48562712 Lukas Hydraulic Power Pack

Operating instructionsfor rescue equipment

Issue 12.2009175010085 GBHydraulic units

(Translation of the original operating instructions)

replaces 03.2009

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Content Page 1. Hazard classes 4 2. Product safety 5 3. Proper use 9 4. Labelling of the units 9 5. Functional description 10 5.1 General information 10 5.2 Motor variants 10 5.3 Valve variants 11 5.4 Pumps 12 5.5 Frames 13 5.6 Connection to the rescue equipment 14 5.7 Connection options 14 6. Assembly of coupling systems 15 6.1 Mono-couplings 15 6.2 Direct connection 15 6.3 Quick-disconnect couplings 16 6.4 Adapter for direct connection to mono-coupling valve block 16 7. Connection of the hoses 17 7.1 Coupling the mono-couplings 18 7.2 Coupling the quick-disconnect couplings 19 7.3 Direct connection 20 8. Set-up and start-up 20 8.1 Set-up 21 8.2 Start-up 21 9. Operation 22 9.1 Starting the motors 22 9.2 Stopping the motors 23 9.3 Controlling the valves 24 10. Dismantling the equipment / deactivation following operation 27 11. Maintenance and service 28 11.1 Recommended testing periods 28 11.2 Hydraulic units with combustion engine 29 11.3 Hydraulic units with electric motor 29

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12. Repairs 30 12.1 General information 30 12.2 Preventive service 31 12.3 Repairs 33 13. Troubleshooting 40 14. Notes 44

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Wear helmet with face protection

Wear safety gloves

Wear safety shoes

Proper recycling

Observe principles of environmental protection

Read and observe operating instructions

We distinguish between various categories of safety instructions. The table below gives you an overview of the assignment of symbols (pictograms) and key words to the specific hazard and possible consequences.

Hazard classes1.

Pictogram Damage / injury to Key word Definition Consequences

hum

anDANGER! Immediate danger Death or major

injury

WARNING!Potentially dangerous situation

Potential death or major injury

CAUTION! Less dangerous situation

Minor or slight injury

devi

ce

CAUTION!Danger of damage

to device / environment

Damage to the equipment,

damage to the environment, damage to

surrounding materials

- REMARK

Advice for application and other important /

useful information and advice

No injury / damage to persons /

environment / equipment

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Product safety2. LUKAS products are developed and manufactured in order to guarantee the best performance and quality when used properly.Operator safety is the most important aspect of the product design. Moreover, the operating instructions are intended to ensure LUKAS products are used safely.The generally applicable legal and other binding regulations pertaining to the prevention of accidents and protection of the environment apply and are to be complied with in addition to the operating instructions.The equipment may only be operated by persons with appropriate training in the safety aspects of such equipment – otherwise, there is a danger of injury occurring.We would like to point out to all users that they should read the operating instructions carefully before using the equipment and comply with the instructions there without restriction.We further recommend that a qualified instructor train you in the use of the product.

WARNING / CAUTION!The operating instructions for the hoses, the accessories and the connected hydraulic equipment must also be observed!

Even if you have already received instructions on how to use the equipment, you should still read through the following safety instructions once again.

WARNING / CAUTION!Ensure that the accessories and connected equipment used are suitable for the maximum operating pressure!

Please ensure that no body parts or clothing get stuck between the visibly moving parts.

The department responsible is to be informed immediately of any changes (including to the operating behaviour). If necessary, the equipment is to be shut down immediately and secured!

Wear protective clothing, safety helmet with visor, safety shoes and protective gloves.

Inspect the equipment before and after use for visible defects or damage.

It is prohibited to work under load if this load is lifted exclusively by hydraulic equipment. If this work is absolutely imperative, additional mechanical supports must be used.

Inspect all lines, hoses and screwed connections for leaks and externally visible damage. If necessary, repair immediately! Squirting hydraulic liquids can result in injuries and fires.

In the event of malfunctions, immediately shut down the equipment and secure it. The malfunction is to be repaired immediately.

Do not carry out any changes (additions or conversions) to the equipment without obtaining the prior approval of LUKAS.

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Comply with all the instructions regarding safety and danger on the equipment and in the operating instructions.

All the instructions regarding safety and danger on the equipment are to be kept complete and in a legible condition.

Please ensure that all safety covers are present on the equipment and that they are in proper and adequate condition.

Any method of operation which impairs safety and/or stability of the equipment is prohibited!

Safety devices may never be deactivated!

The maximum operating pressure set on the equipment must not be changed!

Before the equipment is switched on / started up, and during its operation, it must be ensured that nobody is endangered by the operation of the equipment.

Comply with all specified dates or dates specified in the operating instructions pertaining to regular checks / inspections of the equipment.

When working close to live components and cables, suitable measures must be taken to avoid current transfers or high-voltage transfers to the equipment.

Only original LUKAS accessories and spare parts may be used for repairs.When working with this equipment or when transporting it, ensure that you do not get caught up in the hose or cable loops and trip.

The build-up of static charge with the potential consequence of spark formation is to be avoided when handling the equipment.

When working with combustion engine pumps, never touch the motor and exhaust system, since there is a risk of burning.

Motor pumps may not be used in explosion hazard areas!

Combustion engines must not be used in enclosed spaces, as there is a danger of poisoning and/or asphyxiation!

If fuel for combustion engines is spilled, this fuel must be removed completely before starting the motor.

Filling up during operation of the combustion engine is strictly prohibited!

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Keep combustion engines and their fuel away from ignition sources, as otherwise there is the danger of an explosion.

All damaged electrical components e.g. scorched cables, etc. are to be replaced immediately!

To avoid the danger of fire when using combustion engines, ensure sufficient ventilation and maintain a safety distance of at least 1 m (39.4 in.) to the walls and other screens.

Damage to electrical components may only be repaired by a qualified electrician in compliance with all applicable national and international safety guidelines and regulations.

Please ensure that the combustion engine pumps are always placed on as flat a surface as possible in order to prevent fuel from leaking.

When setting up the units, it must be ensured that they are not impaired by the influences of extreme temperatures.

The equipment is filled with hydraulic fluid. These hydraulic fluids can be harmful to your health if swallowed or if their vapours inhaled. Direct contact with the skin is to be avoided for the same reason. Please also note that hydraulic fluids can also have a negative effect on biological systems.

When working with or storing the equipment, ensure that the function and the safety of the equipment are not impaired by the effects of extreme external temperatures and that the equipment is not damaged in any way. Please note that the equipment can also heat up over a long period of use.

Ensure adequate lighting when you are working.

Before transporting the equipment, always ensure that the accessories are positioned in such a way that they cannot cause an accident.

Always keep these operating instructions within reach where the equipment is used.

Ensure the proper disposal of all removed parts, leftover oil, hydraulic fluid and packaging materials.

The generally applicable, legal and other binding national and international regulations pertaining to the prevention of accidents and protection of the environment apply and are to be implemented in addition to the operating instructions!

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WARNING / DANGER / CAUTION!The equipment is to be used exclusively for the purpose stated in the operating instructions (see chapter "Proper use"). Any form of use beyond this is not considered proper use. The manufacturer / supplier is not liable for any damages resulting from improper use. The user bears sole responsibility for such use.Observance of the operating instructions and compliance with the inspection and maintenance conditions are covered by the definition of proper use.

Never work when you are overtired or intoxicated!

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Proper use3.

Spare parts and accessories for the rescue equipment can be ordered from your authorised LUKAS dealer!

WARNING / DANGER / CAUTION!Always observe the safety notes of these operating instructions with regard to place of installation and type of installation! The units must not be used in all atmospheres, since there could be a danger of explosion!

LUKAS hydraulic units are specially designed to supply LUKAS rescue equipment with hydraulic fluid so that this equipment can be used to rescue victims of road, rail or air traffic accidents as well as from buildings.Their use for supplying pressure / fluid to rescue equipment of other manufacturers is possible, yet requires the technical inspection and approval by LUKAS in each individual case.

Labelling of the units4.

P 640 I G D

Coding for hydraulic units

Type group

Valve variants

Motor variants

Frame variants

HR-

Specifications(e.g. HR = with mounted reels)

Valve variants: O = Single operation A = Alternative operation I = Automatic operation (ISV valve) S = Simultaneous operation T = Triple-flow operation (TRIMO)

Motor variants: E = Electric motor (operation via mains supply) B = Electric motor (operation via battery) G = Gasoline / petrol engine D = Diesel engine

Frame variants: (no entry) = Standard frame D = D frame U = U frame S = Frame for rescue sets F = F frame

-

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The main components (see sample illustration) of all LUKAS hydraulic units are:

1 Fluid reservoir2 Motor3 Pump4 Frame5 Connecting block with control valve6 Carrying handle

As a general principle on all LUKAS hydraulic units, a hydraulic pump is operated with a motor (combustion engine or electric motor) that feeds the fluid from the reservoir and builds up the pressure. The distribution of the fluid is controlled by mounted valves.The mounted frame serves as a simple protective cage and as a mounting base for accessories that can be fitted. The hydraulic unit can also be carried by the frame or using carrying handles mounted on it.

Functional description5. 5.1 General information

5.2 Motor variants

1 2

3

5

6

1

2

3

5

4

1

5

6

WARNING / DANGER / CAUTION! For all motor variants, also comply with the separate operating instructions of

each motor manufacturer.

5.2.1 ElectricalThese hydraulic units are equipped with an electric motor. The electric motor is driven by electricity from the mains supply or by electricity produced by generators. In the case of operation with generators, make sure that voltage fluctuations do not occur, as these have a direct influence on the pumping capacity and stability of the hydraulic unit.The possible operating voltage, the current frequency and the required intensity of current can be found in the separate instructions for your unit in the chapter entitled "Technical data".

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The engines of type Briggs & Stratton have a main switch, which must be actuated for switching the aggregate on and off. The accelerator cable of these engines does not have to be readjusted and is fixed in the position „ “. Nevertheless, if it is necessary in exceptional cases to switch the engine into idle running, the accelerator lever can be lifted over the adjusting plate and be switched into the position „ “.

5.3 Valve variants

5.2.2 Gasoline / petrolThese hydraulic units are equipped with a combustion engine driven by the fuel "gasoline / petrol".(For specific details, please consult the separate operating instructions of the engine manufacturer!)

In all cases, the valves are designed as connecting blocks. This block is firmly integrated into the hydraulic unit. Both hoses (pressure and return) are always connected to the connecting block. There are various connection blocks with different valve variants available for the different requirements of operators and the various areas of application.

REMARK: For certain regions, the selection of the control valves is limited due to applicable

standards and legal regulations. Bear in mind that only the variants that are officially approved for your region will

be deployed!

CAUTION!When operating several pieces of rescue equipment with one unit, ensure that the usable volume of hydraulic fluid in the reservoir is greater than the maximum possible operating fluid volume of all connected rescue equipment.

5.3.1 Control valve "single operation"This variant only enables the connection of one pressure hose and one return hose. Turning a lever / switch controls the pressure application to the pressure hose, i.e. the pressure on the pressure hose is switched on or off.

5.3.2 Control valve "alternative operation"This valve enables the connection of two pressure hoses and two return hoses. Turning a lever / switch controls the pressure application to the pressure hoses. However, only one device can be provided with pressure at any one time.

As a general principle, there are two different connection blocks for each connection block variant. A block is conceived for screwing in mono-couplings directly and for screwing on hoses. On the mono-coupling variants, an adapter can be used to screw on hoses directly. On the hose connection variant, the built-in connection nipples can be replaced by quick-disconnect coupling halves.It goes without saying that LUKAS can also provide adapter sets to connect mono-couplings to a hose connection block. These adapter sets consist of a supply and return hose with a mono-coupling fitted on one end.

5.2.4 DieselThese hydraulic units are equipped with a combustion engine driven by the fuel "diesel".(For specific details, please consult the separate operating instructions of the engine manufacturer!)

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5.4 PumpsDepending on the type, a single-flow, double-flow or triple-flow pump is built into LUKAS hydraulic units. Single-flow pump 1 pump capacity Double-flow pump 2 pump capacities Triple-flow pump 3 pump capacities

The pumps used are always equipped with two pressure levels for each pump capacity, one low-pressure and one high-pressure level.

Low-pressure level (ND) = up to 16 MPa*

High-pressure level (HD) = up to 70 MPa*

The changeover from low pressure to high pressure is carried out automatically in the pump. The maximum pressure is limited by a pressure limiting valve.

WARNING / DANGER / CAUTION!For reasons of safety, the pressure set on this valve must not be adjusted (without direct authorisation from LUKAS)!

5.3.3 Control valve "automatic operation (ISV valve)"This valve enables the connection of two pressure hoses and two return hoses. The patented LUKAS ISV valve provides one device at each connecting block with pressure without a manual switching procedure. Changeover between the two pressure hoses is automatic. With this control valve, the first driven and pressure-operated connected device is always provided with hydraulic fluid. The second connected device, on the other hand, is automatically disconnected from fluid supply.

5.3.4 Control valve "simultaneous operation"This valve enables the connection of two pressure hoses and two return hoses. It has two switching options, each of which controls the pressure application of the pressure hose that is marked accordingly. This means two devices can be supplied with pressure simultaneously and independently of one another. Without impairing the work output, it enables work with two devices simultaneously and independently of one another.

5.3.5 Controlvalve"triple-flowoperation"This valve enables the connection of three pressure hoses and three return hoses. It has three switching options, each of which controls the pressure application of the pressure hose that is marked accordingly. This means three devices can be supplied with pressure simultaneously and independently of one another. Without impairing the work output, it enables work with three devices simultaneously and independently of one another.

*) 1 MPa = 10 bar)

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5.5 FramesAs a general principle, all hydraulic units from the rescue equipment range come with a frame to make them easier to transport.

5.5.1 Standard frameThe standard frames vary depending on the type of hydraulic unit. They range from simple handles through to bow-type handles all the way to a frame adapted according to the unit.It therefore cannot be guaranteed that the entire unit can fit inside the exterior dimensions of the frame of standard frames.

5.5.2 D frameAs a general principle, the D frame dimensions are 500 mm x 440 mm x 480 mm.On D frames, all parts of the unit are located within the frame.In addition, there are mounting possibilities for connection hose reels (one double and two single hose reels).The dimensions mean that this frame fits into in the standard fixing devices of rescue service vehicles.

