53 13.2 Noise emissions (Sound pressure level) 64 13.3](https://reader033.fdocuments.us/reader033/viewer/2022060502/5f1c3887265cd533e715f19b/html5/thumbnails/5.jpg)
5
2. Product safetyLUKAS products are developed andmanufactured to ensure the best performance andqualitywhenusedasintended.Thesafetyoftheoperatoristhemostimportantconsiderationinproductdesign.Furthermore,theoperatinginstructionsareintendedtohelpinusingLUKASproductssafely.Thegenerallyapplicablelegalandotherbindingregulationspertainingtothepreventionofaccidentsandprotectionoftheenvironmentapplyandaretobecompliedwithinadditiontotheoperatinginstructions.Theequipmentmustonlybeoperatedbypersonswithappropriate training in thesafetyaspectsofsuchequipment–otherwise,thereisadangerofinjury.Wewouldliketopointouttoallusersthattheyshouldreadcarefullytheoperatinginstructionsandtheinstructionscontainedthereinbeforetheyusetheequipment,andthattheyshouldcarefullyfollowsuch.Wefurtherrecommendyouhaveaqualifiedtrainershowyouhowtousetheproduct.
CAUTION!The operating instructions for the hoses, accessories and the connecteddevicesmustalsobeheeded!
Evenifyouhavealreadyreceivedinstructiononhowtousetheequipment,youshouldstillreadthroughthefollowingsafetyinstructionsagain.
CAUTION!Ensure that the accessories and connected equipment are suitable for themaximumoperatingpressure!
Pleaseensurethatnobodypartsorclothinggetstuckbetweenthevisiblymovingparts.
Immediatelyreportanychangesthatoccur(includingchangesinoperatingbehaviour)totheappropriatepersons/departments!Ifnecessary,theequipmentistobeshutdownimmediatelyandsecured!
Wearprotectiveclothing,safetyhelmetwithvisor,safetyshoesandprotectivegloves.
Checktheequipmentforvisibleflawsordamagebeforeandafteruse.
Workingundersuspendedloadsisnotpermittedwheresuchloadsarebeingliftedonlybymeansofhydraulicdevices.Ifthisworkisunavoidable,suitablemechanicalsupportsarealsorequired.
Checkalllines,hosesandscrewedconnectionsforleaksandexternallyvisibledamage,andrepairimmediately!Escapinghydraulicfluidcancauseinjuriesandfires.
![Page 6: Instruction manual for rescue equipment Hydraulic power units P … · 2019-11-04 · 13.echnical T data 53. 13.1 Power Unit 53 13.2 Noise emissions (Sound pressure level) 64 13.3](https://reader033.fdocuments.us/reader033/viewer/2022060502/5f1c3887265cd533e715f19b/html5/thumbnails/6.jpg)
6
Intheeventofmalfunctions,immediatelydeactivatethedeviceandsecureit.Repairthefaultimmediately.
Donotcarryoutanychanges(additionsorconversions)totheequipmentwithoutobtainingtheapprovalofLUKASbeforehand.
Observeallsafetyanddangerinformationonthedeviceandintheoperatinginstructions.
Allsafetyanddangerinformationonthedevicemustalwaysbecompleteandinalegiblecondition.
Pleaseensurethatallsafetycoversarepresentontheequipmentandthattheyareinproperandadequatecondition.
Anymodeofoperationwhichcompromisesthesafetyand/orstabilityofthedeviceisforbidden!
Safetydevicesmustneverbedisabled!
Themaximumoperatingpressuresetontheequipmentmustnotbechanged!
Makesurebeforeswitchingon/startingupthedeviceandduringitsoperation,thatthiswillputnooneindanger.
Observeallintervalsforrecurringtestsand/orinspectionsthatareprescribedorstatedintheoperatinginstructions.
Whenworkingclosetolivecomponentsandcables,suitablemeasuresmustbetakentoavoidcurrenttransfersorhigh-voltagetransferstotheequipment.
OnlyoriginalLUKASaccessoriesandsparepartsaretobeusedforrepairs.Whenworkingwiththisequipmentorwhentransportingit,ensurethatyoudonotgetcaughtupinthehoseorcableloopsandtrip.
Thebuild-upofstaticchargeandthereforepossiblesparkingmustbeavoidedwhenhandlingthedevice.
Donottouchtheengineandexhaustsystemwhenrunningwithcombustionenginepumpsbecauseofthedangerofburning.
Motorisedpumpsmustnotbeoperatedinareasatriskofexplosion!
Combustionenginesmustnotbeoperatedinenclosedspacesbecauseofthedangerofpoisoningand/orsmothering.
![Page 7: Instruction manual for rescue equipment Hydraulic power units P … · 2019-11-04 · 13.echnical T data 53. 13.1 Power Unit 53 13.2 Noise emissions (Sound pressure level) 64 13.3](https://reader033.fdocuments.us/reader033/viewer/2022060502/5f1c3887265cd533e715f19b/html5/thumbnails/7.jpg)
7
Keepcombustionenginesandtheirfuelsawayfromsourcesofignitionsinceotherwisetherewillbeadangerofexplosion.
Alldamagedelectricalcomponentse.g.scorchedcables,etc.aretobereplacedimmediately!
Inordertopreventthedangeroffire,youshouldensureadequateventilationwhenoperatingcombustionenginesandyoumustkeepasafetydistanceofatleast1m(39.4 in.)towallsandotherscreens.
Damagetoelectricalcomponentsmustonlyberepairedbyaqualifiedelectricianincompliancewithallapplicablenationalandinternationalsafetyguidelinesandregulations.
Makesurethatthecombustionenginesarealwaysstandingonasflatandhorizontalasurfaceaspossibletopreventfuelfromleakingout.
Whensettinguptheunits,youmustmakesurethattheyarenotimpairedbytheinfluencesofextremetemperatures.
Theequipmentisfilledwithhydraulicfluid.Thishydraulicfluidcanbedetrimentaltohealthifitisswallowedoritsvapourisinhaled.Directcontactwiththeskinmustbeavoidedforthesamereason.Also,whenhandlinghydraulicfluid,notethatitcannegativelyaffectbiologicalsystems.
Whenworkingwithorstoringtheequipment,ensurethatthefunctionandthesafetyoftheequipmentarenotimpairedbytheeffectsofsevereexternaltemperaturesorthattheequipmentisdamagedinanyway.Pleasenotethattheequipmentcanalsoheatupoveralongperiodofuse.
Makesurethereisadequatelightingwhileworking.
Beforetransportingtheequipment,alwaysensurethattheaccessoriesarepositionedinsuchawaythattheycannotcauseanaccident.
Alwayskeeptheseoperatinginstructionseasilyaccessibleattheplaceofoperation.
Ensuretheproperdisposalofallremovedparts,leftoveroil,hydraulicfluidandpackagingmaterials.
Ifyouspillanyfuelwhenusingcombustionengines,youmustremovethespilledfuelcompletelybeforestartingtheengine.
Refuellingwhilsttheengineisrunningisstrictlyprohibited!
![Page 8: Instruction manual for rescue equipment Hydraulic power units P … · 2019-11-04 · 13.echnical T data 53. 13.1 Power Unit 53 13.2 Noise emissions (Sound pressure level) 64 13.3](https://reader033.fdocuments.us/reader033/viewer/2022060502/5f1c3887265cd533e715f19b/html5/thumbnails/8.jpg)
8
The generally applicable, legal and other binding national and international regulationspertainingtothepreventionofaccidentsandprotectionoftheenvironmentapplyandaretobeimplementedinadditiontotheoperatinginstructions.
WARNING/CAUTION!Thedeviceisintended exclusively for the purpose stated in the operating instructions (see chapter "Proper Use"). Any other use is not in accordance with its designated use.Themanufacturer/supplierisnotliableforanydamagesresultingfromimproperuse.Theuserbearssoleresponsibilityforsuchuse.Proper use includes observance of the operating instructions and compliance with theinspectionandmaintenanceconditions.
Never work in a fatigued or intoxicated state!
WARNING/CAUTION!Ifyoustillinjureyourselfonthehydraulicunit,cleanthewoundimmediatelyandconsultadoctortohaveitattendedto!Ifyougethydraulicfluidinyoureye,rinseitimmediatelyseveraltimeswithclear,cleanwaterandconsultadoctor!Also,ifyouswallowhydraulicfluidyoushouldconsultadoctor!
![Page 9: Instruction manual for rescue equipment Hydraulic power units P … · 2019-11-04 · 13.echnical T data 53. 13.1 Power Unit 53 13.2 Noise emissions (Sound pressure level) 64 13.3](https://reader033.fdocuments.us/reader033/viewer/2022060502/5f1c3887265cd533e715f19b/html5/thumbnails/9.jpg)
9
3. Intended use
You can obtain accessories and replacement parts for the rescue apparatus from yourauthorisedLUKASdealer!
WARNING/CAUTION!Thesafetyinstructionsinthisoperatinginstructionmanualconcerningthesiteoferectionandtypeoferectionmustalwaysbeobserved!
LUKAS hydraulic units are specially designed to supply LUKAS rescue equipment withhydraulicfluidsothatthisequipmentcanbeusedtorescuevictimsofroad,railorairtrafficaccidentsaswellasfrombuildings.Their use for supplying pressure / fluid to rescue equipment of other manufacturers ispossible,yet requires the technical inspectionandapprovalbyLUKAS ineach individualcase.Theequipmentisnotdesignedtooperatewithouthosesorequipment(operatingtimewithouthosesorequipment<15minutes).
ATTENTION!Whenselectingtheunitstoconnecttotheunit,bearinmindthatthemaximumpossibleuseablevolumeofhydraulicfluidislimited.Thesumofthemax.requiredoperatingvolume(hydraulicfluid)ofallconnectedequipmentmustnotexceedthemaximumpossibleusablevolumeofthepowerunit!
NOTE:AlwaysregisteryourhydraulicunitontheLUKASHydraulikGmbHinternetsite.Thisistheonlywaytoguaranteeyourextendedwarrantycover.Beforeyouusecouplingsfromadifferentcompany,youmustcontactLUKASoranauthoriseddealer.
LUKASP635unitsarenot explosionprotected!Whenusing the equipment in explosion-risk areas youmust make sure thatoperationoftheunitdoesnottriggeranexplosion!TheresponsibilityforexplosionpreventionorforrulingoutworkwiththeP635restswiththeoperatorofthedeviceorwiththepersonresponsibleattheplaceofuse.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 isunavoidable,cleantheequipmentimmediatelyafterwardswithasuitablecleaningagent.
![Page 10: Instruction manual for rescue equipment Hydraulic power units P … · 2019-11-04 · 13.echnical T data 53. 13.1 Power Unit 53 13.2 Noise emissions (Sound pressure level) 64 13.3](https://reader033.fdocuments.us/reader033/viewer/2022060502/5f1c3887265cd533e715f19b/html5/thumbnails/10.jpg)
10
4. Power unit designation
P 635 S G
Codingforhydraulicpowerunits
Typegroup
Valvevariants
Motorvariants
Valve variants: S = Simultaneousoperation Motor variants: G = Petrolengine E = Electricmotor
Specifications: DHR = Withintegralreels Tube variants: COAX = Tubeintube
InthecaseofallLUKAShydraulicpowerunits,thehydraulicpumpisoperatedwithamotor.Thepumpconveysthefluidfromthehydraulicoiltankandbuildsupthepressureinthetool.Fluidisdistributedtotheconnectedequipmentthroughcontrolvalves.
TwoversionsoftypeP635unitareavailable: 1. smallframewithoutreel 2. largeframewithmountedreel
The telescopic carrying handles are an optional accessory for the first version and canalwaysberetrofitted.
5. Functional description 5.1 General information
DHRSpecification
COAXTubevariants
NOTE:Ahosereelisonlyincludedwiththesecondversionandcannotberetrofittedatalaterdate!
![Page 11: Instruction manual for rescue equipment Hydraulic power units P … · 2019-11-04 · 13.echnical T data 53. 13.1 Power Unit 53 13.2 Noise emissions (Sound pressure level) 64 13.3](https://reader033.fdocuments.us/reader033/viewer/2022060502/5f1c3887265cd533e715f19b/html5/thumbnails/11.jpg)
11
5.2 Installation of the power unit
1 Petroltank 2 Hydraulicfluidtank 3 Enginewithhydraulicpump 4 Connectingblockwith
controlvalves 5 Speedadjustinglever 6 Cable-pullstarter 7 "TURBO"controllever 8 Mono-coupling(female) 9 Fueltankcap10 Fillercaphydraulicfluid11 Frame12 Rubberbuffer13 Sidepanel14 Airfilter15 Choke16 Fueltap17 ON/OFFswitch(engine
switch)18 Engineoilfillercap/dipstick19 Filllevelindicator
Equipmentback
15 16 17
6
14
18
5
P 635 SG
19
14
3
7
8
2
9
10
11
12 13
19
![Page 12: Instruction manual for rescue equipment Hydraulic power units P … · 2019-11-04 · 13.echnical T data 53. 13.1 Power Unit 53 13.2 Noise emissions (Sound pressure level) 64 13.3](https://reader033.fdocuments.us/reader033/viewer/2022060502/5f1c3887265cd533e715f19b/html5/thumbnails/12.jpg)
12
8 Mono-couplings10 Hydraulicfluidfillcap20 Telescopiccarryinghandle (alsooptionallyavailableforretrofitting)21 Hosereel22 Lock(hosereel)23 Crankhandle(hosereel)24 Hoseguide25 Toolholder
8
20
21 242223
10
25
P 635 SG-DHR-COAX
P 635 SG-DHR
![Page 13: Instruction manual for rescue equipment Hydraulic power units P … · 2019-11-04 · 13.echnical T data 53. 13.1 Power Unit 53 13.2 Noise emissions (Sound pressure level) 64 13.3](https://reader033.fdocuments.us/reader033/viewer/2022060502/5f1c3887265cd533e715f19b/html5/thumbnails/13.jpg)
13
1 Electricmotorwithhydraulicpump
2 Hydraulicfluidtank 3 Connectingblockwith
controlvalves 4 Mono-coupling(female) 5 Fillercaphydraulicfluid 6 Filllevelindicator 7 Frame 8 Rubberbuffer 9 Sidepanel10 ON/OFFswitch(engine
switch) 11 “TURBO”controllever20 Telescopiccarryinghandle (alsooptionallyavailable
forretrofitting)21 Hosereel22 Lock(hosereel)23 Crankhandle(hosereel)24 Hoseguide25 Toolholder
P 635 SE-DHR-COAX
P 635 SE
1
4
8
7
6
9
3
2
5
11
10
4
20
21 2422
523
25
![Page 14: Instruction manual for rescue equipment Hydraulic power units P … · 2019-11-04 · 13.echnical T data 53. 13.1 Power Unit 53 13.2 Noise emissions (Sound pressure level) 64 13.3](https://reader033.fdocuments.us/reader033/viewer/2022060502/5f1c3887265cd533e715f19b/html5/thumbnails/14.jpg)
14
5.3 Motor variants
WARNING/CAUTION! See also the separate operating instructions of each engine manufacturer
accompanyingthedelivery.
5.3.1 Petrol engineThesehydraulicunitsareequippedwithacombustionenginedrivenbythefuel"petrol".Thepowerunitsareequippedwithacable-pullstarterwithwhichtheengineisstarted.(For specific details, please consult the separate operating instructions of the enginemanufacturer!)
NOTE:TheengineinstalledintheLUKASpowerunitsdoesnotmatcheverydetailoftheenginedescribedinthemanufacturer'sseparateoperatinginstructions.Nevertheless, it is important that you follow all safety rules and operating,maintenance and storage instructions in the separate engine instructions asabsolutesincetheyarenotaffectedbyadjustmentsmadebyLUKAS.
HONDA motors have a main switch that must be activated to switch the power unit on and off.Thespeedadjustingleveronthesepowerunitshastwoswitchpositions.Switch position 1 (standard): Speed 3000 1/min " " and Switch position 2: Speed 3800 1/min " ".
Thesettingisadjustedbymovingthespeedadjustinglever.
5.3.2 Electric motorThesehydraulicunitsareequippedwithanelectricmotor.Theelectricmotorisdrivenbyelectricityfromthemainssupplyorbyelectricityproducedbygenerators.Inthecaseofoperationwithgenerators,makesurethatvoltagefluctuationsdonotoccur,asthesehaveadirectinfluenceonthepumpingcapacityandstabilityofthehydraulicunit.Thepossibleoperatingvoltage,thecurrentfrequencyandtherequiredintensityofcurrentcanbefoundintheseparateinstructionsforyourunitinthechapterentitled“Technicaldata”.
NOTE:Using an extremely long electrical connection cable may reduce the outputresistanceandthepowersupplytothemotor.Theperformanceofthemotorwillbeaffectedasaresult.
![Page 15: Instruction manual for rescue equipment Hydraulic power units P … · 2019-11-04 · 13.echnical T data 53. 13.1 Power Unit 53 13.2 Noise emissions (Sound pressure level) 64 13.3](https://reader033.fdocuments.us/reader033/viewer/2022060502/5f1c3887265cd533e715f19b/html5/thumbnails/15.jpg)
15
5.4 ValvesBothvalvesofthepowerunitinthepumpblockarefixedinplace.Thepumpblockisfullyintegrated into the hydraulic power unit. The hose assemblies (pressure line (grey) andreturn(blue))mustbeconnectedtothepumpblock.Therescueequipmentisconnectedtothehoseassemblies.ModelP635unitsareequippedwithaSIMOconnectingblock.
TheconnectingblockoftheP635alsohasaTURBOfunction.Witha“TURBO”controllever,eitherbothconnecteddevicescanbesuppliedsimultaneouslywithhydraulicfluid,orasingledevicecanbesuppliedwithdoublethevolume(=TURBOfunction). By supplying at double the feed rate, the speed of the connected device isincreased.
Thehosesareconnectedwiththeconnectingblockviamono-couplings.
5.4.1 Control valve "simultaneous operation" (SIMO)Thisvalveenablestheconnectionoftwopressurehosesandtworeturnhoses.Ithastwoswitching options, each of which controls the pressure application of the pressure hosethatismarkedaccordingly.Thismeansthattwo devices can be supplied with pressure simultaneously and independently of each other.Without impairingtheworkoutput, itenablesworkwithtwodevicessimultaneouslyandindependentlyofeachother.
ATTENTION!When operating several pieces of rescue equipment with one unit, ensurethat theusablevolumeofhydraulicfluid in thepowerunit isgreater than themaximumpossibleoperatingfluidvolumeofallconnectedrescueequipment.
![Page 16: Instruction manual for rescue equipment Hydraulic power units P … · 2019-11-04 · 13.echnical T data 53. 13.1 Power Unit 53 13.2 Noise emissions (Sound pressure level) 64 13.3](https://reader033.fdocuments.us/reader033/viewer/2022060502/5f1c3887265cd533e715f19b/html5/thumbnails/16.jpg)
16
TheLUKAShydraulicpowerunitsmodelP635areequippedwithaSIMOconnectingblock.Thepumpisrigidlyconnectedtotheconnectingblock. Double-flowpumpforoperatingwithSIMOvalve
Thepumpusedalwayshastwopressurestagesperpumpfeedflow,onelowpressureandonehighpressure.
Low-pressurelevel(LP) = upto14MPa*
High-pressurelevel(HP)= upto70MPa*
Thechangeoverfromlowpressuretohighpressureiscarriedoutautomaticallybythepump.Thissystemissecuredwithapressurelimitingvalve.Therefore,themaximumpermissiblesystempressurecannotbeexceeded.
5.5 Pumps
*)1MPa=10bar)
5.6 Frame with side sectionsTheP635hydraulicpowerunitismountedwithinaframe.Theframeandsidepanelsarealsoused,despitetherobustdesign,toprotectthepowerunitfromexternalinfluences,suchasforexample,dirtordamage.
5.7 Connection to the rescue equipment
Connectiontotherescueequipmentisviaextensionhosepairsorviahosereels.Theyaresuppliedinvariouslengths.(Forspecificdetails,pleaseconsulttheLUKASrangeofaccessoriesorcontactyourLUKASdealer.)
WARNING/CAUTION!Forsafetyreasons,thepressuresetonthisvalvemustnotbeadjusted(withouttheapprovalofLUKASdirectly)!
![Page 17: Instruction manual for rescue equipment Hydraulic power units P … · 2019-11-04 · 13.echnical T data 53. 13.1 Power Unit 53 13.2 Noise emissions (Sound pressure level) 64 13.3](https://reader033.fdocuments.us/reader033/viewer/2022060502/5f1c3887265cd533e715f19b/html5/thumbnails/17.jpg)
17
5.8 Hose reelsThehosereelsweredesignedtostoreextensionhosepairsleadingbetweenthehydraulicsupplyand theworkingequipment (hosepairsare included in thedeliveryasstandard).Theextensionhosepairsareconnectedtothehosereelsandrolledontothedrums.Ahosereelwithextensionhosepairscancoverlongdistancesbetweenthehydraulicsupplyandtheworkingequipment,allowingyoutokeepthehydraulicunitonavehicle,forexample.The possibility of rolling up and unrolling the hose allows you to adapt the hose lengthaccordinglyandreducetheamountofunnecessaryorpotentiallydangerousexcesshoselyingontheground.Theextensionhosepairsareeasiertotransportandstorewhenfullyrolledup.Moreover,thehosereelsareequippedwithahoseguidethatfacilitateseasierrollingupandunrolling.Theunitisconnectedtotheworkingequipmentviacouplings.
CAUTION!Inordertoavoidpotentiallossesinpressure,thelengthoftheextensionhoselinesmustnotexceed30m!
5.9 Carrying handleTypeP635LUKAShydraulicunitswithoutahosereelcanbefittedwithoptionalcarryinghandles.Thescopeofdeliveryofunitswithahosereelalreadyincludeshandles.TheP653canbetransportedmoreergonomicallyusingthecarryinghandles.
5.10 ToolholderTypeP635LUKAShydraulicunitswithahosereelarefittedwithaToolholder.TheToolholderisusuallydesignedtoattachaspreaderandatypeS700cutter.Needlesstosay,itispossibletoadaptthemounttoaccommodateallLUKAScuttersandspreadersaswellasmodifyitatalaterdate.TheToolholderallowsyoutotransportaunitwithdevicesstillattached.Younolongerhavetodetachandstoredevicesseparatelyafteruse.YouonlyhavetowindthehoselinesontothereelsandpositionthedevicesontheToolholderagain.Devicessecuredtotheunitdonotposeariskduringtransport.
![Page 18: Instruction manual for rescue equipment Hydraulic power units P … · 2019-11-04 · 13.echnical T data 53. 13.1 Power Unit 53 13.2 Noise emissions (Sound pressure level) 64 13.3](https://reader033.fdocuments.us/reader033/viewer/2022060502/5f1c3887265cd533e715f19b/html5/thumbnails/18.jpg)
18
ATTENTION!Whenconnectingthehoseassemblies/units,alwaysensurethattheconnectioncomponentsarenotdirty.Cleanpriortouseifnecessary!
WARNING/CAUTION! Before connecting the 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 directlybeforeconnectingtheequipment!
6. Connecting the hoses / devices
Mono-couplinghalve(male)
Mono-couplinghalve(female)
Dustprotectioncaps
Thehoselines/unitsareconnectedviaquick-disconnectcouplinghalves(femaleandmale)tothehydraulicpumporhosereelinsuchawaythattheycannotbeswappedover.
0
1
0
![Page 19: Instruction manual for rescue equipment Hydraulic power units P … · 2019-11-04 · 13.echnical T data 53. 13.1 Power Unit 53 13.2 Noise emissions (Sound pressure level) 64 13.3](https://reader033.fdocuments.us/reader033/viewer/2022060502/5f1c3887265cd533e715f19b/html5/thumbnails/19.jpg)
19
BA C
C
Remove the dust caps before coupling together. Then push themale and female partstogetherand turn the locking sleeveon the female coupling in thedirection "1" until thelockingsleeveclicks inplace.Theconnectionhasbeenmadeand locked.Decoupling isaccomplishedbyturningthelockingsleeveindirection"0".Couplingofthehoseassemblieswhenunderpressureisalsopossible,assumingthattheconnectedequipmentisnotturnedon.
NOTE:We recommend connecting the coupling halves in a depressurised statewhenworkinginareaswithlowambienttemperatureandusingextensionhoseassemblies/hosereels,asotherwisethecouplingmayrequiretheapplicationofagreatdealofforce.
Fordustprotection,thesupplieddustcapsmustberefitted.
Using the dust protection caps: Thedustprotectioncaps"A"havetwoexternalgrooves"B".Thedustprotectioncapsmustbeinsertedinthefemalecouplinginsuchawaythatthegroovescanbeguidedoverthepins"C".Screwinthedustprotectioncapstothestoptofixinthefemalecouplings.
![Page 20: Instruction manual for rescue equipment Hydraulic power units P … · 2019-11-04 · 13.echnical T data 53. 13.1 Power Unit 53 13.2 Noise emissions (Sound pressure level) 64 13.3](https://reader033.fdocuments.us/reader033/viewer/2022060502/5f1c3887265cd533e715f19b/html5/thumbnails/20.jpg)
20
7. Set-up and commissioning
7.1 Set-up
7.2 Commissioning
WARNING/CAUTION!Because of possible spark formation, combustion engine units and electricalequipment cannot be used in an explosion-risk area. Units with combustionenginesmustnotbeusedinenclosedspaces,asthereisadangerofpoisoningand/orasphyxiation!