5.5.3 U frameThe U frame differs from the D frame with regard to outer dimensions and shape. There are currently no mounting possibilities for hose reels on this frame.

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5.6 Connection to the rescue equipment

5.7 Connection options

Connection with the rescue equipment is via extension hose pairs or hose reels. These are available in various lengths, coloured bend protections and with various connection options.The individual hoses of a hose pair are to be differentiated by colour to prevent confusion of the pressure and return hoses.(For specific details, please consult the LUKAS range of accessories or contact your LUKAS dealer).

The connections for the hydraulic hoses are always on the valve block.In the standard range, only mono-couplings or alternatively direct connections, or quick-disconnect couplings or alternatively direct connections are envisaged. Depending on the coupling variant, an autonomous connecting block is fitted on the unit.In order to be able to use the direct connection as an alternative possible connection, an adapter or connection nipple (male) must be fitted in the connecting block beforehand.(Fitting the adapter, see chapter "Assembly of coupling systems")

5.5.4 Frame for rescue setsThe frame for rescue sets is specifically designed for the motor / engine and all the components included in a rescue set. In some cases, these frames have additional mounting options or special attachment parts.(For specific information, please contact your authorised LUKAS dealer or LUKAS directly.)

5.5.5 F framesThe F frame is currently the largest frame in the LUKAS range. This frame is deployed if the size of the motor and mounted parts makes other frame variants too small. The special shape of this frame enables mounting of connection hose reels (one double and two single hose reels).This frame is mainly used for combustion engine units with triple-flow control valves (TRIMO units).

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Assembly of coupling systems6. 6.1 Mono-couplings

6.2 Direct connection

Only female mono-coupling halves are mounted on the connecting block of the hydraulic unit.The female coupling is screwed into the valve block with a tightening torque of MA = 40 Nm.

On the connecting block of the hydraulic unit, the connection nipple (male) is screwed into the valve block with a tightening torque of MA = 40 Nm.Subsequently, suitable locking elements (e.g. locking ball with nut) must be screwed onto the connection nipples or the hoses must be connected immediately.

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6.3 Quick-disconnect couplings

6.4 Adapter for direct connection to mono-coupling valve block

On the connecting block of the hydraulic unit, the connection nipples are replaced by quick-disconnect couplings to enable connection of hoses equipped with this coupling system.First of all, remove the connection nipples and then screw in the quick-disconnect couplings. The return hose connection (marked in blue) must always be equipped with a female quick-disconnect coupling. Both the female quick-disconnect couplings and the male quick-disconnect couplings are screwed into the valve block with a tightening torque of MA = 40 Nm. To conclude, quick-disconnect couplings must be sealed with matching dust protection caps.

Connection nipples and adapters must be mounted on the connecting block of the hydraulic unit so that the hoses can be screwed onto them directly. To achieve this, first of all remove the mono-couplings and locking screws of the return connections, then screw in the connection nipples and adapters. The connection nipples and adapters are screwed into the valve block with a tightening torque of MA = 40 Nm.To conclude, suitable locking elements (e.g. locking ball with nut) must be screwed onto the connection nipples or the hoses must be connected immediately.

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CAUTION!When connecting the hose assemblies, always ensure that the connection components are not soiled; clean beforehand if necessary!

REMARK:The devices can be equipped with different coupling systems. They usually only differ with regard to the article number and not the designation.It goes without saying that the coupling systems can also be re-equipped at a later time.The coupling system for the factory status of the equipment can be found in the separate instructions for your unit in the chapter entitled "Technical data".

WARNING / DANGER / CAUTION! Before connecting equipment, make sure that all the components used are suitable for the maximum operating pressure of the hydraulic unit! In cases of doubt, you must consult LUKAS directly before connecting the equipment!

Connection of the hoses7.

REMARK:Before you want to connect hoses to and disconnect hoses from the hydraulic unit as well as to couple and uncouple hoses with quick-disconnect couplings, ensure that the actuating valves of the pump unit have been set at static pressure or that the unit has been switched off or, in the case of electric pumps, has been disconnected from the mains!

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7.1 Coupling the mono-couplingsThe hydraulic hoses are connected without the risk of confusion via mono-coupling halves (male and female) to the hydraulic pump.

M o n o - c o u p l i n g halve (male)

Mono-coup l i ng halve (female)

Dust protection caps

Before coupling, remove dust protection caps, then connect male and female, and turn the locking sleeve of the female to direction "1" until the locking sleeve locks into place. The connection is now in place and secure. Decouple by turning the locking sleeve to direction "0".The equipment can also be coupled under pressure provided the connected equipment is not activated.

REMARK:At low ambient temperatures and if you are using extension hoses / hose reels, we recommend connecting the coupling halves at static pressure, as otherwise coupling can require the application of a great deal of force.

To protect against dust, the accompanying dust protection caps must be replaced.

WARNING / DANGER / CAUTION!The mono-couplings must not be screwed off the hoses and / or the hoses must not be swapped!

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The equipment is connected to the hydraulic pump via quick-disconnect coupling halves (male and female).

Before coupling, remove the dust protection caps, then pull back and hold the locking sleeve of the female coupling (position X). Connect the nipple and female coupling and let go of the locking sleeve. To conclude, turn the locking sleeve into position Y. The connection is now in place and secure. Uncouple in reverse order.

WARNING / DANGER / CAUTION!Some quick-disconnect couplings have special functions. Therefore it is not permitted to screw them off the hoses or to swap them!

X

Y

To protect against dust, the accompanying dust protection caps must be replaced.

REMARK:Coupling of the devices is only possible when the hoses are depressurised.

7.2 Coupling the quick-disconnect couplings

CAUTION!Always couple the return hose first and then the supply hose!On disconnecting, you should always disconnect the supply line first and then the return pipe!

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Set-up and start-up8.

7.3 Direct connection

The hydraulic hoses are screw-connected to the connecting block of the hydraulic unit. Screw-in sleeves or adapters are mounted in the valve block. The hoses are secured directly onto these screw-in sleeves or adapters by means of union nuts. To do so, you must first remove the dust protection caps or locking screws and the steel balls underneath, then fit the corresponding hydraulic hose and use the union nut of the hose to screw it firmly to the screw-in sleeve or adapter. Please observe the torque of 35 Nm.

CAUTION!Before commissioning the 620, the locking screw of the hydraulic fluid reservoir must be replaced by the supplied filling screw with venting function. The locking screw only serves the purpose of securing the hydraulic reservoir during transportation and is to be stored in line with accepted principles.

REMARK:In order to be able to mount the hoses directly onto the connecting block, adapters or connection nipples have to be screwed into the valve block beforehand.

CAUTION!Always connect the return hose first and then the supply hose!

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8.1 Set-up

8.2 Start-up

WARNING / DANGER / CAUTION!Combustion engine units and most electrical units must not be used in a potentially explosive situation (danger of the formation of sparks). Units with combustion engines must not be used in enclosed spaces, as there is a danger of poisoning and/or asphyxiation!

The unit is to be set up in a suitable location (safe location / flat surface / sufficient distance from vehicles, loads, sources of ignition, etc.).LUKAS units work perfectly at an angle of up to 30°. However, in order to guarantee maximum safety and fluid withdrawal, they should be operated in as horizontal a position as possible.

Please proceed as follows:1. First of all, check the hydraulic fluid level of the unit.

Depending on the unit type, the fluid level is indicated at a fluid inspection glass (maximum = centre of inspection glass; fluid must be topped up if the fluid level is no longer visible in the inspection glass) or by a fluid dipstick (usually fitted to a fluid filling screw). If necessary, you should top up the fluid to the maximum level.

2. Now connect the mains plug of the hydraulic units with electric motor to the power supply (exception: units for accumulator operation).

3. Then vent the hydraulic unit. Set all levers of the distributor valve to circulation at static pressure (see chapter "Valve variants"). The actual venting is carried out in the units in a different manner, depending on the drive motor:

a) Gasoline / petrol engine: - Remove plug connector from the spark plug. - Slowly turn the starter rope several times. For a motor with electric starter, activate the starter several times. - Then replace the plug connector. b) Diesel engine: - Slowly turn the starter rope several times in such a way that the engine does not start. c) Electric motor (power and accumulator operation): - Turn the motor on and after nearly 10 seconds off again, do this a few times.

(Before switching back on, the motor must be at a standstill!) This procedure means that the pump can slowly extract and be well vented. The hydraulic

fluid reservoir is equipped with automatic venting, which means no further venting measures are required.

4. Check the level of the fluid in the reservoir once more. If necessary, top up the fluid.5. To conclude, you can now connect the extension hoses and/or hose reels (unless already

connected to the unit) and/or couple the rescue equipment.

MAXIMUM

MINIMUMMAXIMUMMINIMUM

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Operation9. CAUTION!As a general principle, before starting up the motor, the hydraulic unit is to be switched to circulation at static pressure (i.e. the outlet valves are to be opened, for example). Only in this way is it possible to start the unit without a hydraulic load.

9.1.1 Gasoline / petrol and diesel enginesBefore starting the combustion engines, check that the fuel tank is full and that the engine oil level is within the permitted tolerances. If necessary, top up the relevant fluid.

Flow chart for starting Briggs & Stratton motors, unit type 640:1. Open gasoline / petrol tap and switch the main switch

to position '1' (ON).2. Move the lever from switch position A to switch

position C, if not fixed in position C.3. Pull the starter rope or activate the E starter

Lever at top

Lever at bottom

EF

G H

KJ

9.1 Starting the motors

Please consult the separate operating instructions of the motor manufacturer for the precise procedure for starting the combustion engine!

Flow chart for starting Intek motors, unit type 640:1. Open gasoline / petrol tap2. Move top lever from switching position E to switching

position F3. Move bottom lever (choke) from switching position G

to switching position H4. Pull the starter rope or activate the E starter5. When the motor is running, switch bottom lever back

to switching position G.

Flow chart for starting Honda motors, unit type 620:1. Open gasoline / petrol tap2. Switch the ON/OFF switch to ON.3. Move lever from switching position J to switching

position K (choke)4. Pull starter rope5. When the motor is running, switch lever back to

switching position J

AC

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An electric starter is available from the LUKAS range of accessories for some units.(For specific details, please consult the LUKAS range of accessories or contact your LUKAS dealer).

On these units, after checking the fluid levels, proceed as follows:1. Switch to "START ENGINE"2. Turn the ignition key clockwise.

Charge the accumulator of the electric starter:1. Switch to "CHARGE BATTERY"2. Connect the supplied charger to the mounted socket.

10.1.2 Electric motorsBefore starting the electric motors, check that all electrical connections and cables are in proper order. First of all, connect the power cable (for motors with power supply) to the supply socket.The motor is started by turning the ON/OFF switch to the ON position.

CAUTION!Electric motors need a brief, very high starting current. When using a generator, you should therefore check to see that it can also supply the relevant current strength.The current supply has to be fused with min. 25 A (triple-flow operation min. 30 A)

9.2 Stopping the motors9.2.1 Gasoline / petrol and diesel enginesThe gasoline / petrol and diesel engines stop automatically when the fuel tank is empty.Should they stop moving beforehand, the following procedure is required:

Flow chart for stopping Briggs & Stratton motors, unit type 640:1. Switch the main switch to position '0' (OFF). (The throttle lever has not to be switched back to

position A!)2. When the engine has come to a standstill, close the

fuel tap.

Flow chart for stopping Intek motors, unit type 640:1. Move the top lever from switching position F to

switching position E2. When the engine has come to a standstill, close the

fuel tap.

Lever at top

Lever at bottom

EF

G H

AC

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9.3 Controlling the valves

Flow chart for stopping Honda motors, unit type 620:1. Set the ON / OFF switch to the OFF position.2. When the engine has come to a standstill, close the

fuel tap.

Please consult the separate operating instructions of the motor manufacturer for the precise procedure for stopping combustion engines!

WARNING / CAUTION!Never touch the hot motor / engine parts: this could result in severe burns!

9.2.2 Electric motorsThe movements of the electric motors are stopped by changing the ON/OFF switch to the OFF position. This also stops the pumping output of the connected hydraulic pump.

WARNING / DANGER / CAUTION!For valves which can be connected to several rescue devices, you must ensure all unnecessary connections are closed with steel fasteners (supplied with the valve blocks).

9.3.1 Control valve "single operation"A lever is fitted on this valve. The pressure application of the pressure hose is controlled by turning a lever.

There are 2 switching stages: 0 = circulation at static pressure (no pressure supplied to the hydraulic hose) 1 = pressure supply to the pressure hose

9.3.2 Control valve "alternative operation"A lever is fitted on this valve. The pressure application of the pressure hoses is controlled by turning a lever.

There are 3 switching stages: A = pressure supply to the pressure hose 1 B = pressure supply to the pressure hose 2 C = pressure relief of both pressure hoses 1 and 2

CAUTION!As a general principle, before starting up the motor, the hydraulic unit is to be switched to circulation at static pressure (i.e. the outlet valves are to be opened, for example). Only in this way is it possible to start the unit without a hydraulic load.

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9.3.3 Control valve "automatic operation (ISV valve)"There is no direct control option for this valve, since the pressure application is controlled automatically. Nonetheless, the unit also has 2 levers or switches. The top lever controls whether or not one device (switching position "A") or two devices (switching position “A + B”) should be operated. The side switch is to control the outlet valve, which means that in switch position "0" the unit is switched to circulation at static pressure.

Control lever for switch positions

Control switch / lever for the outlet valve

Special feature for the operation of control valves "automatic operation (ISV valve)":

Case 1: Two hose pairs and two rescue devices connected:As a rule, two hose pairs are connected to the valve. Changeover between the two connected rescue devices is automatic.Switch the control lever for switch positions to position "A+B".To supply the connected rescue equipment with hydraulic fluid, the control lever for the outlet valve must be switched to position "1". To return the valve to circulation at static pressure, the control lever for the outlet valve must be switched to position "0".

Case 2: One hose pair and one rescue device are connected (at connection A):If only one hose pair is connected at the valve, the following instructions are important: 1. The valve connections where no hoses are connected, must be sealed by means of

special locking screws, for example, in such a way that no hydraulic fluid can escape on pressure application.