Theunitistobesetupinasuitablelocation(securelocation/flatsurface/sufficientdistancefromvehicles,loads,sourcesofignition,etc.).LUKASunitsworkperfectlyatanangleofupto20°.However,inordertoguaranteemaximumsafetyandfluidwithdrawal,theyshouldbeoperatedinashorizontalapositionaspossible.
ATTENTION!Nevermixupthefuelandhydraulicfluidtankswhenfillingthetank;thiscandamagethepowerunit!
NOTE:Theengineoil levelmustbeinspectedbeforethefirstcommissioningorafterlongerperiodsofstorage.Firstfilltheengineortopuptheengineoil!Forsafetyreasons,LUKASpowerunitsdonotcontainengineoilupondelivery!
7.2.1 First commissioning - Powerunitwithoutengineoil,hydraulicfluidandpetrol.
1.Pourhydraulicoilintothehydraulicfluidtankuntilthefilllevel indicator in the viewingwindow is betweenMIN/MAX (see illustration on the right). The upper markshowstheabsolutefilllevelwhenconnectingadditionalequipmentwithincreasedusablevolume.Theresultingfillquantityisupto5.0l.
Hydraulic oil filllevelindicator
![Page 21: Instruction manual for rescue equipment Hydraulic power units P … · 2019-11-04 · 13.echnical T data 53. 13.1 Power Unit 53 13.2 Noise emissions (Sound pressure level) 64 13.3](https://reader033.fdocuments.us/reader033/viewer/2022060502/5f1c3887265cd533e715f19b/html5/thumbnails/21.jpg)
21
2.Nowbleedthehydraulicpowerunit:3.Opentheventingplugonthepumpblock
4.Tiltthepowerunitbackwardsbyapprox.90°(seeillustration)andwaituntiloilcomesoutfromthebolt.
5.Whenoilcomesoutattheventingplug,theairhasbeenremovedfromthepump.Firstclosetheventingplugandthenreturnthepowerunittothelevel.
6.Pourintheengineoilaccordingtotheinstructionsinthescopeofdeliveryincludedwiththeseparatemanufactureroperatinginstructionsregardingthefilleropening(engineoilfillercap,seechapter"Installationofthepowerunit").
7.Pourfuel(petrol)intothetankuntilthefilllevelisjustbelowthefilleropening.Ifthepowerunitisrestingonaninclinedsurface,donotfillthetanktoitsmaximumcapacity.
8.Checkthehydraulicoillevel.Topupifnecessary.9.Nowconnect theextensionhosesand/orhose reels (unlessalreadyconnected to the
unit)and/orcoupletherescueequipment.
VentingplugPumpblock
90°90°90°
![Page 22: Instruction manual for rescue equipment Hydraulic power units P … · 2019-11-04 · 13.echnical T data 53. 13.1 Power Unit 53 13.2 Noise emissions (Sound pressure level) 64 13.3](https://reader033.fdocuments.us/reader033/viewer/2022060502/5f1c3887265cd533e715f19b/html5/thumbnails/22.jpg)
22
7.2.2 Commissioning(afterthefirstfillingorpriortouse)
1.Check the fluid level of the engine oil, the hydraulic fluid and the fuel tank.Top up ifnecessary. For precise reading off of the fluid levels and for filling, the hydraulic unitshouldbeaslevelaspossible.
2.Nowconnecttheextensionhosesand/orhosereels(unlessalreadyconnectedtotheunit)and/orcoupletherescueequipment.
8.1.1 Petrol engineBeforestartingthecombustionengine,checkthatthefueltankisfullandthattheengineoilleveliswithinthepermittedtolerances.Ifnecessary,topuptherelevantfluid.
1.Openthepetroltap2.SettheON/OFFswitchtotheONposition.3.MovetheleverfromswitchingpositionAtoswitching
positionB(choke)whenstartingcold4.Pullthecable-starter.5.When themotor is running,switch the leverback to
positionA.
For the detailed procedure for starting the combustionengine,pleaseseetheseparate operating instructions of the engine manufacturer!
8.1.2 Electric motorBeforestartingtheelectricmotors,checkthatallelectricalconnectionsandcablesare inproper order. First of all, connect the power cable (formotorswith power supply) to thesupplysocket.TheON/OFFswitchislocatedontheterminalboxofthemotor(seefigurebelow).Tostart,pressthegreenbuttonoftheON/OFFswitch.
BA
8.1 Starting the engine
8. Operation
ATTENTION!Electricmotorsdrawabrief,veryhighstartingcurrent.Whenusingagenerator,youshouldthereforechecktoseethatitcansupplytherelevantcurrentstrength.Thepowersupplymustbeprotectedbya25Afuseatleast.
![Page 23: Instruction manual for rescue equipment Hydraulic power units P … · 2019-11-04 · 13.echnical T data 53. 13.1 Power Unit 53 13.2 Noise emissions (Sound pressure level) 64 13.3](https://reader033.fdocuments.us/reader033/viewer/2022060502/5f1c3887265cd533e715f19b/html5/thumbnails/23.jpg)
23
Theenginemustbeswitchedoffforrefuelling!Procedure:1.Openthefueltankcap.2. Fillthetankwithfueluntilthefilllevelisjustbelowthefilleropening.
3.Closethefueltankagainwiththefueltankcap.
WARNING/CAUTION!Besurenottospill fuel. Inparticular,hotenginepartsmustnotcomeintocontactwithfuel;dangeroffireotherwise!Iffuelisspilled,itmustbecleanedupimmediatelywithasuitableabsorbentcloth.Indoingso,becarefulnottoburnyourselfononeofthehotengineparts!Theusedclothmustthenbecleanedordisposedofaccordingtotherelevantprovisionsandguidelines!
8.3 Refuelling (petrol engines only)
8.2.1 Petrol engine1.SettheON/OFFswitchtotheOFFposition.2.Whentheenginehascometoastandstill,closethe
fueltap.
For more details on switching off the engine, please refer to the separate operatinginstructions of the engine manufacturer!
8.2.2 Electric motorToswitchoffthemotorpresstheredbuttonoftheON/OFFswitchonthemotorterminalbox.Whentheengineisswitchedoff,theconnectedhydraulicpumpstopsdelivering.
CAUTION!Nevertouchhotengineparts:thiscouldresultinsevereburns!
8.2 Turning the engine off
![Page 24: Instruction manual for rescue equipment Hydraulic power units P … · 2019-11-04 · 13.echnical T data 53. 13.1 Power Unit 53 13.2 Noise emissions (Sound pressure level) 64 13.3](https://reader033.fdocuments.us/reader033/viewer/2022060502/5f1c3887265cd533e715f19b/html5/thumbnails/24.jpg)
24
8.4 Controlling the valves
8.4.1 "Simultaneous operation" control valve (SIMO) P 635 SG/SE
Thepumpblockalsohasa“TURBO”controllever,allowingtheusertoswitchtothe“TURBO”function(seediagramabove).Withthisfunction,theswitchpositionofthe“TURBO”controllevercanbeusedtosupplyoneofthetwoconnectionswithdoublethevolume.The "TURBO" function is activated by turning the “TURBO” control lever towards theconnectionthatistobepressurisedatthedoubledpumpingoutput.
NOTE:The“TURBO”controllevermustalwaysbemovedcompletelyuptothestop.
![Page 25: Instruction manual for rescue equipment Hydraulic power units P … · 2019-11-04 · 13.echnical T data 53. 13.1 Power Unit 53 13.2 Noise emissions (Sound pressure level) 64 13.3](https://reader033.fdocuments.us/reader033/viewer/2022060502/5f1c3887265cd533e715f19b/html5/thumbnails/25.jpg)
25
8.5 Hose reels 8.5.1 Locking brakeThe locking brake is designed to prevent extension hose pairs from unrolling duringtransportation!Pullandturnknobthrough90°toreleasethelockingbrake.Toapplythelockingbrake,turnknobthroughapprox.90°untilitengagesautomatically.
8.5.3 UnrollingPulltheextensionhosepairuntiltherequiredlengthhasunrolledfromthehosereel.
CAUTION!Releasethelockingbrakeonthehosereelbeforehandtoavoiddamagingthereelandthepairofhoses!
Thecrankhandleshouldmakethehoseeasiertorollup!Tousethecrankhandle,pulllever,foldoutwardsthrough90°andreleasesothatitengages.To foldaway thecrankhandle,pull lever fold inwards through90°and releaseso that itengages.
8.5.2 Crank handle
90° 90°
![Page 26: Instruction manual for rescue equipment Hydraulic power units P … · 2019-11-04 · 13.echnical T data 53. 13.1 Power Unit 53 13.2 Noise emissions (Sound pressure level) 64 13.3](https://reader033.fdocuments.us/reader033/viewer/2022060502/5f1c3887265cd533e715f19b/html5/thumbnails/26.jpg)
26
8.5.4 Rolling up
NOTE:Werecommendusingthecrankhandletorollupthehoses!
- Foldoutthecrankhandle.- Checkthatthelockingbrakeonthedoublehosereelsisreleased.- Alignthereelssothattheunrolledhosesarerolledupinastraightline.Youwillfindthat
thehosesrollupmoreeasily.- Youcannowrollupthepairofextensionhosesbyturningthecrankhandle.
Make sure that the direction of rotation is always the same as shown in the illustration!
Directionofrotation"Rollingup"
Hose
Elbowpiece
Make sure that the pair of extension hoses is always rolled up correctly onto the hose drum.
We recommend guiding the pair of extension hoses with your hand during the rolling process. You must always guide the pair of hoses in a perpendicular direction to the reel axis because of the hose guide attached to the hose reel.
- Youmustthenapplythelockingbrakeonthedoublehosereels.
CAUTION!Thebendprotection on the hoses should only rest lightly on the hoseguidewhenthehoseisrolledupcompletely.However,ifthehoselineisrolledupsofarthatthebendprotectionispressedupagainstthehoseguide,thefollowingcouldoccur: - Thehosematerial is stretchedand thehosedamaged,possiblybeyond
repair. - The couplings, bend protection and hoses may be damaged during
transportationorstorage.
![Page 27: Instruction manual for rescue equipment Hydraulic power units P … · 2019-11-04 · 13.echnical T data 53. 13.1 Power Unit 53 13.2 Noise emissions (Sound pressure level) 64 13.3](https://reader033.fdocuments.us/reader033/viewer/2022060502/5f1c3887265cd533e715f19b/html5/thumbnails/27.jpg)
27
Alwaysfullyextendandsecurethecarryinghandlesbeforeusingthemtotransporttheunit.When not in use, always insert and secure the carrying handles to prevent them fromrestrictingyourmovementwhenoperatingtheunit.Thehandlesshouldalsobeinsertedandsecuredwhenstoredtoreducetheriskofaccident.
Procedure (fitting the telescopic carrying handles to units without a reel):1. Removeprotectivecovers"A"usingascrewdriver.
2. Insert telescopiccarryinghandle"B" intheframeandscrewinguidesleeve"C"withmedium-strengththreadlocker.
3. Thenslidethetelescopiccarryinghandleallthewayinandlockinposition.
A
BC
8.6 Telescopic carrying handles
Unitswithahose reel are fittedwith carryinghandles.Unitswithoutahose reel canberetrofittedwithhandlesifrequired.ThehandlesshouldbeusedtotransporttheP635.Thetelescopiccarryinghandlesarescreweddirectlytotheframe.Theblankingplugsmustberemovedbeforethehandlescanbeattached.Turnthehandlesclockwise(approx.1revolution)intheendpositions(retractedorextendedcompletely)tosecurethemproperly.Turnthehandlesanticlockwise(approx.1revolution)tounlockthem.
![Page 28: Instruction manual for rescue equipment Hydraulic power units P … · 2019-11-04 · 13.echnical T data 53. 13.1 Power Unit 53 13.2 Noise emissions (Sound pressure level) 64 13.3](https://reader033.fdocuments.us/reader033/viewer/2022060502/5f1c3887265cd533e715f19b/html5/thumbnails/28.jpg)
28
8.7 ToolholderTo removea device from thedevice tray, theholdingstrapmustbeopened.Thedeviceistheneasytoremove.
Placementofthespreaderisdonein reverse order.Make sure thattherescuedevicerestsfirmlyonthedevicetray, theholdingstrapislockedandfirmlytightened.
Remove a spreader:
1
3
2
Release the holding strap bypressing the red pushbutton.
Lift up the spreader at the rearhandle.
Remove the spreader in thedirectionofthereel.
![Page 29: Instruction manual for rescue equipment Hydraulic power units P … · 2019-11-04 · 13.echnical T data 53. 13.1 Power Unit 53 13.2 Noise emissions (Sound pressure level) 64 13.3](https://reader033.fdocuments.us/reader033/viewer/2022060502/5f1c3887265cd533e715f19b/html5/thumbnails/29.jpg)
29
Procedure (fitting and adjusting the Toolholder):
NOTE:IfyouwishtoinstallaToolholderatalatertimeoradaptanexistingmounttoanewdevice,followtheworkingstepsdescribedbelow.
1.Fastenholder“A”totherail“C”withtwoscrews“B”.
A
B
C
B
2.Fixthesupports“D”and“E”totherail“F”withtwoscrews“B”
D
E
F
B
B
GG
D
F Fastenbracket“D”torail“F”withtwothreadedpins“G”.
![Page 30: Instruction manual for rescue equipment Hydraulic power units P … · 2019-11-04 · 13.echnical T data 53. 13.1 Power Unit 53 13.2 Noise emissions (Sound pressure level) 64 13.3](https://reader033.fdocuments.us/reader033/viewer/2022060502/5f1c3887265cd533e715f19b/html5/thumbnails/30.jpg)
30
Dependingonthesizeoftherescuedevices,thesupportsmustbeadapted.Support“E”canbeinstalledonbothsidesoftherail“F”.
3.Nowadaptthesupportstotheappropriaterescuedevices. Loosen the fastening screws slightly so that the supports are easy to move.
Thescrewsmustnotbecompletelyunscrewed. Thesupportscanbeadjustedtoalmostanydeviceoralmostanyindividualpreferred
position. Finallytightenalltheloosenedscrewstofixtheadjustedholderposition.
4.Themountisdismantledinreverseorder.
E
F
![Page 31: Instruction manual for rescue equipment Hydraulic power units P … · 2019-11-04 · 13.echnical T data 53. 13.1 Power Unit 53 13.2 Noise emissions (Sound pressure level) 64 13.3](https://reader033.fdocuments.us/reader033/viewer/2022060502/5f1c3887265cd533e715f19b/html5/thumbnails/31.jpg)
31
9. Dismantling the equipment / deactivation following operation
WARNING for power units with combustion engines!Checkthattheengineswitchissettothe“OFF“positionandremainstheretopreventtheunwantedstartingofthepowerunit!
Mono-couplings:If the connected hose assemblies are to be dismantled during shut-down, decouple asdescribedinchapter"Couplingthemono-couplings".Ensurethatyouputthedustprotectioncapsbackontothemono-couplinghalves.
Cleanthehydraulicpowerunitofanystubborndirtpriortostorage.
If theequipment is tobestored fora longerperiodof time, theexterior is tobecleanedcompletely and themechanicallymobile parts are to be lubricated. If storing a unitwithcombustionengine,youshouldalsoremovethefuelfromthefueltank.Avoidstoringthehydraulicpowerunitsinadampenvironment.Observe the additional regulations in the separate operating instructions for the hoses.
CAUTION!Depending on the size and weight of the hydraulic power unit it should betransportedtothestoragelocationbyoneormorepersons.
NOTE:Ifyourunitisequippedwithahosereel,thehosesmustberolledontothereelscorrectly!
Oncetheworkhasbeencompleted,allconnectedequipment is tobereset to itsneutralposition(storageposition)beforetheunitisshutdown.Youcanthenswitchofftheengineofthepowerunitanddisconnectitfromthemainssupply,ifusinganelectricmotor.
![Page 32: Instruction manual for rescue equipment Hydraulic power units P … · 2019-11-04 · 13.echnical T data 53. 13.1 Power Unit 53 13.2 Noise emissions (Sound pressure level) 64 13.3](https://reader033.fdocuments.us/reader033/viewer/2022060502/5f1c3887265cd533e715f19b/html5/thumbnails/32.jpg)
32
10. TestsThe hydraulic power units are subject to very high levels ofmechanical stress.A visualinspectionmustthereforebecarriedoutaftereveryuseandatleastonevisualinspectionmustbecarriedouteverysixmonths.This reveals wear and tear in good time; punctual replacement of these wearing partspreventsdamageto theequipment.Alsocheckregularly thatall thesecuringscrewsaretightened(ifapplicable,complywithprescribedtighteningtorques)Every3yearsorwhentheremightbedoubtsregardingthesafetyorreliabilityoftheunit,anadditionalfunctioncheckistobecarriedout(inthisconnection,complywiththeapplicablenational and international regulationswith regard to themaintenance intervals of rescueequipment).Operating time per day In the Federal Republic ofGermany, regular safetyinspections according to the regulations of the Gesetzlichen Unfallversicherung (GUV;connoted‘Legalaccidentinsurance’)aremandatory.
ATTENTION!Cleanoffanydirtbeforecheckingtheequipment!
WARNING/CAUTION!To perform inspections,maintenance and repairs, personal safety equipmentappropriatefortheworkisanabsoluterequirement.(whennecessaryalsousescreens).
LUKASoffersasuitabletestkitforthefunctiontestofthehydraulicunits.(Forspecificdetails,pleaseconsulttheLUKASrangeofaccessoriesorcontactyourLUKASdealer.)
10.1 Recommended test intervals10.1.1 General visual inspection
Avisualinspectionmustbecarriedoutaftereveryuse,butatleastonceeverysixmonths.
![Page 33: Instruction manual for rescue equipment Hydraulic power units P … · 2019-11-04 · 13.echnical T data 53. 13.1 Power Unit 53 13.2 Noise emissions (Sound pressure level) 64 13.3](https://reader033.fdocuments.us/reader033/viewer/2022060502/5f1c3887265cd533e715f19b/html5/thumbnails/33.jpg)
33
Visual Inspection
• Tightnessofallhydraulicconnections,• Generaltightness,noleakage(sweatedoilsdonothaveanyinfluenceonthefunction),• isthereanydetectabledamagetotheengine,connectingblocks,ontheframeortheside
sections,• Isthereanysignofdamagetothehydraulicsorfueltank,• Sideplatespresentandtightened,• Presenceand legibility of the identificationplate, all actuation signs, instruction signs,
markingsandwarnings,• Thepresenceandperfectconditionofallcovers(e.g.exhaustdeflector),• Allfluidlevelsarewithinthespecifiedtolerances,• Aretherotaryswitchesandswitchingleversinproperworkingorderandundamaged,• Couplingsmustbeeasytocouple,• Dustprotectioncapsmustbeavailable,• Allrequiredaccessoryparts(e.g.sparkingplug,sparkingplugspannerandfuelcan)are
present.
Functional test• Unconventionalornoticeablenoisesheardduringoperation• Cable-pullstarterfullyfunctional,• Engineswitchfullyfunctional,• Testformaximumload.
10.2 Hydraulic unit with petrol engine
Operating time per day Functional test
upto1hour 1xannually
upto8hours 1xperquarter
upto24hours 1xpermonth
In addition to these test intervals you need to carry out a function test if: - theunitmakessuspiciousnoises, - thereisajustifiedsuspicionofinternaldamagetotheunit.
Ifthenoisesandsuspicionsreferredtoaboveariseseveraltimesinamonth,orifmaximumpressurecannotbeachievedduringthefunctiontest,youneedtocontactLUKAScustomerservice immediately. The contact details are given in the Chapter "Fault analysis".
10.1.2 Function check
NOTE:usetheLUKAStestkit,includingtestinginstructions,forthefunctiontest.
![Page 34: Instruction manual for rescue equipment Hydraulic power units P … · 2019-11-04 · 13.echnical T data 53. 13.1 Power Unit 53 13.2 Noise emissions (Sound pressure level) 64 13.3](https://reader033.fdocuments.us/reader033/viewer/2022060502/5f1c3887265cd533e715f19b/html5/thumbnails/34.jpg)
34
Visual Inspection
• Tightnessofallhydraulicconnections,• Generaltightness,noleakage(sweatedoilsdonothaveanyinfluenceonthefunction),• isthereanydetectabledamagetotheengine,connectingblocks,ontheframeortheside
sections,• Isthereanysignofdamagetothehydraulicsorfueltank,• Sideplatespresentandtightened,• Presenceand legibility of the identificationplate, all actuation signs, instruction signs,
markingsandwarnings,• Thepresenceandperfectconditionofallcovers(e.g.fancover),• Allfluidlevelsarewithinthespecifiedtolerances,• ON/OFFswitchinproperworkingorder,undamaged,• Couplingsmustbeeasytocouple,• Dustprotectioncapsmustbeavailable,• Allelectricalattachments(suchascablesandplugs)mustbepresentandundamaged.
Functional test• Unconventionalornoticeablenoisesheardduringoperation• Cable-pullstarterfullyfunctional,• Engineswitchfullyfunctional,• Testformaximumload.
10.3 Hydraulic unit with electric motor
NOTE:usetheLUKAStestkit,includingtestinginstructions,forthefunctiontest.
![Page 35: Instruction manual for rescue equipment Hydraulic power units P … · 2019-11-04 · 13.echnical T data 53. 13.1 Power Unit 53 13.2 Noise emissions (Sound pressure level) 64 13.3](https://reader033.fdocuments.us/reader033/viewer/2022060502/5f1c3887265cd533e715f19b/html5/thumbnails/35.jpg)
35
10.4 Hose reelsVisual inspection
Hose reel• Generaltightness(noleaks)• Hosedrumsrotateeasily• Allfixingscrewsarepresentandtightened• Frameanddrumundamaged• Crankhandlepresent,undamagedandfullyfunctional• Lockingbrakeondoublehosereelpresentandfullyfunctional• Allsignspresentandlegible
Hoses• Visualinspectionforvisibledamageandleaks• Checkageofhose(replaceafter10yearsatthelatest)• Hoseconnectiononmountedreelsecureandnotleaking• Couplingsmustbeeasytocouple• Dustcapsfitted
Functional check• Extensionhosepairsunrollandrollupsmoothly.• Nosuspiciousnoises
![Page 36: Instruction manual for rescue equipment Hydraulic power units P … · 2019-11-04 · 13.echnical T data 53. 13.1 Power Unit 53 13.2 Noise emissions (Sound pressure level) 64 13.3](https://reader033.fdocuments.us/reader033/viewer/2022060502/5f1c3887265cd533e715f19b/html5/thumbnails/36.jpg)
36
11.1 General informationLUKAShydraulicunitsmodelP635requireonlylimitedmaintenance.Forservice work, specialtrainingisunnecessary;however,knowledgeofthefunctionofthepowerunit,thelegalsafetyinstructionsanddealingwiththerequiredtoolsarebasicprerequisites.
ATTENTION!Neveruseunnecessaryforceduringmaintenanceworkthatcoulddamagethecomponentsofthepowerunitorcompromiseoperationalsafety.
Duetothecomplexinstallation,service workonthehydraulicpowerunitmustonlybeexecutedbytheequipmentmanufacturer,personneltrainedbytheequipmentmanufacturer,orauthorisedLUKASdealers.
WARNING/CAUTION!Protective clothes must be worn when maintenance and repairs are beingcarriedout,sincethedevicesmayalsobepressurisedwhennotinoperation.
Duringwork,ensurethatallcomponentsareparticularlyclean,sincedirtcandamagetherescueequipment!
11. Maintenance and repair
![Page 37: Instruction manual for rescue equipment Hydraulic power units P … · 2019-11-04 · 13.echnical T data 53. 13.1 Power Unit 53 13.2 Noise emissions (Sound pressure level) 64 13.3](https://reader033.fdocuments.us/reader033/viewer/2022060502/5f1c3887265cd533e715f19b/html5/thumbnails/37.jpg)
37
ATTENTION!Since LUKAS hydraulic units are designed for top performance, only thosecomponentsinthereplacementpartslistsfortherelevantunitcanbereplaced.Anyothercomponentsintheunitmayonlybereplacedif:- YouhaveparticipatedinanappropriateLUKASservicetrainingcourse.- YouhavetheexpresspermissionofLUKAScustomerservice(uponrequest,
wewillcheckforthegrantofpermission.Examinationineachindividualcasenecessary!)
Whencleaningunitsandequipment,notethatnocleaningagentmaybeusedthathasapHvalueoutsidetherange5-8!
ATTENTION!Attentionmustbepaidtoensuringthatnooperatingfluidscanescapefromunitswithcombustionenginesduringrepairwork!
11.2 Service work on the hydraulic unit
11.2.1 Care instructionsTheexteriorofthedevicemustbecleanedfromtimetotime(not the electrical contacts) andthemetallicsurfaces(not the electrical contacts)mustbetreatedwithasuitableagenttoprotectagainstcorrosion.(Incaseofdoubt,contactyourauthorisedLUKASdealerorLUKASdirectly!)
11.2.2 Function and load test Ifthereisanydoubtregardingthesafetyorreliabilityoftheequipment,afunctionandstresstestmustalsobeperformed.LUKASoffersappropriatetestingequipmentforthis.
11.2.3 Replacing the hydraulic fluid- Afterapprox.200deployments,butafterthreeyearsatthelatest,replacethehydraulic
fluid.- Thefluidshouldbereplacedafterithaswarmedup.- Theenginemustbeswitchedoff!- Theusedhydraulicfluidmustbedisposedofproperly.