2. The control lever for switch positions must be in position "A". 3. The hydraulic fluid supply of the connected rescue equipment and switching to circulation

at static pressure take place by switching the control lever for the outlet valve. ("1" = fluid supply; "0" = circulation at static pressure)

REMARK:Single-device operation is only possible at connection A.

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9.3.4 Control valve "simultaneous operation"Two levers are fitted on this valve. Each lever is assigned to one pressure port. The pressure application of the relevant pressure hose is controlled by turning the relevant lever.

There are 2 switching stages for each lever: 0 = circulation at static pressure (no pressure supplied to the hydraulic hose) 1 = pressure supply to the pressure hose

9.3.5 Controlvalve"triple-flowoperation"Three levers are fitted on this valve. Each lever is assigned to one pressure port. The pressure application of the relevant pressure hose is controlled by turning the relevant lever.

There are 2 switching stages for each lever: 0 = circulation at static pressure (no pressure supplied to the hydraulic hose) 1 = pressure supply to the pressure hose

Case 3: Two hose pairs and one rescue device are connected (at connection A):If two hose pairs are connected and there is only one rescue device at the hose pair of connection "A", the following instructions are important: 1. The control lever for switch positions must be in position "A". 2. The hydraulic fluid supply of the connected rescue equipment and switching to circulation

at static pressure take place by switching the control lever for the outlet valve. ("1" = fluid supply; "0" = circulation at static pressure)

Case 4: Two hose pairs (with quick-disconnect couplings) and one rescue device are connected (at connection B):If two hose pairs are connected and a rescue device is only connected at the hose pair of connection "B", the device works neither in switch position "A" nor in switch position "A+B".The second hose pair at connection A without a connected rescue device indicates to the valve that a device is connected at connection A that has to be supplied with maximum operating pressure. This switches off connection B, which is no longer supplied with hydraulic fluid.To exclude this possibility, you should either connect a second rescue device or join the supply and return hoses of the connection that is not used (short-circuiting).

Case 5: Two hose pairs (with mono-couplings) and one rescue device connected (at connection B):If two hose pairs are connected and a rescue device is only connected at the hose pair of connection "B", the device only works in switch position "A+B". This is made possible by the female mono-coupling halve, which enables an internal fluid circulation when not connected.

27

Once work has been completed, all connected equipment is to be reset to its base position before the unit is shut down. You can now stop the motor of the unit / switch it off and, if using an electric motor (without accumulator), disconnect it from the mains supply.

Mono-couplings:If the connected hose assemblies have to be dismantled during shut-down, decouple as described in chapter "Coupling the mono-couplings". Ensure that you replace the dust protection caps onto the mono-coupling halves.Clean heavy soiling caused during use of the hydraulic unit before storage.

Quick-disconnect couplings:If the connected hose assemblies have to be dismantled during shut-down, decouple as described in chapter "Coupling the quick-disconnect couplings". Ensure that you replace the dust protection caps onto the mono-coupling halves.Clean heavy soiling caused during use of the hydraulic unit before storage.

Direct connection:This connection should only be unscrewed when it is absolutely necessary, e. g. when you have a longer storage time, when decommissioning, for maintenance tasks, etc.If the connected hose assemblies have to be dismantled during shut-down, first of all disconnect the pressure hose and then the return hose. Ensure that you replace the dust protection caps onto the screw-in sleeves and onto the hoses. Clean heavy soiling caused during use of the hydraulic unit before storage.

If the equipment is to be stored for a longer period of time, the exterior is to be cleaned completely and the mechanical moving parts are to be lubricated. If storing a unit with combustion engine, you should also remove the fuel from the fuel tank.Avoid storing the hydraulic units in a damp environment.Please observe the regulations in the chapter entitled "Safety regulations for hoses".

Dismantling the equipment / deactivation 10. following operation

CAUTION!Depending on the size and the weight of the hydraulic unit, it should be transported to the storage site by one person or several people.

28

Maintenance and service11. The hydraulic units are subject to very high mechanical loads. A visual inspection is therefore to be carried out after every use: however, at least one visual inspection is to be carried out every six months. This reveals wear and tear in good time; punctual replacement of these wearing parts prevents damage to the equipment. Also check regularly that all the securing screws are tightened (if applicable, comply with prescribed tightening torques)Every 3 years or when there might be doubts regarding the safety or reliability of the unit, an additional function check is to be carried out (in this connection, comply with the applicable national and international regulations with regard to the maintenance intervals of rescue equipment). In the Federal Republic of Germany, regular safety inspections according to the regulations of the Gesetzliche Unfallversicherung (GUV; 'statutory accident insurance') are mandatory.

CAUTION!Clean off any dirt before checking the equipment!

WARNING / DANGER / CAUTION!In order to carry out maintenance and repair work, tools appropriate for the job and personal protection equipment obligatory (including protective covers).

LUKAS offers a suitable test kit for the function test of the hydraulic units.(For specific details, please consult the LUKAS range of accessories or contact your LUKAS dealer).

11.1 Recommended testing periods11.1.1 Visual inspection

11.1.2 Function testA visual inspection must be made after each use / latest once a year.

Operating time per day Function test

up to 1 hour once per year

up to 8 hours once per 3 months

up to 24 hours once per month

Beyond these testing periods, a function test should be accomplished, if the aggregate makes suspicious noises, or there is a reasonable suspicion of an internal damage of the aggregate.If the noises or suspicious factors named above should occur several times during one month or the hydraulic unit does not reach the nominal pressure (75% of the maximum pressure) during the functional test, you will have to contact the LUKAS customer service immediately. You will find the contact information in the chapter 'Troubleshooting'.

29

Visual inspection

Hydraulic units• Check that all hydraulic connections are tightened,• General tightness, no leakage (the hot oils do not have any influence on the function)• Is there any damage apparent on the motor, valve blocks or on the casing?• Existence and stability of carrying frame• Are type plate, all activation plates, signs, identification marks and warning labels are

present and legible?• Are all covers (e.g. protective roof, exhaust cover) present and undamaged?• Are all liquid levels within the specified tolerances?• Are the starters in proper working order and undamaged?• Couplings must be easy to couple• Dust protection caps must be available• All necessary accessories (such as spark plugs, plug socket and fuel canister must be

present.

Hoses (see also "Safety regulations for hydraulic hoses")• Visual check for visible damage• Check for leaks.

Function test• No suspicious noises.• Test for maximum load. (Recommendation: use the LUKAS test kit, including testing instructions, for the function

test).

11.2 Hydraulic units with combustion engine

11.3 Hydraulic units with electric motorVisual inspection

Hydraulic units• Check that all hydraulic connections are tightened• General tightness, no leakage (the hot oils do not have any influence on the function)• Is there any damage apparent on the motor, valve blocks or on the casing?• Existence and stability of carrying frame• Are the type plate, all activation plates, signs, identification marks and warning labels

present and legible?• Are all covers (e.g. protective roof, fan cover) present and undamaged?• Are all liquid levels within the specified tolerances?• ON/OFF switch in proper working order, undamaged• Couplings must be easy to couple• Dust protection caps must be available• All electrical attachments (such as cables and plugs) must be present and undamaged

Hoses (see also "Safety regulations for hydraulic hoses")• Visual check for visible damage• Check for leaks

30

REMARK:Please always return the guarantee registration card to LUKAS Hydraulik GmbH. Only then are you entitled to the extended guarantee.

CAUTION!Since LUKAS hydraulic units are designed for top performance, only those components in the spare parts lists of the relevant unit may be replaced.Further components in the unit may only be replaced if:- You have participated in appropriate LUKAS service training,- You have the explicit permission of the LUKAS customer service (on request,

check for granting permission. Check is necessary in each individual case!)

REMARK:Do not carry out any repairs without the relevant LUKAS spare parts list, since this contains the necessary torques for screws and / or important additional information.

CAUTION!Attention must be paid to ensuring that no fuel can escape from units with combustion engines during repair work!

Repairs12. 12.1 General informationServicing may only be carried out by the manufacturer or personnel trained by the manufacturer and by authorised LUKAS dealers.Only LUKAS spare parts may be used to replace all components (see spare parts list) since special tools, assembly instructions, safety aspects, inspections might have to complied with (see also chapter "Maintenance and service”).During assembly, ensure the complete cleanliness of all components, since dirt can damage the rescue equipment!

WARNING / DANGER / CAUTION!Protective clothing must be worn when repairs are being carried out, since parts of the units can also be pressurised in an idle state.

Function test• No suspicious noises• Test for maximum load (Recommendation: use the LUKAS test kit, including testing instructions, for the function

test).

REMARK:Before you use couplings from a different company, you must contact LUKAS or an authorised dealer.

31

12.2 Preventive service12.2.1 Care regulationsThe exterior of the equipment is to be cleaned from time to time in order to protect it from external corrosion. Oil is to be applied to the metallic surfaces.

12.2.2 Function and load testIf there is any doubt regarding the safety or reliability of the equipment, a function and load test must also be performed.LUKAS offers appropriate test equipment.

12.2.3 Replacingthehydraulicfluid- After approx. 200 deployments, but after three years at the latest, replace the hydraulic

fluid- The fluid should be replaced when it is warmed up.- The motor must be switched off!- The old hydraulic fluid must be disposed of properly.

Procedure:1. Place the collection basin underneath the drain plug of the unit.2. Undo the venting and drain plug of the unit and let the fluid flow into the collection basin.

This enables easy cleaning of the hydraulic unit.

32

4. Remove the reservoir and the seal below it.

5. Free the entire reservoir of dirt using a smooth cloth.6. When fitting the reservoir, replace the reservoir seal and tighten the fastening screws

(tightening torque, see spare parts list or separate instructions for your unit in the chapter entitled "Technical data".).

7. Also replace the seal ring of the drain plug and fit it as specified in the spare parts list.8. Add the new hydraulic fluid to the reservoir through the filling plug.9. Finally, the unit must be vented as described in the chapter entitled "Start-up"

3. The fastening screws of the hydraulic fluid reservoir must then be loosened.

33

12.3 RepairsWhen carrying out permitted repairs, please observe the relevant spare parts lists with the remarks and drawings they contain.Should there be any uncertainties regarding the repairs, please contact your authorised LUKAS dealer or LUKAS Customer Service.

CAUTION!Valve blocks and motors / engines may only be replaced by qualified personnel (e.g. equipment supervisor) taking account of all applicable standards, regulations and laws.

12.3.1 Replacing the handle / frameReplace the handles or frame if they are severely deformed or broken. To replace the frame, undo the fastening screws of the handle or frame and replace it with a new one. Tighten the fastening screws. Please consult the appropriate spare parts lists for any torques and additional assembly instructions.

34

12.3.2 Mono-couplingsThe mono-couplings on the connection hoses on the equipment must be replaced in the event of:- external damage- the locking device not working- hydraulic fluid continually leaking in a coupled/uncoupled state.

WARNING / DANGER / CAUTION!Never repair couplings: they are to be replaced by original LUKAS parts!

Procedure when mounted on hoses:

1. Remove the cover from the couplings.

2. Loosen the union nuts of the hose assembly and remove the coupling.

3. Position the new coupling and tighten the union nuts of the hose assemblies with a torque of MA = 40 Nm and push the cover of the couplings back on.

Procedure when mounted into the valve block:

1. Remove the coupling from the valve block.

2. Position the new coupling and tighten it with a torque of MA = 40 Nm.

CAUTION!As the case may be, make sure that port 'T' or 'T1' of the unit is always connected to port 'T' of the mono-coupling.

35

12.3.5 Replacing hosesReplace hoses if they are leaky or defective, and if they are older than 10 years. To replace the hoses, undo the union nuts of the hose connections, remove the hose to be replaced and replace it with a new hose. Tighten the union nut during the assembly with a torque of MA = 40 Nm.

REMARK when using mono-couplings:If you want to replace the hoses, you have to dismantle the mono-couplings (if mounted).

CAUTION (with mono-coupling-system)!As the case may be, make sure that port 'T' or 'T1' of the unit is always connected to port 'T' of the mono-coupling.

12.3.3 Quick-disconnect couplingsThe quick-disconnect couplings must be replaced in the event of:- external damage- the locking device not working- hydraulic fluid continually leaking in a coupled/uncoupled state.

WARNING / DANGER / CAUTION!Never repair couplings: they are to be replaced by original LUKAS parts!

Procedure when mounted on hoses:

1. Loosen the union nut of the hose assembly and remove the coupling.

2. Position the new coupling and tighten the union nut of the hose assemblies with a torque of MA = 35 Nm.

Procedure when mounted into the valve block:

1. Remove the coupling from the valve block.

2. Position the new coupling and tighten it with a torque of MA = 40 Nm.

12.3.4 Direct connectionThe screw-in sleeves must be replaced in the event of:- external damage- hydraulic fluid continually leaking in connected / unconnected state.

Procedure:

1. Remove the screw-in sleeve from the valve block.

2. Position the new screw-in sleeve and tighten it with a torque of MA = 40 Nm.

36

CAUTION with (quick-disconnect-system)!As the case may be, make sure that reservoir port 'T' or 'T1' of the unit is always equipped with a female quick-disconnect coupling.On the other hand, the supply ports must be equipped with a male quick-disconnect coupling.

12.3.6 Replacing the valve blocksReplace the valve blocks if they are leaky or defective and direct repair of the valve block by a dealer or LUKAS is no longer possible. The valve block may only be replaced when the hydraulic unit is switched off. Electric motors must be disconnected from the power supply.

Replacing the valve blocks of the 640 units:1. Disconnect all hoses from the valve block.

2. Loosen the fastening screws of the hydraulic fluid reservoir and remove the fluid filler caps.

3. Remove the hydraulic fluid reservoir. Please ensure that the hydraulic fluid does not

become contaminated, or replace the hydraulic fluid.

4. Loosen the union nut on the piping of the valve block and the fastening screws of the valve block.

5. Remove this and the seal underneath it.6. Remove the connection nipple for the piping and the

return pipe from the valve block.

37

7. Clean the fastening point and the connection nipple for the piping using a non-fibrous cloth.

8. Screw the connection nipple for the piping and the return pipe into the valve block and tighten.

9. Apply seal using sealant.10. Place a new seal on the fastening point and bolt the new valve block to the unit once

again. Please consult the spare parts lists for the necessary torques. If no torques are specified,

the screws are to be tightened in such a way that no leakage and overload of the screwed connections can occur.

11. Reassemble the hydraulic fluid reservoir. (If necessary, replace the reservoir seal). Please consult the spare parts lists for the necessary torques.12. Vent the unit once the repairs are complete.

Replacing the valve blocks of the 620 units:

1. Disconnect all hoses from the valve block.

2. Loosen the fastening screw of the valve block.CAUTION! Do not loosen the fastening screw of theconnectionflange!

3. Remove the valve block.4. Position the new O-rings at the correct points of the

connection flange. Observe the relevant spare parts list.

38

5. Position the new valve block on the connection flange, making sure you do not move or damage the O-rings.

6. Now screw on the fastening screws of the valve block and tighten. Please consult the spare parts lists for the necessary torques.7. Vent the unit once the repairs are complete.

12.3.7 Replacing the engines / motorsReplace the engines / motors if they are defective and direct repair of the valve block by a dealer or the manufacturer is no longer possible. The engine / motor may only be replaced with the hydraulic motor switched off. Electric motors must be disconnected from the power supply.Engines / motors may only be replaced as a complete component. Empty the fuel tanks of combustion engines beforehand and make sure that no engine oil escapes when you are removing the engine.

Procedure for replacing the engine / motor:1. Loosen the fastening screws of the engine / motor. Observe the relevant spare parts list.

2. Pull the engine / motor off. Please ensure that you do not damage the engine / motor shaft mount.

3. Equip the shaft of the new engine / motor with an appropriate adjusting key (provided it is not already in place).

4. Grease the shaft of the new engine / motor and push the shaft of the new engine / motor into the engine / motor shaft mount.

Ensure that the adjusting key of the engine / motor shaft is inserted into the correct guide of the engine / motor shaft mount.

5. Assemble the engine / motor using fastening screws and tighten.

Please consult the spare parts list for the necessary torques.

6. For combustion engine pumps, top up the necessary liquid levels (e.g. engine oil, fuel). For electric motor pumps, connect the necessary electrical cables.

39

7. Perform a function test with the hydraulic unit (as described in the chapter entitled "Maintenance and service").

(Recommendation: use the LUKAS test kit, including testing instructions, for the function test).

12.3.8 LabelsAll damaged and/or illegible labels (safety notices, type plate, etc.) must be renewed.

Procedure:

1. Remove damaged and/or illegible labels.

2. Clean the surfaces using acetone.

3. Attach new labels.

Make sure that the labels are attached in the right position. If you are no longer sure about this, contact your authorised LUKAS dealer or LUKAS directly.

40

Troubleshooting13. In the case of defects which directly affect the motor / engine, please consult the separate operating instructions of the motor / engine manufacturer.

Trouble Cause SolutionElectric motor does not start following activation of the switch

Power cable not connected Connect power cable correctly

Battery flat Charge batteryElectric motor defective or overloaded due to another defect in the unit

Shut down immediately and have repaired by authorised dealer, motor / engine manufacturer or directly by LUKAS

Combustion engine will not start

Fuel tank empty Top up fuelElectric starter battery flat Charge electric starter

batteryFuel tap not open Open the fuel tapStarting switch is not at “ON”

Set starting switch to “ON”

Lever not set to choke Set lever to chokeCombustion engine defective or overloaded due to another defect in the unit

Have repaired by authorised dealer, motor / engine manufacturer or directly by LUKAS

Too low ambient temperature

For the solution, consult the separate operating instructions of the motor / engine manufacturer.

The motor / engine is running, but the connected rescue equipment is not moving / moving very slowly upon activation of the valve.

Hose assembly not connected properly or is damaged

Inspect the connection of the hose assembly and, if necessary, reconnect

Valve in the connecting block not switched for pressure application in the supply line.

Switch valve in the connecting block for pressure application in the supply line.

Connecting block defective Replace connecting blockHave repaired by authorised dealer or directly by LUKAS

Defective pump unit Have repaired by authorised dealer or directly by LUKAS

Mono-coupling (female) defective

Replace mono-coupling (female)

41

Trouble Cause SolutionThe connected rescue equipment does not move on activation of the valve, or moves only very slowly or unevenly.

Air in the hydraulic supply Vent the hydraulic system

Pressure relief on the unit is still active (circulation at static pressure)

Check the switching positions of the valve lever(s) and, if necessary, reset (as far as the final position)

For the ISV valve: Have repaired by authorised dealer or directly by LUKAS

Connecting block defective Replace connecting blockHave repaired by authorised dealer or directly by LUKAS

Defective pump unit Have repaired by authorised dealer or directly by LUKAS

Mono-coupling (female) defective

Replace mono-coupling (female)

Connected rescue device does not reach its final position

Insufficient fluid in the hydraulic reservoir

Top up hydraulic fluid to the maximum filling level

Caution! Before topping up the rescue equipment, return to the base position!

Usable hydraulic fluid volume of the unit is insufficient

Use a different rescue device with a usable quantity below the maximum usable quantity of the unit

Connected rescue device does not reach its specific performance data

Maximum permitted operating pressure of the pump is not reached

Have the pressure limiting valve reset or repaired by authorised dealer or directly by LUKAS

Pump or connecting block defective

Have repaired by authorised dealer or directly by LUKAS

42

Trouble Cause SolutionFluid leaks from the hydraulic fluid reservoir (especially from the filler screw)

Return of the hydraulic fluid from the rescue device exceeds the reservoir’s maximum quantity when filled.

Reduce the level in the hydraulic fluid reservoir to the mark on the dipstick or inspection glass

Defective seal Have repaired by authorised dealer or directly by LUKAS

Leaking fluid between engine and flange bearing

Radial shaft seal on the drive shaft is defective

Have repaired by authorised dealer or directly by LUKAS

Hydraulic fluid milky and cloudy

Water / condensation in the system

Immediately replace hydraulic fluid

With mono-coupling-system: hose assembly cannot be coupled

Pressure too high (e.g. caused by excessive ambient temperature)

Switch valve block to circulation at static pressureFor the ISV valve: Have repaired by authorised dealer or directly by LUKAS

Coupling defective Coupling needs to be replaced immediately

With mono-coupling-system: It is frequently not possible to couple hose assemblies

Hydraulic fluid not adapted to the application situation

Hydraulic fluid must be replaced (see chapter “Recommended hydraulic fluids”)


With quick-disconnect coupling system: hose assembly cannot be coupled

Pressurised Switch valve block to circulation at static pressureFor the ISV valve: Have repaired by authorised dealer or directly by LUKAS


With mono-coupling-system: Leak in the couplings


43

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

LUKAS Hydraulik GmbH

Weinstraße 39, D-91058 ErlangenPostfach 2560, D-91013 Erlangen

Tel.: (+49) 09131 / 698 - 348Fax.: (+49) 09131 / 698 - 353

REMARK:Before shipping units of the type P620x, the locking screw for transport protection must be bolted onto the unit once again. (Reverse order as shown in the chapter "Set-up and start-up").

Trouble Cause SolutionWith quick-disconnect coupling system: Leak in the coupling (male)

Safety valve reacted After pressure release, there is no more leakage.

Coupling (male) defective Coupling (male) needs to be replaced immediately

With quick-disconnect coupling system: Leak in the coupling (female)

Female coupling defective Female coupling needs to be replaced immediately

Hydraulic fluid leak on the hoses or the connections

Leak, possible damage Replace hoses

Damage on the surface of the hydraulic hoses

Mechanical damage or contact with aggressive agents

Replace hoses

44

Notes14.

45

46

47

LUKAS Hydraulik GmbHWeinstraße 39, D-91058 ErlangenPostfach 2560, D-91013 ErlangenTel.: (+49) 0 91 31 / 698 - 0Fax.: (+49) 0 91 31 / 698 - 394e-mail: [email protected]

Made in GERMANY

© Copyright 2010 LUKAS Hydraulik GmbHAggregate_BA_GB_175010085_1209.indd

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Operating instructionsRescue

Publication 12.2008179101085 GB

Hand pump LH2and accessories


2

3

Contents Page 1. Danger classes 4 2. Product safety 4 3. Proper use 7 4. Main components of the hand pump 8 5. Functional description 8 5.1 Base pump 8 5.2 Adapter blocks 9 6. Connection options for rescue equipment 9 6.1 Fittings 9 6.2 Quick-disconnect-couplings 10 6.3 Monocouplings 11 7. Commissioning 12 7.1 Unlocking the pump 12 7.2 Retracting the handle 12 7.3 Bleeding the pump 12 8. Operation 13 8.1 Operation 13 8.2 Shutdown / storage 14 9. Transport 14 10. Maintenance and repair 14 10.1 Basic requirements 14 10.2 Maintenance 15 10.3 Hydraulic fluid change or adding hydraulic fluid 16 10.4 Care 16 10.5 Repair 17 11. Troubleshooting 20 12. Technical data 23 12.1 Data of the hand pumps 23 12.2 Hydraulic fluid recommendation 24 12.3 Hose lines 25 12.4 Operating and storage temperature ranges 25 13. Notes 26

4

Wear helmet with face guard

Wear protective gloves

Wear safety shoes

We distinguish between various categories of safety instructions. The table shown below shows you the overview, via the assignment of symbols (pictograms) and signal words, of the concrete danger and the possible consequences.

Danger classes1.


hum

an

DANGER! Immediate danger Death or major injury





devi

ce






- NOTE





Product safety2. LUKAS products are developed and produced in order to ensure the best performance and quality with proper use.The safety of the operator is the most important consideration in the product design. In addition, the operating instructions are to help in using the LUKAS products safely.In addition to the operating instructions, all generally applicable, statutory and other binding rules for accident prevention and for environmental protection must be heeded and disseminated.The device must only be operated by educated persons who are trained in safety technology, since otherwise there is a risk of injury.We advise all users before using the device to carefully read through the operating instructions and to follow the instructions contained therein without exception.

Proper recycling

Protect the environment

Read and follow operating instructions

5

We also recommend that you get instructed by a qualified trainer in the use of the product.

WARNING / CAUTION!The operating instructions for the hoses, the accessories and the connected devices must also be heeded!

Even if you have already received instruction, you should read the following safety instructions again.

Make sure that no body parts or clothing get between the openly visible moving parts of the device.

Immediately report changes that occur (including changes in operating behaviour) to the appropriate persons/departments! If necessary, immediately shut down and secure the device!

Wear protective clothing, protective helm with visor, safety shoes and protective gloves.

Check the device for visible defects or damage before and after use.

Working under loads is prohibited if they are raised exclusively with hydraulic devices. If this work is unavoidable, sufficient mechanical supports are additionally required.

Check all lines, hoses and screwed connections for leaks and externally visible damages and repair immediately! Escaping hydraulic fluid can lead to injuries and fires.

In the event of malfunctions, shut down the device immediately and secure it. You should have the malfunction repaired immediately.

Do not make any changes (add-ons or conversions) on the device without the approval of LUKAS.

Heed all safety instructions and hazard warnings on the device and in the operating instructions.

All safety instructions and hazard warnings on the device are to be kept intact and in a legible condition.

Make sure that all safety covers are present on the device and in proper working condition.

Any work procedure that detracts from the safety and/or stability of the device should be abandoned!

Safety equipment must never be disabled!

The maximum permissible operating pressure must not be changed.

6

Before switching on/engaging the device or while operating the device, it must be ensured that no one is endangered by the operation of the device.

Observe all intervals that are prescribed or specified in the operating instructions for recurring tests and/or inspections.

When working in the vicinity of live components and lines, take appropriate measures for preventing current transfers or high voltage flashovers to the device.

For repairs only original LUKAS accessories and spare parts are to be used.Make sure that you do not get caught in the hose loops and trip when working with or transporting the device.

Prevent electrostatic discharge, which has the possible consequence of spark formation, when handling the device.

When the hand pumps are set up, care needs to be taken that they are not impaired by extremely strong temperature changes.

The device is filled with hydraulic fluid. These hydraulic fluids can be detrimental to health if they are swallowed or their vapours are inhaled. Direct contact with the skin should be avoided for the same reason. Also, when handling hydraulic fluids, note that they can negatively affect biological systems.

When operating and/or storing the device, make sure that the function and the safety of the device are not impaired by strong external temperature differences or that the device is damaged. Keep in mind that the device can also heat up when it is continuously used.

Make sure there is adequate lighting while working.

Before transporting the device, always check to see that the accessories are positioned securely to prevent the possibility of an accident.

Always keep these operating instructions easily accessible at the site where the device is used.

Make sure you properly dispose of all removed parts, leftover hydraulic fluid, leftover oil and packing materials.

In addition to the safety instructions of these operating instructions, all generally applicable, statutory and otherwise binding national and international rules for accident prevention need to be heeded and disseminated!

7

WARNING / CAUTION / ATTENTION!The device is specified exclusively for the purpose represented in the operating instructions (see Chapter "Proper use"). Any use that differs or goes beyond this is considered improper. The manufacturer/supplier shall not be held liable for damages resulting from improper use. The risk shall be borne solely by the user.Proper use also includes heeding the operating instructions and complying with the inspection and maintenance requirements.

Never work in a fatigued or intoxicated state!

Proper use3.

Accessories and spare parts for the rescue equipment can be obtained from your authorised LUKAS dealer!

The LUKAS hand pump is used for the operation of LUKAS rescue devices.They can be used as an additional or replacement drive source along with the LUKAS hydraulic unit (e.g. in areas at risk for explosion).Use with equipment of other manufacturers is possible, but requires technical testing and approval of LUKAS on a case-by-case basis.

WARNING / CAUTION / ATTENTION!Always note the product limitations with respect to operating pressure, load limit values and operating conditions. The operating pressure should not be higher than the lowest maximum operating pressure of any system components.

The operating pressure should NEVER be set higher than that which is specified in the "Technical Data" chapter. A higher setting may cause property damage and/or injuries.

Make sure that the usable capacity of the hand pump (see chapter "Technical Data") is sufficient for operating the connected cylinders or devices. The required hydraulic fluid operating quantity can be found in the chapter "Technical Data" or in the operating instructions of the devices to be operated.

8

Main components of the hand pump4.