![Page 38: Instruction manual for rescue equipment Hydraulic power units P … · 2019-11-04 · 13.echnical T data 53. 13.1 Power Unit 53 13.2 Noise emissions (Sound pressure level) 64 13.3](https://reader033.fdocuments.us/reader033/viewer/2022060502/5f1c3887265cd533e715f19b/html5/thumbnails/38.jpg)
38
5. Pourthenewhydraulicfluidthroughthefillerneckintothehydraulictankandclosetheneckagainwithfillercap"B".
6. TheunitthenhastobebledagainasdescribedintheChapter"Commissioning".
Replacing the hydraulic fluid - procedure:1. Placethepowerunitonaslightlyelevatedbasesothatthedrainplugforthehydraulic
fluidcanbeeasilyreached.2. Placeasuitablecollectioncontainerunderthe"A"drainplug.3. Openthe"B"fillercap,removethe"A"drainplugandletthehydraulicfluidrunintothe
providedcollectioncontainer.4. Screwthe"A"drainpluginagain(tighteningtorquemax.5Nm).
11.2.4 Changing decalsAlldamagedand/orillegibledecals(safetynotices,typeplateetc.)mustbereplaced.
Procedure:1.Removedamagedand/orillegibledecals.2.Cleansurfaceswithindustrialalcohol.3. Affixnewdecals.
Takecaretoaffixthedecalsinthecorrectpositions.Ifthisisnolongerknown,youshouldaskyourauthorisedLUKASdealerorcontactLUKASdirectly.
A
B
![Page 39: Instruction manual for rescue equipment Hydraulic power units P … · 2019-11-04 · 13.echnical T data 53. 13.1 Power Unit 53 13.2 Noise emissions (Sound pressure level) 64 13.3](https://reader033.fdocuments.us/reader033/viewer/2022060502/5f1c3887265cd533e715f19b/html5/thumbnails/39.jpg)
39
NOTE:Non-observanceofthemaintenanceplancanleadtomalfunctionsthatarenotcoveredbythewarranty.
Fordismantlingthesparkingplug,useacommercially-availablesparkingplugspannerwithuniversaljointandspannersizeof16mm(5/8inch).Astraight/rigidsparkingplugspannerwoulddamageorbreakoffthesparkingplug!
(also observe the separate instructions from the engine manufacturer)
First month or after the first 20 hours (first time):• Replaceengineoil(seeoperatinginstructionsoftheenginemanufacturer).
You must conduct the following service measures every 50 operating hours:• Cleantheairfilterelement.• Afterusinginadustyenvironment,inspecttheairfilterelementandcleanimmediately,
ifnecessary.
You must conduct the following service measures every 100 operating hours:• Replaceengineoil.• Checkthesparkingplug,cleanifnecessary/settheelectrodegapofthesparkingplug
You must conduct the following service measures every 200 operating hours:• Replacethesparkingplug• Replaceairfilter
(Thefollowingserviceworkshouldbeexecutedbyanauthoriseddealer,LUKASdirectlyorthe engine manufacturer.)
You must conduct the following service measures every 300 operating hours:• Replacethesparkingplugandthefilterelement• Cleanandadjustthecarburettor,valveclearance,valveseatandcylinderhead.
You must conduct the following service measures every 1000 operating hours or every 2 years:
• Checkthestarter• Inspecttheenginefordamage• Checkthefuellineandreplace,ifnecessary.
11.3 Additional service work on unit with a petrol engine
![Page 40: Instruction manual for rescue equipment Hydraulic power units P … · 2019-11-04 · 13.echnical T data 53. 13.1 Power Unit 53 13.2 Noise emissions (Sound pressure level) 64 13.3](https://reader033.fdocuments.us/reader033/viewer/2022060502/5f1c3887265cd533e715f19b/html5/thumbnails/40.jpg)
40
11.3.1 Replacing and cleaning the air filter
Procedure:Ifpresent,removetherearsidepanelofthehydraulicpowerunit,inthatthefixingclipandthesidepanelareremoved.1.Unscrewbothboltsfromtheairfiltercoverandremovethecover.2.Removethefoamairfilterinsertfromthecover.3.Takethepaperairfilterinsertfromtheairfilterhousing.4.Checkbothairfilterinsertsandreplaceifdamaged.Thepaperairfilterinsertmustalways
bereplacedatplannedintervals.5.Cleantheairfilterinsertsifreusingthem. Paperairfilterinsert:Tapoutthepaperairfilterinsertafewtimesonahardsurfaceto
removedirtorblowcompressedair[notmorethan207kPa(2.1kg/cm)]fromtheairfilterhousingsidethroughthefilterinsert.Neverattempttobrushoutdirtbecauseitwouldbepressedinbythebristles.Replacethepaperairfilterinsertifitisexceedinglydirty.
Foam air filter insert: Clean in warm soapy water, rinse and allow to dry thoroughly. Orcleaninnon-flammablesolventandletdry.Donotintroduceanyoiltothefoamairfilterinsert.
6.Wipeawaydirtfromtheinsideoftheairfilterhousingwithadampcloth.Ensurethatdirtdoesnotpenetratetheairductleadingtothecarburettor.
7.Thenre-fitthefilter.
NOTE:Keepingtheairfilteringoodconditionisextremelyimportant.Penetratingdirtleadstodamageandwearintheengineincaseofincorrectinstallation,incorrectdamageorunsuitablefilterinserts. Alwayskeeptheairfilterinsertclean.
AirfiltercoverBolts
Foamairfilterinsert:
Paperairfilterinsert:
Airfilterhousing
![Page 41: Instruction manual for rescue equipment Hydraulic power units P … · 2019-11-04 · 13.echnical T data 53. 13.1 Power Unit 53 13.2 Noise emissions (Sound pressure level) 64 13.3](https://reader033.fdocuments.us/reader033/viewer/2022060502/5f1c3887265cd533e715f19b/html5/thumbnails/41.jpg)
41
11.3.2 Replacing, cleaning and setting the sparking plug
Procedure:Inordertodelivergoodperformance,thesparkingplugmusthaveacorrectelectrodegapandbefreefromdeposits.1.Detachthesparkingplugconnectorandremoveanydirtnearthesparkingplug.2.Unscrewthesparkingplugusinga16mm(5/8inch)sparkingplugspanner.3.Checkthesparkingplug.Replacethesparkingplugifitisdamaged,extremelydirty,the
sealingwasherisinpoorconditionortheelectrodesareworn.4.Measure theelectrodegapon thesparkingplugwithawire feelergauge.Correct the
electrodegap,ifrequired,bycarefullybendingthesideelectrode.Targetelectrodegap:0.6-0.7mm(0.024-0.028in)
5.Carefullyscrewinthesparkingplugbyhandinordertoavoidstrippingthethread.6.Tightenthesparkingplugaftermountingwitha5/8-inchsparkingplugspannerinorderto
compressthewasher.7.Anewsparkingplugshouldbetightenedbyanadditional1/2turnafterfittinginorderto
compressthewasher.8.Ausedsparkingplugshouldbetightenedbyanadditional1/8to1/4turnafterfittingin
ordertocompressthewasher.9.Placethesparkingplugconnectoronthesparkingplug.
NOTE: Aloosesparkingplugcanoverheatanddamagetheengine.Asparkingplugthatistootightcandamagethethreadinthecylinderhead.
0.6-0.7mm(0.024-0.028in)
Gasket
Sideelectrode
11.3.3 Replacing the engine oil and the engine oil filter
Fortheprocedureforreplacingtheengineoilandengineoilfilter,pleaserefertotheseparateoperatinginstructionsoftheenginemanufacturer!
Sparkingplugspanner
Sparkingplugcon-nector
![Page 42: Instruction manual for rescue equipment Hydraulic power units P … · 2019-11-04 · 13.echnical T data 53. 13.1 Power Unit 53 13.2 Noise emissions (Sound pressure level) 64 13.3](https://reader033.fdocuments.us/reader033/viewer/2022060502/5f1c3887265cd533e715f19b/html5/thumbnails/42.jpg)
42
11.4 Maintenance work on mounted hose reel Avisualinspectionofthefittedhosesandcouplingsistobecarriedoutaftereveryuseoreverysixmonths.Componentsshowingobvioussignsofdamageorleaksmustbereplaced.Ifscrewedconnectionsstarttoleak,checkwhethertheyaretightfirstofall.Iftheleakcontinuesafterthescrewedconnectionhasbeentightened,thescrewedconnectionisdefectiveandmustbereplaced.Hoselineswillageovertimeandmustbereplacedaccordingtostatutoryregulations.Iftherearenoapplicablestatutoryregulations,thehosesmustbereplacedafter10yearsatthelatest.(Read the separate operating instructions for the hoses.)
11.4.1 Replacing the extension hose lines (double hose)
Procedure:
1. First of all, empty the hydraulic reservoirasdescribedinthechapter"Replacingthehydraulicfluid".
2. Unrollextensionhoses"A".Slideprotectivehoses "B" over elbow piece "C", leavingthe screwed connection uncovered.Thenunscrewthehoses.
C
A
B
![Page 43: Instruction manual for rescue equipment Hydraulic power units P … · 2019-11-04 · 13.echnical T data 53. 13.1 Power Unit 53 13.2 Noise emissions (Sound pressure level) 64 13.3](https://reader033.fdocuments.us/reader033/viewer/2022060502/5f1c3887265cd533e715f19b/html5/thumbnails/43.jpg)
43
3. Screw the new extension hoses onto the elbowpieceswithatorqueof
MA=40Nm.Donotforgettoslideprotectivehoses"B"backoverthescrewedconnections.
The protective hose set must be fitted to the reel!
B 4. Rolluptheextensionhoseagain. 5. Thehydraulicfluidreservoirmustthenbefilledandtheunitvented.
11.4.2 Replacing the extension hose lines (mono hose)
A
B 2. Unroll extension hoses “A”.
Unscrewthehoses“A”fromcouplingconnection“B”.
3. Screw the new extension hoses onto the coupling connection “B” with a torque of MA=35Nm.
1. Firstofall,empty thehydraulic reservoirasdescribed in thechapter “Replacing thehydraulicfluid”.
![Page 44: Instruction manual for rescue equipment Hydraulic power units P … · 2019-11-04 · 13.echnical T data 53. 13.1 Power Unit 53 13.2 Noise emissions (Sound pressure level) 64 13.3](https://reader033.fdocuments.us/reader033/viewer/2022060502/5f1c3887265cd533e715f19b/html5/thumbnails/44.jpg)
44
Themono-couplingsmustbereplacedif:- thereisexternaldamage,- thelockingdoesnotfunction,- hydraulicfluidcontinuestoleakinthecoupled/uncoupledstate.
WARNING/CAUTION!Neverrepaircouplings:theymustbereplacedbygenuineLUKASparts!
Procedure for coupling to valve block:
1. Firstemptythehydraulictankasdescribedinthechapter"Replacingthehydraulicfluid".2.Removescrewedfittingsonthecoupling.3.Removecouplingsandunderlyingseals4.Positionthenewcoupling,togetherwiththeseals,ontothevalveblock.5.Re-attachthecouplingswiththeboltsandtightentoatorqueofMA=40Nm.6. Thehydraulicfluidtankmustberefilledandthepowerunitvented.
4. Rolluptheextensionhoseagain.
5. Thehydraulicfluidreservoirmustthenbefilledandtheunitvented.
11.4.3 Mono-couplings
![Page 45: Instruction manual for rescue equipment Hydraulic power units P … · 2019-11-04 · 13.echnical T data 53. 13.1 Power Unit 53 13.2 Noise emissions (Sound pressure level) 64 13.3](https://reader033.fdocuments.us/reader033/viewer/2022060502/5f1c3887265cd533e715f19b/html5/thumbnails/45.jpg)
45
3. Loosentheunionnutsonthehoselinesandremovethecoupling.
Procedure for coupling to hose pairs:
1. Firstemptythehydraulictankasdescribedinthechapter"Replacingthehydraulicfluid".2. Pullthekink-protectionbackfromthecouplings.
ATTENTION!Ensurethatconnection“T1”/"T2"onthepumpblockisalwaysconnectedtoconnection“T”onthemono-coupling.
4.PositionthenewcouplingandtightentheunionnutsonthehoseassembliestoatorqueofMA=40Nmandpushthekink-protectionofthecouplingsback.
5. Thehydraulicfluidtankmustberefilledandthepowerunitvented.
![Page 46: Instruction manual for rescue equipment Hydraulic power units P … · 2019-11-04 · 13.echnical T data 53. 13.1 Power Unit 53 13.2 Noise emissions (Sound pressure level) 64 13.3](https://reader033.fdocuments.us/reader033/viewer/2022060502/5f1c3887265cd533e715f19b/html5/thumbnails/46.jpg)
46
Trouble Check Cause SolutionElectricmotordoesnotoperatewhentheswitchisactuatedordoesnotoperateatfullpower
Checktheconnectioncableontheelectricmotor
Powercablenotconnected
Connectpowercablecorrectly
Defectonconnectioncable
Shutdownimmediatelyandhaverepairedbyauthoriseddealer,motor/enginemanufacturerordirectlybyLUKAS
Extensioncableorcabledrumused?
Cablenotcompletelyuncoiled
Uncoilthepowercablecompletely
Cablelossesinextensioncableorcabledrumstoogreat(electricalresistance)
Useadifferentsuitableextensioncableorcabledrum.
Electricsafetydeviceinpowersupplyhastriggered
Powersupplynotsuitableforelectricmotor
Connectthemotortoadifferentsuitablepowersupply
Electricsafetydeviceinpowersupplyhastriggeredalthoughitissuitableforoperationofthemotor.
Safetydevicetoolow,useadifferentfuse.
Areallvalvesdepressurised(baseposition)?
Electricmotordefectiveoroverloadedduetoanotherdefectintheunit
Shutdownimmediatelyandhaverepairedbyauthoriseddealer,motor/enginemanufacturerordirectlybyLUKAS
12. Fault analysis
NOTE: Incaseoffaultswhichdirectlyaffecttheelectricmotor,pleasealsoobservetheseparateinstructionsintheoperatinginstructionsofthemotormanufacturer.
![Page 47: Instruction manual for rescue equipment Hydraulic power units P … · 2019-11-04 · 13.echnical T data 53. 13.1 Power Unit 53 13.2 Noise emissions (Sound pressure level) 64 13.3](https://reader033.fdocuments.us/reader033/viewer/2022060502/5f1c3887265cd533e715f19b/html5/thumbnails/47.jpg)
47
NOTE: Incaseoffaultswhichdirectlyaffectthecombustionengine,pleasealsoobservetheseparateinstructionsintheoperatinginstructionsoftheenginemanufacturer.
Fault Check Cause SolutionCombustionenginewillnotstart
Checkfuellevelintank
Fueltankempty Topupfuel
Checkfuelline Faultinthefuelline Shutdownimmediatelyandhaverepairedbyauthoriseddealer,motor/enginemanufacturerordirectlybyLUKAS
Inspectengineswitch
Cable-pullstarter Activatecable-pullstarter
MotorswitchnotsettoChoke
SetmotorswitchtoChoke
Hydraulicunitorenginenotsuitablefortheworkingenvironment
Ambienttemperaturetoolow
Forthesolution,consulttheseparateoperatinginstructionsoftheenginemanufacturer.Useadifferenthydraulicfluidoroperatingfluidthatissuitablefortherelevantambienttemperature(seeChapterI"TechnicalData")
Notenoughoxygenintheairbecauseofthealtitudeofapplicationlocationofthehydraulicmotor
Useadifferentmoresuitablehydraulicunit.
Havetheenginesettothealtitudeofapplicationofthehydraulicpowerunitbyanauthoriseddealer,enginemanufacturerorLUKASdirectly(onlyiftheunitistobeusedfrequentlyatthisaltitude).
Checkairfilter Airfiltercontaminated Cleanorreplacetheairfilter.
Areallvalvessettopressure-free(restsetting)?
Combustionmotordefectiveoroverloadedduetodifferentdefectintheunit
Haverepairedbyauthoriseddealer,motor/enginemanufacturerordirectlybyLUKAS
![Page 48: Instruction manual for rescue equipment Hydraulic power units P … · 2019-11-04 · 13.echnical T data 53. 13.1 Power Unit 53 13.2 Noise emissions (Sound pressure level) 64 13.3](https://reader033.fdocuments.us/reader033/viewer/2022060502/5f1c3887265cd533e715f19b/html5/thumbnails/48.jpg)
48
Fault Check Cause SolutionThemotorisrunning,buttheconnectedrescueequipmentisnotmoving/movingveryslowlyuponactivationofthevalve.
Checkhose Hoseassemblynotconnectedproperlyorisdamaged
Checkconnectionofhoseandreconnectifnecessary.
Checktheswitchpositionofthevalveleveronthepumpblockofthehydraulicunit
Valvenotswitchedtosupplylinepressurisation.
Switchvalvetopressureloadofthesupplyline.
Defectivepumpunit HaverepairedbyauthoriseddealerordirectlybyLUKAS
Connectadifferentunitandcheckwhetheritworkswhenactuated
Thepreviouslyconnectedunitisdefective.
Rectificationseeoperatinginstructionsoftheconnectedunit
Mono-coupling(female)defective
Replacemono-coupling(female)
Theconnectedrescueequipmentdoesnotmoveonactivationofthevalve,ormovesonlyveryslowlyorunevenly.
Connectadifferentunitandcheckwhetheritworkswhenactuated
Thepreviouslyconnectedunitisdefective.
Rectificationseeoperatinginstructionsoftheconnectedunit
Checktheswitchingpositionofthe“TURBO”controlleveronthepumpblockofthehydraulicsystem.
The“TURBO”controlleverisnotfullyswitched.
Checktheswitchingpositionofthe"TURBO"controlleverandreswitchifnecessary(toendposition).
Defectivepumpunit HaverepairedbyauthoriseddealerordirectlybyLUKAS
Airinhydraulicsystem Ventthehydraulicsystem
Plug-incoupling(female)defective
Replaceplug-incoupling(female)
Mono-coupling(female)defective
Replacemono-coupling(female)
![Page 49: Instruction manual for rescue equipment Hydraulic power units P … · 2019-11-04 · 13.echnical T data 53. 13.1 Power Unit 53 13.2 Noise emissions (Sound pressure level) 64 13.3](https://reader033.fdocuments.us/reader033/viewer/2022060502/5f1c3887265cd533e715f19b/html5/thumbnails/49.jpg)
49
Fault Check Cause SolutionConnectedrescuedevicedoesnotreachitsfinalposition
Checkhydraulicfluidvolumeinhydraulictank
Insufficientfluidinthehydraulictank
TopuphydraulicfluidtothemaximumfillinglevelCaution! Before topping up the rescue equipment, return to the base position!
Usablehydraulicfluidvolumeoftheunitisinsufficient
Useadifferentrescuedevicewithademandquantitybelowthemaximumusablequantityoftheunit
Connectedrescuedevicedoesnotreachitsspecificperformancedata
Maximumpermittedoperatingpressureofthepumpisnotreached
HavethepressurelimitingvalveresetorrepairedbyauthoriseddealerordirectlybyLUKAS
Pumpblockdefective HaverepairedbyauthoriseddealerordirectlybyLUKAS
Connectedunitdefective
Rectificationseeoperatinginstructionsoftheconnectedunit
Duringfunctiontest:Apressuregaugeinstalledbetweentherescueequipmentandthehydraulicpowerunitdoesnotindicatethemaximumoperatingpressureoftheequipment.
Checkthedetailsoftherescuedevice
Theoperatingpressureoftheconnectedrescuedeviceislockedinternally
Norepairorfaultrectificationrequired
Connectedrescuedeviceisdefective
Consulttheseparateoperatingmanualfortheconnectedrescuedevice
Hydraulicunitdefective HaverepairedbyauthoriseddealerordirectlybyLUKAS
![Page 50: Instruction manual for rescue equipment Hydraulic power units P … · 2019-11-04 · 13.echnical T data 53. 13.1 Power Unit 53 13.2 Noise emissions (Sound pressure level) 64 13.3](https://reader033.fdocuments.us/reader033/viewer/2022060502/5f1c3887265cd533e715f19b/html5/thumbnails/50.jpg)
50
Fault Check Cause SolutionFluidcomingoutfromhydraulicfluidtank
Connectedunitnotinbasepositionyetandfluidcomingoutoffillercap?
Returnofthehydraulicfluidfromtherescuedeviceexceedsthetank’smaximumquantitywhenfilled.
Reducefluidlevelinthehydraulictankto“Minimum”mark,movetheunittothebasepositionandthenfillbackupwithhydraulicfluidtothe“Maximum”level
Fluidleaksfromadifferentlocation?
Leakfromtank,linesorseals
ReplacedefectivecomponentsorrepairbyauthoriseddealerorLUKASdirectly
Leakingfluidbetweenengineandflangebearing
Radialshaftsealonthedriveshaftisdefective
HaverepairedbyauthoriseddealerordirectlybyLUKAS
Hydraulicfluidmilkyandcloudy
Water/condensationinthesystem
Replacethehydraulicfluidimmediately
Hosescannotbecoupled
Couplingdefective Couplingmustbereplacedimmediately
Impossibletoretractorextendcarryinghandles.
Carryinghandlesarestilllocked
Unlockcarryinghandlesandextend.
Carryinghandlesorframedefective
Replacethecarryinghandlesorframe.
Impossibletolockorunlockcarryinghandles
Carryinghandlesorframedefective
Replacethecarryinghandlesorframe.
Hosereeldoesnotturn
Lockingbrakestillapplied
Releaselockingbrake
Hosereeldefective HaverepairedbyauthoriseddealerordirectlybyLUKAS
ImpossibletoattachequipmenttotheToolholder
Toolholdersetincorrectly
AdjusttheToolholdertoaccommodatethedevice.
Toolholderdefective ReplaceToolholder.
![Page 51: Instruction manual for rescue equipment Hydraulic power units P … · 2019-11-04 · 13.echnical T data 53. 13.1 Power Unit 53 13.2 Noise emissions (Sound pressure level) 64 13.3](https://reader033.fdocuments.us/reader033/viewer/2022060502/5f1c3887265cd533e715f19b/html5/thumbnails/51.jpg)
51
Fault Check Cause SolutionItisfrequentlynotpossibletocouplehoseassemblies
Hydraulicfluidnotadaptedtotheapplicationsituation
Hydraulicfluidmustbereplaced(seechapter"Recommendedhydraulicfluids")
Couplingdefective Couplingmustbereplacedimmediately
Leakinthecouplings Couplingdefective Couplingmustbereplacedimmediately
Leakageatthedriveshaftofthehydraulicpump
Shaftsealdefective. Repairbyanauthoriseddealer,bypersonnelspeciallytrainedbyLUKAS,orbyLUKASitself
Fluidescapingfromhosesorjoints
Leak,possibledamage Replacehoses
Surfaceofthehosesdamaged
Mechanicaldamageorcontactwithaggressiveagents
Replacehoses
Hydraulicfluidescapingfrominsidethehosedrum.
Extensionhosepairsdamaged?
Hoselinesdefective. Replacehoses
Screwedconnectiononthehoselinestight?
Connectionbetweenhoselinesandelbowpiecesnottightenough.
Tightenthescrewedconnectionsbetweenthehoselinesandelbowpieces.
Screwedconnectionbetweenelbowpieceandshaftleaking?
Defectiveelbowpieceorseal
Replacetheelbowpieceorseal
Defectiveshaft Repairoffaultbyauthoriseddealer,speciallytrainedLUKASstaffordirectlybyLUKAS
![Page 52: Instruction manual for rescue equipment Hydraulic power units P … · 2019-11-04 · 13.echnical T data 53. 13.1 Power Unit 53 13.2 Noise emissions (Sound pressure level) 64 13.3](https://reader033.fdocuments.us/reader033/viewer/2022060502/5f1c3887265cd533e715f19b/html5/thumbnails/52.jpg)
52
NOTE: Incaseoffaultswhichaffectthecombustionengine,pleasealsoobservetheinstructionsintheseparateoperatinginstructionsoftheenginemanufacturer.
ContactanauthorisedLUKASdealerortheLUKASCustomerServiceDepartmentdirectlyifthemalfunctionscannotberectified.TheaddressfortheLUKASCustomerServicedepartmentis:
LUKAS Hydraulik GmbHA Unit of IDEX Corporation
Weinstraße39, D-91058ErlangenTel.: (+49)09131/698-348Fax.: (+49)09131/698-353
Hydraulicfluidescapingfromtheconnectionsbetweentheconnectionhosesandreelshaft
Connectionhosesdamaged?
Hoselinesdefective. Replacehoses
Screwedconnectiononthehoselinestight?
Hoselinesormalecouplingsnottightenough.
Tightenthescrewedconnectionsonthehoselinesormalecouplings.
Leakbetweenmalecouplingandshaft?
Malecouplingnottightenough
Tightenscrewedconnection.
Sealbetweenmalecouplingandshaftdefective?
Replaceseal.
Malecouplingdefective
Replacemalecoupling
Connectionbetweenhubandshaftleaking
Sealbetweenhubandshaftdefective.
Repairoffaultbyauthoriseddealer,speciallytrainedLUKASstaffordirectlybyLUKAS
![Page 53: Instruction manual for rescue equipment Hydraulic power units P … · 2019-11-04 · 13.echnical T data 53. 13.1 Power Unit 53 13.2 Noise emissions (Sound pressure level) 64 13.3](https://reader033.fdocuments.us/reader033/viewer/2022060502/5f1c3887265cd533e715f19b/html5/thumbnails/53.jpg)
53
13. Technical data
NOTE:The following tables contain only the technical data required for standardacceptance.AdditionaldataconcerningyourunitcanbeobtainedfromLUKASonrequest.The limitation of themax. fill quantity of the hydraulic tank results from the"operabilityatanincline"prescribedinthestandards.
Becauseallvaluesaresubjecttotolerances,theremaybesmalldifferencesbetweenthedataforyourdeviceandthedatainthefollowingtables!The values may also differ because of reading inaccuracies and/or tolerances in themeasuringequipmentused.