1

2

3

4

5

6

7

1 Drain valve 2 Connection plate with fittings or couplings 3 Vent / fill cap 4 Retractable pump lever 5 Tank 6 Lock 7 Base plate

Functional description5. 5.1 Base pumpAll LUKAS hand pumps of this series are two-speed, i.e. they have two operating speeds: • A high speed in the low pressure range (LP) for fast extension of the cylinder or device

while unloaded • A low speed in the high pressure range (HP) for controlled extension of the cylinder or

device while loadedThe switch from low pressure (LP) to high pressure (HP) is automatic at the factory setting for changeover pressure (see chapter "Technical Data").

A pressure port "P" with a G1/4" thread and a return port "T" with an M10 thread are directly available as ports on the pump.To connect rescue equipment, adapter blocks must be installed (see subchapter "Adapter blocks" for more information). In the case of the hand pumps sold by LUKAS, one of these adapter blocks is always included as standard equipment and is already installed.Of course, the installed adapter blocks may be replaced with other ones. However, you must contact an authorised LUKAS dealer or contact LUKAS directly.

The retractable handle of the LUKAS hand pump combines low required pumping force with compact dimensions for storage and transport.In addition, the LUKAS hand pumps for rescue equipment are equipped with a base plate to ensure a more stable position during operation.

9

5.2 Adapter blocksAdapter block Function/useConnection plate with fittings

Possibility of connecting hose lines directly to the hand pump

Connection plate with quick-disconnect-couplings

Possibility of connecting hose lines directly to the hand pump via quick-disconnect-couplings

Connection plate with monocouplings

Possibility of connecting hose lines directly to the hand pump via monocoupling

Connection options for rescue equipment6. ATTENTION!Make sure to store all plugs, screw plugs and/or dust caps in a way that prevents them from getting dirty or lost.After completion of the work, seal off all lines using screw plugs and/or dust caps to prevent contamination of the hand pump.When connecting lines to the hand pump, we recommend positioning it vertically so that the ports point upward. This reduces the danger of hydraulic fluid escaping.

6.1 FittingsThe hose lines are connected via fittings to the hydraulic pump.

1.2.

1. First remove the closure caps from the fittings.

2. Then, you can connect the hose lines to the fittings and tighten them with a tightening torque of MA = 40 Nm.

ATTENTION!The return hose must always be connected at the "T" port of the connection block.The supply hose line must instead be connected at the "P" port.

10

The hose lines are connected via quick-disconnect coupling halves (female and male) to the hydraulic pump in such a way that they cannot be reversed.

Before connecting the couplings, remove the dust cap, then pull back and hold the locking sleeve of the female coupling (Position X). Push the male and female couplings together and release the locking sleeve. Finally, turn the locking sleeve into Position Y. The connection is then made and secured. Decoupling is done in the reverse sequence.

WARNING / CAUTION / ATTENTION! The quick-disconnect-couplings have special functions, in part, and therefore must not be unscrewed and/or reversed!

X

Y

For dust protection, the supplied dust caps must be reattached.

NOTE:Coupling the equipment is only possible if the hoses are depressurised.

6.2 Quick-disconnect-couplings

ATTENTION!Always connect the return line first and then the supply line!

11

6.3 Monocouplings

Male coupling Female coupling

Dust caps

Before coupling, remove dust caps, then connect male and female couplings and turn locking sleeve of the female coupling in direction "1" until the locking sleeve latches. The connection is then made and secured. The decoupling is accomplished by turning the locking sleeve in direction "0".The coupling of the devices under pressure is also possible, assuming the connected equipment is not turned on.

NOTE:We recommend, when ambient temperatures are low and extension hoses / hose winders are used, connecting the coupling halves in a depressurised state because decoupling may otherwise require a very large exertion of force.


WARNING / CAUTION / ATTENTION! The monocouplings must not be unscrewed and/or the hose lines reversed!


12

NOTE:With the LUKAS hand pump, a little idle stroke may occur when the unit is first used in the high pressure range.However, this idle stroke independently stops after a device is operated 2-3 times.

7.1 Unlocking the pumpUnlock (1.) the shipping lock of the pump by sliding the locking pin in the direction of the hand wheel until it comes against the stop.To lock (2.) the pin, move it until it comes against the stop in the other direction. To do this, the lever must be in the home position (at the tank).

Locking pin

ATTENTION! The hand pump should be as close to horizontal as possible, because otherwise the usable amount changes!

The oil fill plug must always be unscrewed one turn before starting operation of the hand pump! This enables the aeration and bleeding of the hydraulic tank. After the work is completed but before transport, the oil fill plug should be retightened!

Commissioning7.

7.2 Retracting the handleYou can pull out the handle by applying pressure to both sides of the thrust piece and simultaneously pulling in the direction of the handle end until the thrust piece re-engages.

1. 2.

1.

2.

7.3 Bleeding the pump1. Open the discharge valve.2. Open the oil fill screw plug on the tank container and check the oil fill level. The oil fill

level should come up to approximately 1-2 cm below the top edge of the oil reservoir.3. In this state, work the pump handle several times.

Hand wheel

13

NOTE:To bleed connected equipment, make sure that the highest point of the connected devices are below the level of the pump.Before operating the pump, you should also open the oil fill screw plug. Only in this way can any trapped air escape the hydraulic system when the pump is operated. You should operate the connected equipment several times without load.When you do this, also follow the separate operating instructions of the connected devices.

WARNING / CAUTION! Under certain circumstances, the pump handle can "kick back". Make sure that your body remains to the side of the pump.

ATTENTION! Never attach an extension to the pump handle that does not belong to the device. These extensions usually cause the pump to become unstable during operation.

Operation8.

NOTE:In order to limit the required force in high pressure operation, we recommended using short strokes with the pump handle. The greatest pumping effect is produced in the last 5 degrees of the stroke.

Should you use a female quick-disconnect-coupling as the port, quick stop may be triggered if the discharge valve is opened too quickly (turning counter-clockwise), i.e. the check valve incorporated in the male quick-disconnect coupling blocks the return flow of oil while the connection between pump and female quick-disconnect coupling is depressurised. This is provided as a safety function in case the connection between the female quick-disconnect-coupling and pump starts to leak and the pressure drops abruptly. In this case, the "quick stop" prevents, for example, an abrupt drop in the load when an hydraulic cylinder is operated. In order to release the quick stop again, more pressure must first be supplied to the device. Then, the pressure can be decreased again by slowly opening the discharge valve.

Procedure:1. Close discharge valve on the hand pump completely (rotate clockwise).2. Connect the return line of the device at the return port "T" and then the high pressure line

at the pressure port "P".3. Move the locking pin into the operating position.4. Supply the device with hydraulic fluid or pressurise by operating the pump lever (up and

down movements).5. To reduce the pressure of the device, slowly open the discharge valve of the hand pump

(turn counter-clockwise). In this way, you can meter the pressure reduction precisely.

8.1 Operation

14

Transport9.

8.2 Shutdown / storageTo shut down or store the pump, seal all hydraulic connections with the associated screw plugs or dust caps.After sealing the hydraulic ports, open the drain screw (not up to the stop!) to depressurise the pump.Then carefully clean the external dirt off of the hand pump.In addition, with a longer storage time, the outside of the device should be cleaned and all visible mechanical moving parts need to be oiled.

ATTENTION! After completion of the work but before transport, check to make sure the oil fill screw plug is screwed in tightly!Make sure the pump is not stored in a damp environment.

The pump lever is used as a carrying handle! Special pumps may be the exception in this case. These pumps are custom-assembled for each customer; therefore, there may be a different transport device or none! In these cases, please refer to your authorised dealers or LUKAS directly. The lever must be locked for transport, as described in the chapter "Unlocking the pump".

Maintenance and repair10.

Service work may only be performed by the device manufacturer or by personnel trained by the device manufacturer and authorised LUKAS dealers.All components must be replaced with original LUKAS spare parts, which are listed in the spare parts list, because in this context even required special tools, assembly instructions, safety aspects and/or checks absolutely must be taken into consideration. During the assembly work, pay particular attention to the cleanliness of all components because dirt can damage the equipment!

10.1 Basic requirements

WARNING / CAUTION / ATTENTION!To perform maintenance and repairs, personal safety equipment appropriate for the work is an absolute requirement. (incl. shields).Assembly and repair work on the pump may only be performed if the entire hydraulic system is depressurised!Couplings should not be repaired; they should be replaced with original LUKAS parts!

NOTE:Always send the warranty tab back to LUKAS hydraulics GmbH.

You should always contact LUKAS or an authorised dealer before using outside couplings.

Do not perform any repairs without the corresponding LUKAS spare parts list, because necessary tightening torques for screw connections and/or in some cases also important additional information are listed there.

15

The equipment is subject to very high mechanical stresses. Therefore, a visual inspection needs to be made after each use, at least once per month (if continually used, once per week). In this way, early signs of wear are recognisable so that damage to the device can be avoided by prompt replacement of these worn parts. Also check regularly to make sure that all attachment screws are tightened (heed any applicable tightening torque specifications).At least once a year (if continually used once every half year) or if there is a doubt about the safety or reliability, a functional check should be also performed (for this purpose, also heed the corresponding applicable national and international specifications related to the maintenance intervals of the devices).

ATTENTION!Clean the device before checking for dirt!Do not use any aggressive agents for cleaning; it could cause damage to the equipment.

Because LUKAS devices are designed for the highest performance, only components may be replaced that are listed in the spare parts lists of the corresponding device.Additional components of the equipment may only be replaced if:- You have participated in a corresponding LUKAS service training course.- You have the express permission of LUKAS customer service (by request,

check on the grant of permission. A check is necessary in each individual case).

10.2 MaintenanceBefore performing maintenance work, clean the hand pump thoroughly.After performing the maintenance work, you should carefully coat all metallic parts with oil to prevent any corrosion.

Checks (Maintenance measures):

Perform a visual inspection of the hand pump at least once per month; in the case of continuous use, once a week.

Visual inspectionHand pump• are all hydraulic connections still tightened,• generally sealed, no leaks present (oil "sweat" has no effect on the operation),• is damage to pump housings, valve blocks or attachment parts recognisable, especially

on the moving parts such as the piston rods,• are all fluid levels within the prescribed tolerances,• are all non-moving parts firmly attached,• is there no corrosion,• freedom of movement for the pump lever and the hand wheels (check in the depressurised state),• the couplings are easy to couple (if attached),• are dust caps in place,• are identification plate, all control decals, instruction decals, labels and warnings present

and legible.

16

NOTE:In this test, an idle time of approximately 2 minutes needs to be observed and the hand pump needs to be reloaded to operating pressure.The resulting max. operating pressure must not drop by more than 5% after 10 seconds.A test pressure gauge is available from the LUKAS line of accessories.

Perform an operational check of the hand pump at least once per year; in the case of continuous use, once every half year.

Operational check• no suspicious noises,• tests at maximum load. Execution: Place the hand pump on a solid base to operate. Then, connect a test manometer to the

supply hose line. Release the pump lever lock and close the discharge valve. Then, the pressurisation to operating pressure corresponding to the specification on the identification plate occurs.

10.3 HydraulicfluidchangeoraddinghydraulicfluidThe hydraulic fluid should be changed if dirty at least once a year. When the hand pump is operated in an especially dusty environment, we recommend changing the fluid at least once every half year.

ATTENTION!Add hydraulic fluid only if the hand pump is disconnected from the lines or the equipment operated with the pump is hydraulically depressurised. Otherwise, after filling the entire hydraulic system could contain more hydraulic fluid than the tank can hold.

Procedure:1. Open the bleed/fill cap on the tank.2. Add hydraulic fluid until the fluid level comes up to 1-2 cm below the top edge of the oil

tank.3. Bleed the hand pump as described in the chapter "bleeding the pump".4. Check the fluid level again and close the tank again at the correct fluid level with the

vent/fill cap on the tank. Should the tank no longer be sufficiently full after bleeding, start the fill procedure again at item 2.

NOTE:Should the fluid level in the tank still not be reached after repeated refilling (during maintenance), we recommend searching for leaks in the hydraulic system.

10.4 CareIf possible, do not store the hand pump in a damp or extremely dusty environment in order to ensure a long service life. If this is unavoidable, you should perform more frequent maintenance and/or shield the pump from these effects if possible.Regularly coat all metal parts with oil to prevent any corrosion.

17

10.5 RepairATTENTION!Because LUKAS devices are designed for the highest performance, only components may be replaced that are listed in the spare parts lists of the corresponding device and whose replacement is described here.Additional components of the equipment may only be replaced if:- You have participated in a corresponding LUKAS service training course.- You have the express permission of LUKAS customer service (by request,

check on the grant of permission. A check is necessary in each individual case).

10.5.1 Base plate replacementThe base plate must be replaced if external damage is present that represents a danger for user and device upon further use. In particular, the base plate must be replaced if the stability of the hand pump can no longer be ensured.

Procedure:1. Remove screws A and B.

2. Remove base plate C and replace it with a new one.3. Reinsert screws A and B and tighten.

A

C

B

10.5.2 Removing tank for cleaning, replacing the tank or the seals

The tank should be cleaned at least once per year in order to remove the accumulated dirt.The tank must be replaced if there is any external damage that impairs the safety of the device.The tank seals must be replaced if there are any leaks at the junction points of the tank.

Procedure:1. Remove base plate as described in the chapter "Replacing

base plate".2. Empty tank by removing the screw plug (item D) and emptying

the tank.

D

ATTENTION!Properly dispose of the removed hydraulic fluid and all damaged components!

18

E F G H Tank J K L

3. Remove the nut (item E) and sealing ring situated under it (item F).4. Remove base plate (item G) and the sealing ring (item H).5. Remove tank and the seal (item J) as well as the connection plate (item K) and seal

(item L).6. The assembly is done in reverse order. Replace all damaged parts with new ones.

The tightening torque of the nuts is 40 Nm.

10.5.3 Lever replacementThe lever must be replaced if external damage is present that represents a danger for user and device upon further use.

Procedure:1. Drive out dowel pin (item M).

M

N

2. Remove lever (item N) and replace with a new one.3. Reinsert dowel pin (item M).

10.5.4 Couplings

WARNING / CAUTION / ATTENTION!Couplings should not be repaired; they should be replaced with original LUKAS parts!

10.5.4.1 MonocouplingsThe monocouplings must be replaced if:- exterior damage is present,- the lock does not function,- in the coupled and/or decoupled state, hydraulic fluid continuously escapes.