13.1 Power Unit13.1.1 Basic dimensions of the power unit (mm [inch])
Units without hose reel:
![Page 54: Instruction manual for rescue equipment Hydraulic power units P … · 2019-11-04 · 13.echnical T data 53. 13.1 Power Unit 53 13.2 Noise emissions (Sound pressure level) 64 13.3](https://reader033.fdocuments.us/reader033/viewer/2022060502/5f1c3887265cd533e715f19b/html5/thumbnails/54.jpg)
54
Units with hose reel (double hose):
Units with hose reel (mono hose):
![Page 55: Instruction manual for rescue equipment Hydraulic power units P … · 2019-11-04 · 13.echnical T data 53. 13.1 Power Unit 53 13.2 Noise emissions (Sound pressure level) 64 13.3](https://reader033.fdocuments.us/reader033/viewer/2022060502/5f1c3887265cd533e715f19b/html5/thumbnails/55.jpg)
55
1) HD = Highpressure 2) ND=Lowpressure 3) 1MPa=10bar
13.1.2 Technical data P 635 SG
Device type P 635 SGArticle number 81-53-40
Motor type 4-strokepetrolengine
Engine power rating[kW] 1,8/2,2[HP] 2.4 / 3.0
Engine speed[min-1]
3000/3800[rpm.]
Feed rate simultaneous (HD)1)
[l/min] 2x0,55/2x0,7[gal.-US/min] 2 x 0.15 / 2 x 0.19
Feed rate turbo (HD)1)
[l/min] 1x1,1/1x1,35[gal.-US/min] 1 x 0.29 / 1 x 0.36
Feed rate simultaneous (ND)2)
[l/min] 2x2,4/2x3,0[gal.-US/min] 2 x 0.63 / 2 x 0.79
Feed rate turbo (ND)2)
[l/min] 1x4,7/1x5,8[gal.-US/min] 1 x 1.24 / 1 x 1.53
Max. operating pressure (HD)1)
[MPa]3) 70[psi.] 10000
Max. operating pressure (ND)2)
[MPa]3) 14[psi.] 2000
Max. fill volume Hydraulicfluid
[l] 5,2[gal.-US] 1.37
Max. usable quantity Hydraulicfluid
[l] 5,0[gal.-US] 1.32
Max. fill volume Petrol
[l] 0,77[gal.-US] 0.20
Weight (incl.petrolandhydraulicfluid)
[kg] 32,5[lbs.] 71,7
Valve variants SimultaneousoperationMax. number of device connections 2Hose reel NO
![Page 56: Instruction manual for rescue equipment Hydraulic power units P … · 2019-11-04 · 13.echnical T data 53. 13.1 Power Unit 53 13.2 Noise emissions (Sound pressure level) 64 13.3](https://reader033.fdocuments.us/reader033/viewer/2022060502/5f1c3887265cd533e715f19b/html5/thumbnails/56.jpg)
56
1) HD = Highpressure 2) ND=Lowpressure 3) 1MPa=10bar
13.1.3 Technical data P 635 SG-DHR
Device type P 635 SG-DHRArticle number 81-54-43
Motor type 4-strokepetrolengine
Engine power rating[kW] 1,8/2,2[HP] 2.4 / 3.0
Engine speed[min-1]
3000/3800[rpm.]
Feed rate simultaneous (HD)1)
[l/min] 2x0,55/2x0,7[gal.-US/min] 2 x 0.15 / 2 x 0.19
Feed rate turbo (HD)1)
[l/min] 1x1,1/1x1,35[gal.-US/min] 1 x 0.29 / 1 x 0.36
Feed rate simultaneous (ND)2)
[l/min] 2x2,4/2x3,0[gal.-US/min] 2 x 0.63 / 2 x 0.79
Feed rate turbo (ND)2)
[l/min] 1x4,7/1x5,8[gal.-US/min] 1 x 1.24 / 1 x 1.53
Max. operating pressure (HD)1)
[MPa]3) 70[psi.] 10000
Max. operating pressure (ND)2)
[MPa]3) 14[psi.] 2000
Max. fill volume Hydraulicfluid
[l] 5,2[gal.-US] 1.37
Max. usable quantity Hydraulicfluid
[l] 5,0[gal.-US] 1.32
Max. fill volume Petrol
[l] 0,77[gal.-US] 0.20
Weight (incl.petrolandhydraulicfluid)
[kg] 72,5[lbs.] 159.8
Valve variants SimultaneousoperationMax. number of device connections 2
Hose reel (double hose)
[m] 2x20[ft] 2 x 66
![Page 57: Instruction manual for rescue equipment Hydraulic power units P … · 2019-11-04 · 13.echnical T data 53. 13.1 Power Unit 53 13.2 Noise emissions (Sound pressure level) 64 13.3](https://reader033.fdocuments.us/reader033/viewer/2022060502/5f1c3887265cd533e715f19b/html5/thumbnails/57.jpg)
57
1) HD = Highpressure 2) ND=Lowpressure 3) 1MPa=10bar
13.1.4 Technical data P 635 SG-DHR-COAX
Device type P 635 SG-DHR-COAXArticle number 81-54-40
Motor type 4-strokepetrolengine
Engine power rating[kW] 1,8/2,2[HP] 2.4 / 3.0
Engine speed[min-1]
3000/3800[rpm.]
Feed rate simultaneous (HD)1)
[l/min] 2x0,55/2x0,7[gal.-US/min] 2 x 0.15 / 2 x 0.19
Feed rate turbo (HD)1)
[l/min] 1x1,1/1x1,35[gal.-US/min] 1 x 0.29 / 1 x 0.36
Feed rate simultaneous (ND)2)
[l/min] 2x2,4/2x3,0[gal.-US/min] 2 x 0.63 / 2 x 0.79
Feed rate turbo (ND)2)
[l/min] 1x4,7/1x5,8[gal.-US/min] 1 x 1.24 / 1 x 1.53
Max. operating pressure (HD)1)
[MPa]3) 70[psi.] 10000
Max. operating pressure (ND)2)
[MPa]3) 14[psi.] 2000
Max. fill volume Hydraulicfluid
[l] 5,2[gal.-US] 1.37
Max. usable quantity Hydraulicfluid
[l] 5,0[gal.-US] 1.32
Max. fill volume Petrol
[l] 0,77[gal.-US] 0.20
Weight (incl.petrolandhydraulicfluid)
[kg] 74,3[lbs.] 163.8
Valve variants SimultaneousoperationMax. number of device connections 2
Hose reel (mono hose)
[m] 2x20[ft] 2 x 66
![Page 58: Instruction manual for rescue equipment Hydraulic power units P … · 2019-11-04 · 13.echnical T data 53. 13.1 Power Unit 53 13.2 Noise emissions (Sound pressure level) 64 13.3](https://reader033.fdocuments.us/reader033/viewer/2022060502/5f1c3887265cd533e715f19b/html5/thumbnails/58.jpg)
58
1) HD = Highpressure 2) ND=Lowpressure 3) 1MPa=10bar
13.1.5 Technical data P 635 SE, 230V / 50Hz
Device type P 635 SE 230V / 50HzRef. number 81-53-41Motor type 230V/50Hz;Electricmotor
Power[kW] 2,2[HP] 3.0
Speed[min-1]
2830[rpm.]
Max. operating pressure (HD)1)
[MPa]3) 70[psi.] 10000
Max. operating pressure (ND)2)
[MPa]3) 14[psi.] 2000
Flow rate (HD)1)
[l/min] 2x0,55/TURBO1x1,1[gal.-US/min] 2 x 0.15 / TURBO 1 x 0.29
Flow rate (ND)2)
[l/min] 2x2,4/TURBO1x4,7[gal.-US/min] 2 x 0.63 / TURBO 1 x 1.24
Max. fill quantity Hydraulicfluid
[l] 5,2[gal.-US] 1.37
Max. usable quantity Hydraulicfluid
[l] 5,0[gal.-US] 1.32
Weight (incl.hydraulicfluid)
[kg] 36,7[lbs.] 80.9
Starting current [A] 43Valve variants Simultaneousoperation
Max. number of device connections 2
Hose reel NO
![Page 59: Instruction manual for rescue equipment Hydraulic power units P … · 2019-11-04 · 13.echnical T data 53. 13.1 Power Unit 53 13.2 Noise emissions (Sound pressure level) 64 13.3](https://reader033.fdocuments.us/reader033/viewer/2022060502/5f1c3887265cd533e715f19b/html5/thumbnails/59.jpg)
59
1) HD = Highpressure 2) ND=Lowpressure 3) 1MPa=10bar
13.1.6 Technical data P 635 SE, 230V / 60Hz
Device type P 635 SE 230V / 60HzRef. number 81-53-42Motor type 230V/60Hz;Electricmotor
Power[kW] 2,2[HP] 3.0
Speed[min-1]
3450[rpm.]
Max. operating pressure (HD)1)
[MPa]3) 70[psi.] 10000
Max. operating pressure (ND)2)
[MPa]3) 14[psi.] 2000
Flow rate (HD)1)
[l/min] 2x0,6/TURBO1x1,2[gal.-US/min] 2 x 0.16 / TURBO 1 x 0.32
Flow rate (ND)2)
[l/min] 2x2,8/TURBO1x5,5[gal.-US/min] 2 x 0.74 / TURBO 1 x 1.45
Max. fill quantity Hydraulicfluid
[l] 5,2[gal.-US] 1.37
Max. usable quantity Hydraulicfluid
[l] 5,0[gal.-US] 1.32
Weight (incl.hydraulicfluid)
[kg] 37,1[lbs.] 81.8
Starting current [A] 60Valve variants Simultaneousoperation
Max. number of device connections 2
Hose reel NO
![Page 60: Instruction manual for rescue equipment Hydraulic power units P … · 2019-11-04 · 13.echnical T data 53. 13.1 Power Unit 53 13.2 Noise emissions (Sound pressure level) 64 13.3](https://reader033.fdocuments.us/reader033/viewer/2022060502/5f1c3887265cd533e715f19b/html5/thumbnails/60.jpg)
60
1) HD = Highpressure 2) ND=Lowpressure 3) 1MPa=10bar
13.1.7 Technical data P 635 SE-DHR, 230V / 50Hz
Device type P 635 SE-DHR 230V / 50HzRef. number 81-54-44Motor type 230V/50Hz;Electricmotor
Power[kW] 2,2[HP] 3.0
Speed[min-1]
2830[rpm.]
Max. operating pressure (HD)1)
[MPa]3) 70[psi.] 10000
Max. operating pressure (ND)2)
[MPa]3) 14[psi.] 2000
Flow rate (HD)1)
[l/min] 2x0,55/TURBO1x1,1[gal.-US/min] 2 x 0.15 / TURBO 1 x 0.29
Flow rate (ND)2)
[l/min] 2x2,4/TURBO1x4,7[gal.-US/min] 2 x 0.63 / TURBO 1 x 1.24
Max. fill quantity Hydraulicfluid
[l] 5,2[gal.-US] 1.37
Max. usable quantity Hydraulicfluid
[l] 5,0[gal.-US] 1.32
Weight (incl.hydraulicfluid)
[kg] 76,7[lbs.] 169.1
Starting current [A] 43Valve variants Simultaneousoperation
Max. number of device connections 2
Hose reel (double hose)
[m] 2x20
[ft] 2 x 66
![Page 61: Instruction manual for rescue equipment Hydraulic power units P … · 2019-11-04 · 13.echnical T data 53. 13.1 Power Unit 53 13.2 Noise emissions (Sound pressure level) 64 13.3](https://reader033.fdocuments.us/reader033/viewer/2022060502/5f1c3887265cd533e715f19b/html5/thumbnails/61.jpg)
61
1) HD = Highpressure 2) ND=Lowpressure 3) 1MPa=10bar
13.1.8 Technical data P 635 SE-DHR, 230V / 60Hz
Device type P 635 SE-DHR 230V / 60HzRef. number 81-54-45Motor type 230V/60Hz;Electricmotor
Power[kW] 2,2[HP] 3.0
Speed[min-1]
3450[rpm.]