19

Procedure for installation in the valve block:1. Unscrew coupling from connection plate.2. Screw new coupling into the connection plate with a torque of MA = 40 Nm.

10.5.4.2 Quick-disconnect-couplingsThe quick-disconnect-couplings should be replaced if:- exterior damage is present,- the lock does not function,- in the coupled and/or decoupled state, hydraulic fluid continuously escapes.

Procedure:1. Unscrew and remove coupling.2. Screw in new screw-on male coupling and tighten with a torque of MA = 35 Nm.

ATTENTION!The return port must always be equipped with a female quick-disconnect-coupling.The supply port should instead be equipped with a male quick-disconnect-coupling.

10.5.5 DecalsAll damaged and/or illegible decals (safety instructions, identification plate, etc.) must be replaced.

Procedure:1. Remove damaged and/or illegible decals.2. Clean surfaces with acetone or industrial alcohol.3. Adhere new decals.

Make sure to adhere the decals in the correct positions. If this is no longer known, you should consult your authorised LUKAS dealer or contact LUKAS directly.

20

Troubleshooting11. Problem Cause Remedy

Connected device does not move, moves only slowly or moves intermittently.

Fluid level in the hydraulic tank too low

Add hydraulic fluid up to max. fill level.

Discharge valve open Close discharge valve.Hose line not properly connected or damaged

Check connection of the hose line and reconnect it if necessary.

Load on the device too high

Use a different device.

Air in the hydraulic system Bleed system as described in the chapter “Bleeding the pump”.

Defect on the device Heed the specifications of the separate operating instructions of the device.

Connected device moves, but does not hold pressure or does not render the specified performance.

Hose line not properly connected or damaged


Leaking seal Locate the leak and have the hand pump serviced by an authorised dealer, by personnel specially trained by LUKAS or by LUKAS directly.

Internal leakage of the pump

Have the hand pump serviced by an authorised dealer, by personnel specially trained by LUKAS or by LUKAS directly.

21

Device does not move back into the starting position, moves incompletely back toward the starting position or moves more slowly into the starting position than normal.

Discharge valve closed Open discharge valve.Fluid level in the hydraulic tank too high

Reduce hydraulic fluid down to max. fill level.

Loose hydraulic coupling Check all couplings and retighten them.

Enclosed air in the system Bleed pump as described in the chapter “Bleeding the pump”.

Line length too long Use shorter lines.Use hydraulic fluid with a different, more suitable viscosity.


Connected device not reaching its limit position



Attention: move the device back into the base position before adding fluid!

Usable hydraulic fluid quantity of the pump is insufficient

Use a different device with a usable quantity below the maximum usable quantity of the pump.

Connected rescue device does not achieve its power-related performance data

Max. permissible operating pressure of the pump is not reached

Replace pressure control valve or have it recalibrated by an authorised dealer or directly by LUKAS.

Fluid leaks on the hydraulic fluid tank (especially at the refill tap)

Due to return flow of the hydraulic fluid from the device, the maximum fill quantity of the tank is exceeded


Seals defective Replace seal.Hydraulic fluid with milky cloudiness

Water or condensation water in the system

Perform hydraulic fluid change immediately.

Problem Cause Remedy

22

In the case of a monocoupling system: Hose lines cannot be coupled

They are under excessive pressure (e.g. due to excessive ambient temperature)

Open discharge valve and bleed device.

Coupling defective Coupling should be replaced immediately.

In the case of a monocoupling system: Hose lines frequently cannot be coupled

Hydraulic fluid of the application situation not adapted

Hydraulic fluid needs to be changed (see the chapter “Hydraulic fluid recommendation” for more information).


In the case of a quick-disconnect coupling system: Hose lines cannot be coupled

System is under pressure Open discharge valve and bleed device.


In the case of a monocoupling system: Leakage at the couplings


In the case of a quick-disconnect coupling system: Leakage on the male coupling

Safety valve has responded (in the decoupled state)

After depressurisation, no further leakage occurs.

Male coupling defective Male coupling should be replaced immediately.

In the case of a quick-disconnect coupling system: Leakage at the female coupling

Female coupling defective Female coupling should be replaced immediately.

Hydraulic fluid escaping from the hoses or at the joints

Leakage, possible damage Replace hoses.


Mechanical damage or contact with aggressive media

Replace hoses.

If the defects cannot be remedied, notify an authorised LUKAS dealer or contact LUKAS Customer Service directly!The address of LUKAS customer service is:



Phone: (+49) 09131 / 698 - 348Fax.: (+49) 09131 / 698 - 353


23

Technical data12. Because all values are subject to tolerances, there cannot be any differences between the data of your device and the data of the following tables!

12.1 Data of the hand pumps

12.1.2 Dimensions, weight, usable quantity and fill quantity

NOTE:The dimensions of the hand pumps are exclusively dependent on the size of the hydraulic fluid tank. The types of hand pumps are not outwardly distinguishable from the outside at the pump head.The weights, usable quantities and fill quantities of the hand pumps are exclusively dependent on the size of the hydraulic fluid tank.

LH 2 / 1.8 - 50Tank size max. operating

pressure in MPa(1 MPa = 10 bar)

12.1.1 Pump labelling

Model series

NOTE:The automatic pressure switch from low pressure to high pressure occurs at 2 MPa (= 20 bar)

Hand pump with fittings:

Hand pump with monocouplings:

Tank size Dimensions Weight min. required

l x w x h (incl. max. hydraulic fluid fill level) Fill quantity

1,8 [l]660 x 200 x 160 [mm] 7 [kg] 2,38 [l]

25.98 x 7.87 x 6.30 [in.] 15.4 [lbs.] 0.63 [gal.-US]

3,8 [l]676 x 200 x 160 [mm] 11,3 [kg] 4,61 [l]

26.61 x 7.87 x 6.30 [in.] 24.9 [lbs.] 1.22 [gal.-US]



1,8 [l]761 x 200 x 160 [mm] 7,5 [kg] 2,38 [l]

29.96 x 7.87 x 6.30 [in.] 16.5 [lbs.] 0.63 [gal.-US]

3,8 [l]777 x 200 x 160 [mm] 11,8 [kg] 4,61 [l]

30.59 x 7.87 x 6.30 [in.] 26.0 [lbs.] 1.22 [gal.-US]

24

Hand pump with quick-disconnect-couplings:

12.2 Hydraulicfluidrecommendation

12.1.4 Flow rates

NOTE:The flow output per piston stroke of the hand pumps depend exclusively on the model series.

Model series Flow output per piston stroke (low pressure)

Flow output per piston stroke (high pressure)

LH 217 [cm³] 1,7 [cm³]

0.85 [Cubic in.] 0.10 [Cubic in.]

Mineral oil DIN ISO 6743-4 for LUKAS hydraulic equipment and others

Oil temperature range Oil code Viscosity rating RemarksA -20 .... +55°C HM 10 VG 10

Oil temperature range Oil code Viscosity rating RemarksA -4.0 .... +131°F HM 10 VG 10

recommended viscosity range: 10...200 mm²/s (10…200 cSt.)Supplied with HM 10 DIN ISO 6743-4.

ATTENTION!Before using hydraulic fluids that do not correspond to the aforementioned specifications and / or are not purchased from LUKAS, you must contact LUKAS!



1,8 [l]724 x 200 x 160 [mm] 7,3 [kg] 2,38 [l]

28.96 x 7.87 x 6.30 [in.] 16.1 [lbs.] 0.63 [gal.-US]

3,8 [l]740 x 200 x 160 [mm] 11,6 [kg] 4,61 [l]

29.13 x 7.87 x 6.30 [in.] 25.6 [lbs.] 1.22 [gal.-US]

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12.3 Hose lines

12.4 Operating and storage temperature ranges

Bending radius Rmin = 38 mm (Rmin = 1.5 in.)

Pressure resistance Safety factor: Burst pressure / max. Operating pressure, min. 4 : 1

Temperature resistance - 40°C ... + 100°C (- 40°F … + 212°F)

Operatingfluid Mineral oil according to DIN EN ISO 6743-4

Operating temperature [°C] / [°F] -20 … +55 -4 … +131Ambient temperature (device in operation) [°C] / [°F] -25 … +45 -13 … +113

Storage temperature (device not in operation) [°C] / [°F] -30 … +60 -22 … +140

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Notes13.

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© Copyright 2008 LUKAS Hydraulik GmbHLH2_RG_BA_GB_1790101085_1208.indd

Please properly dispose of all packing materials and removed parts.

Sub

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LUKAS Hydraulik GmbHWeinstraße 39, D-91058 ErlangenPostfach 2560, D-91013 ErlangenPhone: (+49) 0 91 31 / 698 - 0Fax.: (+49) 0 91 31 / 698 - 394e-mail: [email protected]

Made in GERMANY

1

Operating InstructionsRescue Tools

115001085 GBIssue 10.2007Battery Pump P 600 OB

1 Main switch2 Indicator pin3 Battery4 Connection for charger cable5 Connection for external power supply 24 V DC6 Charge indication panel7 Dump valve8 Carry harness

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Contents page1 Basic Operation and designated Use of the Machine 3

2 Organizational Methods 3

3 General Safety Instructions 3

4 Instructions for Maintenance and Service 4

5 Safety Instructions for Hydraulic Hoses 5

6 Intended Use 7

7 Description 7

8 Commissioning 9

9 Operation 10

10 Maintenance 13

11 Problems / Trouble Shooting 15

12 Repair 16

13 Battery 16

14 Technical Data 17

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1 Basic operation and designated use of the machine

1.1 The machine has been built in accordance with state-of-the-art standards and the recognizedsafety rules. Nevertheless, its use may constitute a risk to life and limb of the user or of third parties,or cause damage to the machine and to other material property.

1.2 The machine must only be used in technically perfect condition in accordance with itsdesignated use and the instructions set out in the operation manual, and only by safety-consciouspersons who are fully aware of the risks involved in operating the machine. Any functional disorders,especially those affecting the safety of the machine/plant, should therefore be rectified immediately!

1.3 The machine is exclusively designed for the use described in the operating manual. Using themachine for purposes other than those mentioned in the manual, such as driving and controllingother hydraulic systems, is considered contrary to its designated use. The manufacturer/suppliercannot be held liable for any damage resulting from such use. The risk of such misuse lies entirelywith the user.Operating the machine within the limits of its designated use also involves observing the instructionsset out in the operating manual and complying with the inspection and maintenance directives.

2 Organizational methods

2.1 The operating manual must always be at hand at the place of use of the machine!

2.2 In addition to the operating instructions, observe and instruct the user in all other generallyapplicable legal and other mandatory regulations relevant to accident prevention and environmentalprotection.This also applies for wearing protective clothing, helmet with visor or goggles and protective gloves.

2.3 In order to avoid injuries, the machine must only be operated by a specially trained operatorwho has undergone a safety training.

2.4 Observe all safety instructions and warnings attached to the machine. Make sure that safetyinstructions and warnings attached to the machine are always complete and perfectly legible.

2.5 Never make any modifications, additions or conversions without the supplier’s approval.

2.6 For repairs only genuine LUKAS spare parts, accessories or system components must beused.

2.7 Adhere to prescribed intervals or those specified in the operating manual for routine checksand inspections.

2.8 Make sure to dispose properly of packing material and dismounted parts!

3 General safety instructions

3.1 In the event of malfunctions, stop the machine immediately and lock it. Have any defectsrectified immediately.

3.2 Before starting up or setting the machine in motion and during operation of the machine makesure that nobody is at risk.

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3.3 Before transporting the machine always check that the accessories have been safely stowedaway.

3.4 Make sure that there is enough lighting during work.

3.5 Avoid any operation that might be a risk to machine stability.

3.6 Check the machine at least after every operation for obvious damage and defects. Report anychanges (incl. changes in the machine’s working behaviour) to the competent organization /personimmediately. If necessary, stop the machine immediately and lock it. All lines, hoses and screwedconnections have to be checked for leaks and obvious damage. Repair damage immediately.Splashed oil may cause injury and fire.

3.7 All safety equipment has to be checked for completeness and flawless condition:- instruction markings and warning signs (safety instructions)- check safety cover (e.g. motor-safety covers, heat protection etc.) if they are available and if

they are in good condition.

3.8 Working under loads is not allowed if they are only lifted by hydraulic cylinders. If the work isindispensable sufficient mechanical supports are needed additionally.

3.9 The pump is filled with hydraulic fluid. Never swallow or breath in this fluid as this could bedangerous to your health ! Avoid direct contact between the fluid and your skin !Be aware that hydraulic fluid may cause negative effects to any kind of biologic systems.

4 Instructions for maintenance and service

4.1 For the execution of maintenance and service work, tools and workshop equipment adaptedto the task on hand are absolutely indispensable.Work on the hydraulic system must be carried out only by personnel having special knowledge andexperience with hydraulic equipment.

4.2 Before putting into operation clean the machine, especially connections and threaded unions,of any traces of oil, fuel or preservatives before carrying out maintenance/repair. Never useaggressive detergents. Use lint-free cleaning rags and pay attention that the components aremeticulously clean during reassembling after repair.

4.3 During dismantling of machines it is necessary to collect the outrunning hydraulic liquidscompletely, so that they cannot reach the ground. They have to be disposed properly according tothe instructions.

4.4 Always tighten any screwed and thread connections that have been loosened duringmaintenance and repair. Observe the stipulated torques.

4.5 Work on the electrical system or equipment may only be carried out by a skilled electricianhimself or by specially instructed personnel under the control and supervision of such electrician andin accordance with the applicable electrical engineering rules.

4.6 The electrical equipment of machines is to be inspected and checked at regular intervals.Defects such as loose connections or scorched cables must be rectified immediately.

4.7 Aggressive material (acid, lye, solvent, vapour) can damage the machine. It is necessary toclean the whole machine if it must be exceptionally operated under such conditions or gets into touchwith these materials. Additionally, the machine must be checked as described under 3.6.

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4.8 Should you observe a loss of speed of the rescue tool during operation the battery must berecharged. Do not continue with the operation until the motor stops. Otherwise there is the risk ofthe battery becoming deep discharged which would reduce its lifetime.

5 Safety Instructions for Hydraulic Hoses

- by no means the hose must be exposed to brake fluid as this fluid will destroy outerlayer of hose

- do not expose the hose to any of the following aggressive fluids:• acid, lye or solvent• alcohol and fuel• battery and automatic transmission fluid• phosphate ester

Clean hose immediately with water and detergent when it was exposed to such fluids.

A T T E N T I O N !

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5.1 Handling of hoses

- never exceed the permissible working pressure as stated on hose and/or literature- avoid any tension (see figure 1) and do not hang any load onto the hose- never exceed the minimum bend radius as resulting kink will cause failure of hose (see figure

2)- do not allow hose to contact sharp edges or rough objects (see figure 3)- avoid any twisting of hose (see figure 4)- do not run over hose with any vehicle or equipment ! Hoses which are put on the surface of

sidewalk or street have to be suitably protected (see figure 5)- do not allow hose to contact areas of high temperature such as mufflers, exhaust manifold,

heaters or burners. Protect the hose as shown in figure 6 or install it in sufficient distancefrom the source of heat.

- it is not allowed to attach weights to the hoses- make sure that no objects fall on the hoses.

5.2 Protection of the working area in case of breakdown of hoses

Hoses have to be installed or protected in such a way that dangers are prevented, if possible, incase of breakdown of the hoses.

Danger can be caused by:- Uncontrolled hose movement after a hose rupture caused e.g. by external influence.- Emerging of the pressure medium under pressure.- Inflammation of pressure medium near igniting sourcesDangers can be prevented by e.g. protective coverings or shieldings

5.2.1 Do not go near leaks!- High pressure oil easily punctures skin causing serious injury,

gangrene or death!- If injured, seek emergency medical help! Immediate surgery is

required to remove oil!- Do not use finger or skin to check for leaks!- Lower load or relieve hydraulic pressure befor loosening finttings!

5.3 Storage of hoses

- Hoses are subject to a natural aging even if they are stored correctly. Therefore, their storageand service time is limited.

When storing the hoses please observe the following:- Store them cool, dry and dustless (eventually wrapped with plastics sheeting); prevent direct

solar radiation and UV rays; shield heat sources which are near the hoses.- Do not use any ozone producing lamps (e.g. fluorescent light sources, mercury-vapor lamp)

or electrical devices next to the hoses.- Hoses have to be stored freely of tension and in a horizontal position. If they are stored in

rings the smallest bending radius determined by the manufacturer must not fall below.

5.4 Marking of hoses

- The hose is marked with the manufacturer's name and quarter/year of production.- The max. allowable pressure and month/year of production is indicated on the hose end fitting.

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5.5 Inspection and replacement intervals of hoses

- After each operation the hoses have to be checked for external damages, cracks,kinks and bubbles!

- The operator has to replace the hoses in appropriate period of times, even if there are novisible security defects on the hoses.

- The hoses have to be replaced 10 years as from date of manufacture at thelatest (see marking on the hose)!

Hoses are subject to a natural aging even if they are stored correctly. Therefore, theirstorage and service time is limited.

- Hoses have to be checked by a skilled person before the first putting intooperation of the technical device and afterwards at least once a year for theirsafe working condition.

A skilled person is somebody having sufficient knowledge concerning hydraulic hosesdue to his special training and knowledge. He/she must be acquainted with the localsafety working conditions, accident prevention regulations, technical regulations andapproved standards (e.g. DIN-Standards), so that he/she is capable to estimate thesafety working conditions of the hydraulic hoses.

5.6 Examples for possible defects of hoses

- Damages of the surface and the interior (e.g. chafe marks, cuts or fissures).- Embrittlement of the surface (fissuration of the hose material).- Deformations, which are not in accordance with the natural shape of the hoses, in

pressureless condition or under pressure or in case of bendings, e.g. separation ofmaterial layers, blister formation, squeezing or break spots.

- Leakage points.- Instructions for installation were not observed.- Emerging of the hose from the end fittings.- Damages or deformations of the end fittings which deteriorate the function and stability of

the end fittings or the connection between hose and end fitting.- Corrosion of the end fittings or the metal inlets, which deteriorates the function and stability.- Storage and operation periods were exceeded.

6 Intended use

The power package as described below must be used only in connectionwith LUKAS rescue tools. The use with other tool brands is possible, butdetails of intended use must be discussed with and approved by LUKAS ineach individual case.

7 Description

7.1 The LUKAS Battery Pump P 600 OB is serving as a portablepower unit for genuine LUKAS Rescue Tools. It consists of adrive unit with pump and motor and a exchangable battery unitwhich is sitting underneath the pump unit.

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7.2 Drive unit with pump and motor

7.2.1 MotorA 24V DC electric motor (2) with a power of 480 W is used for driving the hydraulic pump.

7.2.2 Hydraulic pump with valvesThe hydraulic pressure is produced by a LUKAS radial piston pump (1) with:- low pressure circuit (up to 8 MPa) = LP- high pressure circuit (up to 63 MPa) = HP(10 bar = 1 MPa)

Necessary valves are also integrated in the pump unit:- switch-over from low to high pressure is made automatically by a switch-over valve (3)- the max. system pressure is limited by a pressure relief valve (4) set to 63 MPa- with the dump valve (5) pressure can be released manually.

7.2.3 Oil containerThe hydraulic circuit is designed as a closed loop without connection to the atmosphere. There-fore the hydraulic oil is stored in a flexible diaphragm reservoir which compensates oil levelchanges occuring during operation of rescue tools.

7.2.4 Hydraulic hosesTwo hoses are permanently connected with the pump unit. The pressure hose (mounted atport ”P”) is equipped with a quick- connect plug (type StNi61, closed ended). Pressure can bereleased from the hose through the drain valve on the pump.

7.2.5 Quick connect couplingsA rescue tool can be connected to the pump by means of non-interchangeable quick couplers.

7.3 The battery

The battery is mounted inside a separate housing which can be connected with the pump unit bymeans of a slide-lock mechanism. The housing has a connector for the charging cable.

7.4 The carry harness

For comfortable transport a carry harness is provided. With the harness the pump unit can beaccomodated on your back so that both hands are free for rescue work.By means of the handle on top of the harness the pump can be carried, as well.

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8 Commissioning

8.1 First commissioning

Prior to first commissioning the battery (item 3, see cover page) must be charged. Connect thecharger to a suitable power supply. Connect the plug on the charging cable with the chargingsocket in the battery housing (item 4, see cover page)

8.2 Commissioning

8.2.1 Connection between battery and pump unitMake sure that the pump unit is switched off (check with the main switch position), otherwisesparks might occur. Put the battery on a level, non-slip surface. Put the pump unit on top of thebattery and adjust it so that the marks on pump body and battery housing are in line with eachother (see picture 5). This is to make sure that the contact pins are aligned with the correspondingholes in the contact ring of the battery (see picture 6).Push the pump housing downwards (see picture 7) and turn it clockwise until the contact pinsengage in the end position of the contact ring. Now the pump unit and the battery are connectedboth mechanically and electrically.For disconnecting the battery reverse the sequence described above.Remark: As the contact ring is using a spring-loaded mechanism, the mechanic connection is notabsolutely rigid, i. e. a slight swivelling of the pump unit as against the battery is acceptable.

8.2.2 The Dump ValveOpen the dump valve (see picture 8) by turning it counterclockwise.The dump valve is now open, and the hoses can be connectedwith a rescue tool.

picture 6

contact pins

contact ringwith holes

picture 7picture 5

picture 8

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8.2.3 Connection between pump and rescue toolThe hydraulic hoses are connected free of confusion via mono-coupling halves (male and female)to the hydraulic pump.

Before coupling, remove dust protection caps, then connect male and female, and turn the lockingsleeve of the female to direction „1“ until the locking sleeve locks into place. The connection is nowin place and secure. Decoupling is by turning the locking sleeve to direction „0“.The equipment can also be coupled under pressure provided the connected equipment is notactivated.

REMARK:We recommend coupling the coupling halves in a pressureless state, when working in areaswith low ambient temperature and the usage of extension hose assemblies / hose reels,otherwise decoupling could need very high expenditure of force.

To protect them from dust, the accompanying dust protection caps must be put back on.

CAUTION!The mono-couplings may not be screwed off the hose assemblies and / or the hose assembliesbe confused!

9 Operation

9.1 Warning:Due to the risk of electric sparks the pump unit must not be used in explosive atmosphere !Under extreme operating conditions it may happen that metal parts of the pump are becoming veryhot ! Do not touch metal parts due to the risk of burnings !

mono-couplinghalve (male)

mono-couplinghalve (female)

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9.2 Function of the main switch

With the main switch (see picture 9) the pump can be switchedon or off. In the ”on” position the main switch is illuminated.To prevent damage of the pump unit through voltage peaks acircuit breaker is integrated into the main switch. When activatedthe circuit breaker would set the main switch automatically to the”off” position. As soon as the voltage peak is over the pumpcan be switched on again.

9.3 Working with pump and connected rescue tool

When the rescue tool is connected with the pump (see chapter 8.2.3), the dump valve must beclosed (see chapter 8.2.2). The tool is now supplied with hydraulic oil and can be operated bymeans of the star grip.

9.4 The charge indication panel

When the pump is switched on, the charge condition of the battery can be visually checked withthree lights in different colours:- ”green” means that the battery is full- ”yellow” means that the battery is approx. half full- the red light goes on when the battery is almost empty

Should you observe a loss of speed of the rescue tool and the red light is permanently on, chargethe battery immediately or change it against a fresh one. Do not continue with the operation untilthe motor stops !Otherwise there is the risk of the battery becoming deep discharged which would reduce its lifetime.Remark: The ”true” battery capacity can be seen only when the pump is in no-load condition.Depending on the stress situation of the rescue tool the battery voltage may vary so that the redlight goes on just for a second, e. g. when an extreme cutting job is made.

9.5 External power supply

The P 600 OB pump can optionally be driven by an external batterye. g. the truck battery. It must be made sure, however, that thebattery has 24 V and no more than 20 A ! Never exceed thesevalnes, otherwise the pump may be destroyed.For connection of such a battery the P 600 OB is equipped with aconnection point (see picture 10). A suitable connection cable canbe supplied upon request.

9.6 Change of battery

For changing the battery refer to chapter 8.2.1.

9.7 The indicator pin

On top of the pump unit is a pin (item 2, see cover page) which is connected with the hydraulic oilreservoir. Should the reservoir be overfilled the pin would be pushed upwards so that the red shaftbecomes visible. In this case excess oil must be drained from the reservoir (see chapters 9.8 and10.3).

picture 10

picture 9

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9.8 Succesive operation of several LUKAS rescue tools

Depending on the rescue situation it might be necessary to employ the pump for a second or thirdrescue tool (of course one after another). In such cases observe the following:Prior to connection of a second tool it must be made sure that the first tool has been fullyclosed/retracted ! Of course, the second tool must also be fully closed prior to connectionof a third one and so on. This is necessary for keeping the oil volume of the closed circuiton the same level throughout the whole operation cycle.

Attention: Do never use the P 600 OB for closing/retracting a rescue tool which has already beenextended with a second pump. Otherwise there is the risk of the diaphragm tank being damagedby too large oil volume !

9.9 The carry harness

9.9.1 DescriptionThe pump is delivered complete with a carry harness(item 8, see cover page). The harness consists of a stableyet extremely light frame with handle, two shoulder strapswith quickadjust mechanism, a adjustable belly girt and afixing rail (item 11.2) with arresting lever (item 11.1) Thecounter part for accomodation of the fixing rail is mountedon the housing of the pump by means of two allen screws(see picture 12, item 12.1).

9.9.2 Individual adjustment of the accommodation railThe position of the accommodation rail can be individuallyadjusted by opening the two allen screws. Set the rail to the mostcomfortable position and tighten the screws properly.It is also possible to mount the accommodation rail on the oppositeside of the pump housing:remove the two allen screws with plastic disks completely and set the rail to the wanted position.Place the thinner plastic disk on top of the rail and make sure that harness and pump are alignedin the vertical position. Tighten the rail with the two allen screws.

9.9.3 Handling of the harnessFor fixing the harness on the pump put it in the position as shown on picture 12. Open the arrestinglever (12.3) as far as possible. Push the harness forward until it engages into the accomodationrail (see picture 13). Depress the arresting lever completely and make sure that the rail is safelylocked.Hang the unit over your shoulders, use the D-clamps for pushing the shoulder straps forward andpull them tight (see picture 14). Finally, close the belly girt and pull it tight.

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11.1

11.2

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9.10 General remarkWhen the connected rescue tool is not needed for a longer period of time, open the dump valve(see picture 8) and switch the pump off so as to save battery capacity.

10 Maintenance

10.1 Pump unitAfter each operation all components have to be checked on proper function (clean them first ifnecessary):- check whether hydraulic fittings and couplers are tightened; tighten them if necessary- check pump unit, metal hood, battery housing, valves and hoses on external damage- check whether all signs, warning labels and switching symbols are complete and legible- check the oil tank on correct oil level (see chapter 10.3)- check the unit on oil leakage. Defective seals must be replaced immediately.

10.2 Hydraulic tightness

Check the unit on oil leakage and make sure that eventually damaged seals are replacedimmediately.

10.3 Checking hydraulic oil

Attention: Carry out the following procedure over an oil pan and dispose of used oil according tolocal regulations and laws !

The P 600 OB is filled with hydraulic oil viscosity class HLP 22.- check oil level in the reservoir after each operation; refill/drain oil if necessary (observe

LUKAS oil recommendation 10.5)- change hydraulic oil after approx. 50 operations, however after 2 years at the latest

Remark: Select type of hydraulic oil according to prevailing ambient temperatureconditions (see LUKAS oil recommendation10.5)

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12.2

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For checking of the hydraulic oil level proceed as follows:

1) Remove the hood on top of the pump unit by opening the 8allen screws on the bottom end of the hood.

2) Remove the yellow filler screw on top of the oil reservoir.3) Push the diaphragm downwards until oil is coming out of the

filler screw so as to make sure that no air remains in the tankand lock the tank with the filler screw.

4) For checking the correct filling volume adjust the upper part ofthe oil tank to a horizontal position. Measure the distance bet-ween reservoir bottom and upper edge.The correct distance would be 147 mm.

5) Should the distance be other than 147 mm, refill or drain hydraulic oil.