Max. operating pressure (HD)1)
[MPa]3) 70[psi.] 10000
Max. operating pressure (ND)2)
[MPa]3) 14[psi.] 2000
Flow rate (HD)1)
[l/min] 2x0,6/TURBO1x1,2[gal.-US/min] 2 x 0.16 / TURBO 1 x 0.32
Flow rate (ND)2)
[l/min] 2x2,8/TURBO1x5,5[gal.-US/min] 2 x 0.74 / TURBO 1 x 1.45
Max. fill quantity Hydraulicfluid
[l] 5,2[gal.-US] 1.37
Max. usable quantity Hydraulicfluid
[l] 5,0[gal.-US] 1.32
Weight (incl.hydraulicfluid)
[kg] 77,1[lbs.] 170.0
Starting current [A] 60Valve variants Simultaneousoperation
Max. number of device connections 2
Hose reel (double hose)
[m] 2x20
[ft] 2 x 66
![Page 62: Instruction manual for rescue equipment Hydraulic power units P … · 2019-11-04 · 13.echnical T data 53. 13.1 Power Unit 53 13.2 Noise emissions (Sound pressure level) 64 13.3](https://reader033.fdocuments.us/reader033/viewer/2022060502/5f1c3887265cd533e715f19b/html5/thumbnails/62.jpg)
62
1) HD = Highpressure 2) ND=Lowpressure 3) 1MPa=10bar
13.1.9 Technical data P 635 SE-DHR-COAX, 230V / 50Hz
Device type P 635 SE-DHR-COAX 230V / 50HzRef. number 81-54-41Motor type 230V/50Hz;Electricmotor
Power[kW] 2,2[HP] 3.0
Speed[min-1]
2830[rpm.]
Max. operating pressure (HD)1)
[MPa]3) 70[psi.] 10000
Max. operating pressure (ND)2)
[MPa]3) 14[psi.] 2000
Flow rate (HD)1)
[l/min] 2x0,55/TURBO1x1,1[gal.-US/min] 2 x 0.15 / TURBO 1 x 0.29
Flow rate (ND)2)
[l/min] 2x2,4/TURBO1x4,7[gal.-US/min] 2 x 0.63 / TURBO 1 x 1.24
Max. fill quantity Hydraulicfluid
[l] 5,2[gal.-US] 1.37
Max. usable quantity Hydraulicfluid
[l] 5,0[gal.-US] 1.32
Weight (incl.hydraulicfluid)
[kg] 78,5[lbs.] 173.1
Starting current [A] 43Valve variants Simultaneousoperation
Max. number of device connections 2
Hose reel (mono hose)
[m] 2x20
[ft] 2 x 66
![Page 63: Instruction manual for rescue equipment Hydraulic power units P … · 2019-11-04 · 13.echnical T data 53. 13.1 Power Unit 53 13.2 Noise emissions (Sound pressure level) 64 13.3](https://reader033.fdocuments.us/reader033/viewer/2022060502/5f1c3887265cd533e715f19b/html5/thumbnails/63.jpg)
63
1) HD = Highpressure 2) ND=Lowpressure 3) 1MPa=10bar
13.1.10 Technical data P 635 SE-DHR-COAX, 230V / 60Hz
Device type P 635 SE-DHR-COAX 230V / 60HzRef. number 81-54-42Motor type 230V/60Hz;Electricmotor
Power[kW] 2,2[HP] 3.0
Speed[min-1]
3450[rpm.]
Max. operating pressure (HD)1)
[MPa]3) 70[psi.] 10000
Max. operating pressure (ND)2)
[MPa]3) 14[psi.] 2000
Flow rate (HD)1)
[l/min] 2x0,6/TURBO1x1,2[gal.-US/min] 2 x 0.16 / TURBO 1 x 0.32
Flow rate (ND)2)
[l/min] 2x2,8/TURBO1x5,5[gal.-US/min] 2 x 0.74 / TURBO 1 x 1.45
Max. fill quantity Hydraulicfluid
[l] 5,2[gal.-US] 1.37
Max. usable quantity Hydraulicfluid
[l] 5,0[gal.-US] 1.32
Weight (incl.hydraulicfluid)
[kg] 78,9[lbs.] 173.9
Starting current [A] 60Valve variants Simultaneousoperation
Max. number of device connections 2
Hose reel (mono hose)
[m] 2x20[ft] 2 x 66
![Page 64: Instruction manual for rescue equipment Hydraulic power units P … · 2019-11-04 · 13.echnical T data 53. 13.1 Power Unit 53 13.2 Noise emissions (Sound pressure level) 64 13.3](https://reader033.fdocuments.us/reader033/viewer/2022060502/5f1c3887265cd533e715f19b/html5/thumbnails/64.jpg)
64
13.2 Noise emissions (Sound pressure level)
Device typeP 635 SG
P 635 SG-DHRP 635 SG-DHR-COAX
Speed [min-1]/[rpm.] 3000 3800Idle run(accordingtoEN) [dB(A)] 80 84Full load(accordingtoEN) [dB(A)] 84 88Idle run(accordingtoNFPA) [dB(A)] 73 77
Full load(accordingtoNFPA) [dB(A)] 77 80
Device type
P 635 SE 230V / 50Hz
P 635 SE-DHR 230V / 50Hz
P 635 SE-DHR-COAX 230V / 50Hz
P 635 SE 230V / 60Hz
P 635 SE-DHR 230V / 60Hz
P 635 SE-DHR-COAX 230V / 60Hz
Speed [min-1]/[rpm.] 2830 3450Idle run(accordingtoEN) [dB(A)] 75 76Full load(accordingtoEN) [dB(A)] 81 82Idle run(accordingtoNFPA) [dB(A)] 71 72Full load(accordingtoNFPA) [dB(A)] 75 76
![Page 65: Instruction manual for rescue equipment Hydraulic power units P … · 2019-11-04 · 13.echnical T data 53. 13.1 Power Unit 53 13.2 Noise emissions (Sound pressure level) 64 13.3](https://reader033.fdocuments.us/reader033/viewer/2022060502/5f1c3887265cd533e715f19b/html5/thumbnails/65.jpg)
65
Explanation of dual number noise emission values according to DIN EN 13204:2016-12Serialnumberofthemachine,operatingconditionsandothercharacteristicproperties:Model ...P 635 SG, P 635 SG-DHR, P 635 SG-DHR-COAX type...81-53-40,81-54-43,81-54-40,maximumworkingpressure...700bar,enginespeed....3800[min-1]/[rpm]INDICATEDDUALNUMBERNOISEEMISSIONVALUESaccordingtoENISO4871MeasuredA-ratedemissionsoundpressurelevelLpA,indB,referredto20μPa....88Measurementuncertainty,KpA,indB.....4MeasuredA-ratedemissionsoundpowerlevel(ifrequired)LWA,indB,referredto1pW....101Measurementuncertainty,KpA,indB.....4Values determined according to EN 13204, Appendix B, using basic standards ENISO3744andENISO11201.NOTE!Thesumofthemeasurednoiseemissionvaluesandtheassociatedmeasurementuncer-taintythatcanoccurduringthemeasurementrepresenttheupperlimitofthemeasuredvalues.
Explanation of dual number noise emission values according to DIN EN 13204:2016-12Serialnumberofthemachine,operatingconditionsandothercharacteristicproperties:Model ...P 635 SE 230V / 50Hz, P 635 SE-DHR 230V / 50Hz, P 635 SE-DHR-COAX 230V / 50Hz,type...81-53-41,81-54-44,81-54-41, maximumworkingpressure...700bar,enginespeed....2830[min-1]/[rpm]INDICATEDDUALNUMBERNOISEEMISSIONVALUESaccordingtoENISO4871MeasuredA-ratedemissionsoundpressurelevelLpA,indB,referredto20μPa....87Measurementuncertainty,KpA,indB.....4MeasuredA-ratedemissionsoundpowerlevel(ifrequired)LWA,indB,referredto1pW....102Measurementuncertainty,KpA,indB.....4Values determined according to EN 13204, Appendix B, using basic standards ENISO3744andENISO11201.NOTE!Thesumofthemeasurednoiseemissionvaluesandtheassociatedmeasurementuncer-taintythatcanoccurduringthemeasurementrepresenttheupperlimitofthemeasuredvalues.
![Page 66: Instruction manual for rescue equipment Hydraulic power units P … · 2019-11-04 · 13.echnical T data 53. 13.1 Power Unit 53 13.2 Noise emissions (Sound pressure level) 64 13.3](https://reader033.fdocuments.us/reader033/viewer/2022060502/5f1c3887265cd533e715f19b/html5/thumbnails/66.jpg)
66
13.3 Sparking plug
13.5 Fuel
Sparking plug type: CR5HSB(NGK) U16FSR-UB(DENSO)
Fuel: Lead-freepetrol ROZ91toROZ98
13.4 Sparking plug spanner
Universal joint sparking plug spanner with spanner size 16 mm (5/8 inch)
Explanation of dual number noise emission values according to DIN EN 13204:2016-12Serialnumberofthemachine,operatingconditionsandothercharacteristicproperties:Model ...P 635 SE 230V / 60Hz, P 635 SE-DHR 230V / 60Hz, P 635 SE-DHR-COAX 230V / 60Hz,type...81-53-42,81-54-45,81-54-42, maximumworkingpressure...700bar,enginespeed....3450[min-1]/[rpm]INDICATEDDUALNUMBERNOISEEMISSIONVALUESaccordingtoENISO4871MeasuredA-ratedemissionsoundpressurelevelLpA,indB,referredto20μPa....83Measurementuncertainty,KpA,indB.....4MeasuredA-ratedemissionsoundpowerlevel(ifrequired)LWA,indB,referredto1pW....97Measurementuncertainty,KpA,indB.....4Values determined according to EN 13204, Appendix B, using basic standards ENISO3744andENISO11201.NOTE!Thesumofthemeasurednoiseemissionvaluesandtheassociatedmeasurementuncer-taintythatcanoccurduringthemeasurementrepresenttheupperlimitofthemeasuredvalues.
![Page 67: Instruction manual for rescue equipment Hydraulic power units P … · 2019-11-04 · 13.echnical T data 53. 13.1 Power Unit 53 13.2 Noise emissions (Sound pressure level) 64 13.3](https://reader033.fdocuments.us/reader033/viewer/2022060502/5f1c3887265cd533e715f19b/html5/thumbnails/67.jpg)
67
13.7 Hydraulic fluid recommendation
13.8 Operating and storage temperature range
MineraloilDINISO6743-4forLUKAShydraulicequipmentandothers
Oiltemperaturerange Oildesignation Viscosityrating RemarksA -20....+55°C HM10 VG10
Oiltemperaturerange Oildesignation Viscosityrating RemarksA -4.0 .... +131°F HM10 VG10
recommendedrangeofviscosity:10...200mm²/s(10…200 cSt.)SuppliedwithHM10DINISO6743-4.
ATTENTION!Beforeyouusehydraulicfluidsfromadifferentmanufacturer,youmustcontactLUKASoranauthoriseddealer.
Operating temperature [°C]/[°F] -20 … +55 -4 … +131
Storage temperature (devicenotinoperation) [°C]/[°F] -30 … +60 -22 … +140
13.6 Engine oil
![Page 68: Instruction manual for rescue equipment Hydraulic power units P … · 2019-11-04 · 13.echnical T data 53. 13.1 Power Unit 53 13.2 Noise emissions (Sound pressure level) 64 13.3](https://reader033.fdocuments.us/reader033/viewer/2022060502/5f1c3887265cd533e715f19b/html5/thumbnails/68.jpg)
68
14. EC Declaration of Conformity
![Page 69: Instruction manual for rescue equipment Hydraulic power units P … · 2019-11-04 · 13.echnical T data 53. 13.1 Power Unit 53 13.2 Noise emissions (Sound pressure level) 64 13.3](https://reader033.fdocuments.us/reader033/viewer/2022060502/5f1c3887265cd533e715f19b/html5/thumbnails/69.jpg)
69
15. Notes
![Page 70: Instruction manual for rescue equipment Hydraulic power units P … · 2019-11-04 · 13.echnical T data 53. 13.1 Power Unit 53 13.2 Noise emissions (Sound pressure level) 64 13.3](https://reader033.fdocuments.us/reader033/viewer/2022060502/5f1c3887265cd533e715f19b/html5/thumbnails/70.jpg)
70
![Page 71: Instruction manual for rescue equipment Hydraulic power units P … · 2019-11-04 · 13.echnical T data 53. 13.1 Power Unit 53 13.2 Noise emissions (Sound pressure level) 64 13.3](https://reader033.fdocuments.us/reader033/viewer/2022060502/5f1c3887265cd533e715f19b/html5/thumbnails/71.jpg)
71
![Page 72: Instruction manual for rescue equipment Hydraulic power units P … · 2019-11-04 · 13.echnical T data 53. 13.1 Power Unit 53 13.2 Noise emissions (Sound pressure level) 64 13.3](https://reader033.fdocuments.us/reader033/viewer/2022060502/5f1c3887265cd533e715f19b/html5/thumbnails/72.jpg)
Please duly dispose of all packaging materials and removed items.
Subj
ect t
o ch
ange
© Copyright 2017 LUKAS Hydraulik GmbHP635_manual_175635085_en.indd
LUKAS Hydraulik GmbHA Unit of IDEX Corporation
Weinstraße 39, D-91058 ErlangenTel.: 0049 (0) 91 31 / 698 - 0Fax.: 0049 (0) 91 31 / 698 - 394e-mail: [email protected]
Made in GERMANY
WARNING/CAUTION! Beforeconnectingtheequipment,makesurethatall the components used are suitable for the
maximum operating pressure of the hydraulic unit!Incasesofdoubt,you must consult LUKAS
directlybeforeconnectingtheequipment!