10.4 Changing hydraulic oil

For changing of the hydraulic oil proceed as follows:1) Remove the hood on top of the pump unit by opening the 8 allen screws on the bottom end

of the hood.2) Remove the yellow filler screw on top of the oil reservoir3) Put the pump upside down and drain the oil completely4) Adjust the tank so that the distance between reservoir bottom and upper edge is 147 mm.5) Fill in fresh hydraulic oil until oil is coming out of the filler screw so as to make sure that no

air remains in the tank..6) Hold the tank in its position and lock the tank with the filler screw.7) Connect the battery (see 8.2), couple the two hydraulic hoses with each other and open

the drain valve (see 8.3).8) Switch the motor several times on and immediately off again before it reaches high speed.9) Switch the motor on, close the drain valve and keep the motor running for a few seconds.10) Open the dump valve, switch the motor off and uncouple the hoses.11) Open the filler screw again and repeat the procedure as per para 5 and 6, if necessary.12) Lock the tank with the filler screw and clean the tank surface with a suitable cloth.13) Mount the hood again.

10.5 For LUKAS hydraulic devices, use mineral oil in accordance withDIN 51 524 and others

Recommended viscosity range: 10 ... 200 mm²/s,

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Range of oil temperature Viscosity rating RemarksA - 24 ... + 30 °C HL 5B - 18 ... + 50 °C HLP 10C - 8 ... + 75 °C HLP 22D + 5 ... + 80 °C HLP 32E - 8 ... + 70 °C HF - E 15 biodegradable

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11 Problems / trouble shooting

Index: P = problem S = symptom C = checkP: pump fails to deliver oilS: rescue tool doesn’t move when the star grip is turnedC: hoses and quick couplers properly connected ? Battery properly charged ?

-> After adding or changing hydraulic oil the pump must be vented (see 10.3)-> Is the red light on the charge indication panel on ?

-> Recharge the battery.

P: system pressure is not reachedC: check with a testing pressure gauge

-> Spring of the pressure relief valve needs readjustment-> Valve must be readjusted by an authorized dealer

-> Radial piston pump doesn’t function properly-> Function of piston elements to be checked by an authorized dealer

P: hose couplings cannot be connectedS: the hose is still presurized

-> Open the dump valve to release pressure from the hose

P: the connected rescue tool cannot be fully openedC. the tool can be properly closed

-> The oil quantity in the reservoir is not sufficient-> Close and uncouple the tool. Refill hydraulic oil as per para 10.3. Please read also

Para 9.8 ”operation of several rescue tools”

P: the thermo breaker on the main switch is activatedS: the main switch returns to ”off” automaticallyC: check correct power supply – 24V DC and max. 20A

-> switch the pump on again-> should the thermo switch open again, the electric system must be checked by an

authorized dealer

P: the indicator pin is extendedS: the red shaft of the pin becomes visible

-> adjust the hydraulic oil level as per para 10.3

F: Pump cannot be switched offS: The pump is running even with the main switch set to ”off”

-> Remove the battery from the pump (see chapter 9.6)Attention! This will cause sparks on the electric contacts. In hazardous atmospherethere is the risk of a explosion. Take suitable measures for your personal protection so

as not to come in contact with eventual sparks.

F: No rescue tool is connected, the hoses on the pump are pressurized and the dump valve isfaulty.S: Couplings cannot be connected, even when the dump valve is opened

-> Make sure that the pump intentionally or unintentionally cannot be switched on andcontact a authorized LUKAS dealer or the LUKAS service department.

If the defects cannot be repaired, contact an authorized LUKAS dealer or the LUKAS servicedepartment. The address: LUKAS Hydraulik GmbH, Weinstraße 39, 91058 Erlangen – Germany,Tel. +49 / 9131 698 348, Fax +49 / 9131 698-353.

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12 Repair

For all repairs only genuine LUKAS spare parts as listed in the spare parts list may be used, sinceit is absolutely necessary to consider for this purpose spezial tools, safety aspects and checks thatmight be required (see chapter 4).

13 Battery

13.1 The P 600 OB is supplied complete with a CP-100 9 Ah battery pack.

13.2 Special safety instructions for the battery:

The CP-100 Pack 9 Ah includes a lead-acid battery which is fully sealed. However, observe thefollowing:- do not charge the battery in gas-tight rooms- when charging the battery, put it on its rubber feet on a level, non-slip surface- do never short-circuit the electric contact points- don’t throw the battery into open fire- do not dispose of an old battery with the normal waste- make sure that the battery is recycled in ecology-friendly manner and observe local regula-

tions on recycling

13.3 Charging the battery

It is possible to charge the battery both separated from or being connected with the pump unit. Inthe later case it is essential that the main switch on the pump is set to ”off”, otherwise the batterywill not be charged.For charging only the LUKAS charger ref. 84150/7506 must be used. The sleeve for connection tothe charger is on the front side of the battery housing. The charging time is 6 hours, a quick-charging is not possible. Observe the operating manual of the charger !

Attention: The connection sleeve on the battery housing must only be used to connect thecharger. It is not permissible to insert a power cord into this sleeve (e. g. for powering anexternal consumer device). A contact of the sleeve with electrically conductive objects willcause a total damage of the battery.

13.4 Charger

The carger is a special device with automatic voltage adjustment. It is available with LUKAS underref. no. 84150/7506.

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14 Technical data

14.1 Pump unit

14.2 Battery The working time with one battery under average rescue conditions is30 to 45 min.

14.2.1 Technical data

14.3 Noise emission

14.4 Others

14.5 LUKAS Hoses

Voltage 24 VDCCurrent max. 20 AMotor power max. 480 WProtection class IP 12Hydraulic oil filling 1.6 lUsable oil quantity 1.2 lOil delivery low pressure 1.33 l/minOil delivery high pressure 0.33 l/minDimensions (h x w x d) 570 x 179 x 174 mmWeight (incl. oil filling) 18.8 kgTemperature range -15 up to +50 °CWorking position vertically (with the battery downwards) - horizontal

position is also possible

Voltage 24 VDCCurrent max. 20 ANominal capacity 9 AhDimensions (l x w x h) 179 x 174 x 170 mmWeight (battery only) 6.6 kg

Following the regulations of EN ISO 3744:measuring distance above ground level 1.0 m

no load full loadMeasuring distance 1 m 73 dB(A) 77 dB(A)Measuring distance 4 m 62 dB(A) 68 dB(A)Measuring distance 5 m 61 dB(A) 67 dB(A)

Working temperature -20 ... +55°CAmbient temperature (power pack in operation) -24 ... +45°CStorage temperature (power pack not in operation) -30 ... +60°C

Bending radius Rmin = 25 mmBurst resistance safety factor: burst pressure / max. operating pressure, min. 4 : 1Temperature resistance - 40°C ... + 100°COperating medium Mineral oil according to DIN 51524

18P600OB_BA_GB_115001085.p65 subject to revision

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LUKAS Hydraulik GmbHA Unit of IDEX CorporationWeinstraße 39, 91058 ErlangenPostfach 2560, 91013 Erlangen GermanyTelefon +49(0)9131/698-0 • Telefax +49(0)9131/698-394E-mail: [email protected]

Operating instructions

176101085 GBHose reels


Issue 08.2009

2

1. Hazard classes 4 2. Product safety 5 3. Proper use 8 4. Description 9 4.1 General information 9 4.2 Single hose reel 9 4.3 Double hose reel 10 4.4 Mounted single hose reel 12 5. Connecting the equipment 12 5.1 On the side of the hydraulic unit 12 5.2 On the side of the equipment 12 5.3 Coupling the mono-couplings 13 5.4 Coupling the quick-disconnect-couplings 14 5.5 Direct connection of the hose reels to the hydraulic pump or the control unit 15 6. Operation 15 6.1 Safety notes 15 6.2 Start-up 16 6.3 Parking brake (applies only to double hose reels) 16 6.4 Unrolling 17 6.5 Coiling 17 7. Dismantling the equipment / deactivation following operation 18 7.1 Equipment 18 7.2 Hydraulic unit 18 7.3 Hoses 18 7.4 Hose reel 19 8. Maintenance and service 19 9. Assembly of mounted hose reels onto hydraulic unit frames 20 9.1 Mounted single hose reel 20 9.2 Double hose reel 20 10. Assembly of auxiliary sets on hose reels 21 10.1 Double hose reel (auxiliary set with quick-disconnect-couplings) 21 10.2 Double hose reel (auxiliary set with mono-couplings) 21

Content Page

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11. Repairs 23 11.1 General information 23 11.2 Preventative service 24 11.3 Repairs 25 12. Troubleshooting 32 13. Technical Data 35 13.1 Generalreelidentification 35 13.2 Maximum operating pressure 35 13.3 Technical data for the hose reels 35 13.4 Further technical datas of the hose reels 36 13.5 Further technical datas of the hose reels 36 14. EC Declarations of conformity 37 15. Notes 38

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Wear helmet with face protection

Wear safety gloves

Wear safety shoes

Proper recycling

Observe principles of environmental protection

Read and observe operating instructions

We distinguish between various categories of safety notes. The table below gives you an overview of the assignment of symbols (pictograms) and key words to the specific hazard and possible consequences.

Hazard classes1.


hum

an

DANGER! Immediate danger Death or major injury





devi

ce






- REMARK





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Product safety2.

Wear protective clothing, safety helmet with visor, protective gloves

Inspect the equipment before and after use for visible defects or damage.

The responsible department is to be informed immediately of any changes (including to the operating behaviour). If necessary, the equipment is to be deactivated immediately and secured!

Inspect all cables, hoses and screwed connections for leaks and externally visible damage. Repair them immediately! Squirting hydraulic liquids can result in injuries and fires.

In the event of malfunctions, immediately deactivate the equipment and secure it. The malfunction is to be repaired immediately.

Do not carry out any changes (additions or conversions) to the equipment without obtaining the prior approval of LUKAS.

LUKAS products are developed and manufactured in order to guarantee the best performance and quality when used properly. Operator safety is the most important aspect of the product design. Moreover, the operating instructions are intended to help the safe use of LUKAS products. The generally applicable, legal and other binding regulations pertaining to the prevention of accidents and protection of the environment apply and are to be implemented in addition to the operating instructions.The equipment may only be operated by persons with appropriate training in the safety aspects of such equipment – otherwise, there is a danger of injury occurring. We would like to point out to all users that they should read carefully the operating instructions and the instructions contained therein before they use the equipment, and that they should carefully follow such. We further recommend that a qualified trainer train you in the use of the product.

WARNING / CAUTION!The operating instructions for the hoses, the accessories and the connected hydraulic equipment must also be observed!

Even if you have already received instructions on how to use the equipment, you should still read the following safety notes through again.

WARNING / CAUTION!Ensure that the accessories and connected equipment used are suitable for the max. operating pressure!

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Observe all safety and danger notes on the equipment and in the operating instructions.

All safety and danger notes on the device are to be kept complete and in a legible condition.

Any mode of operation which impairs safety and/or stability of the equipment is forbidden!

Comply with all specified dates or dates specified in the operating instructions pertaining to regular controls / inspections on the equipment.

Safety devices may never be deactivated!

The maximum permitted operating pressure noted on the equipment may not be exceeded.

Only original LUKAS accessories and spare parts may be used for repairs.

Please ensure that, when working with this equipment or during transportation of such, you don’t get stuck in the looped hoses and trip.

When working close to live components and cables, suitable measures must be taken to avoid current transfers or high-voltage transfers to the equipment.

The formation of electrostatic charging with the potential consequence of spark formation associated with handling this equipment is to be avoided.

The equipment is filled with a hydraulic fluid. These hydraulic fluids can be dangerous to health if swallowed or their vapours inhaled. Direct contact with the skin is to be avoided for the same reason. Please also note that hydraulic fluids can have a negative effect on biological systems.

When working with or storing the equipment, ensure that the function and the safety of the equipment are not impaired by the effects of stark external temperatures or that the equipment is damaged in any way. Please note that the equipment can also heat up over a long period of use.

Ensure adequate lighting when you are working.

Before transporting the equipment, always ensure that the accessories are positioned such that they cannot cause an accident.

Always keep these operating instructions within reach where the equipment is used.

Ensure the proper disposal of all removed parts, left-over oil, left-over hydraulic fluid and packaging materials.

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The generally applicable, legal and other binding national and international regulations pertaining to the prevention of accidents and protection of the environment apply and are to be implemented in addition to the operating instructions.

W A R N I N G / C A U T I O N !The equipment is to be used exclusively for the purpose stated in the operating instructions (see chapter “Proper Use”). Any other or further use is not considered proper use. The manufacturer / supplier is not liable for any damages resulting from improper use. The user bears sole responsibility for such. Observance of the operating instructions and compliance with the inspection and maintenance conditions are part of the proper use.

Never work when you are overtired or intoxicated!

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Proper use3.

Spare parts and accessories for the rescue tool can be ordered from your authorisied LUKAS-dealer!

The LUKAS hose reels are used for mounting extension hose pairs between the hydraulic supply and the equipment (hose pairs are included as standard in the delivery). The extension hose pairs are connected to the hose reel and coiled onto the drum. The use of a LUKAS hose reel with extension hose pairs enables a greater distance between the hydraulic supply and the equipment. This allows the hydraulic unit to stay on the emergency vehicle, for example. During use, unrolling / coiling enables optimum adaptation of the hose length, thereby reducing the amount of unnecessary / annoying hoses lying around. In a coiled state, the extension hose pairs can also be transported more easily, and storage is easier.

The hose reels can also be used under water at a depth of up to 40 m (131 ft).

CAUTION!In this case, you must strictly observe any leaks in order to avoid threats to the environment.

CAUTION!Because of possible loss of pressure, only extension hose lines having a maximum length of 20 m may be connected on the equipment side and on the device side the length may also be no more than max. 30 m!

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Description4. 4.1 General information

4.2 Single hose reelThe single hose reel comprises one carrier frame and one shaft with hose drum. One extention hose pair can be connected to the equipment side of the reel.Connection to the hydraulic pump or control unit is made by screwing the connecting hose pair directly into the control unit or valve block on the pump or by connecting the hose pair to the pump or the control unit by means of couplings.

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3

4

5

6

Quick-disconnect coupling system:

87

Mono-coupling system:

Basically, a reel comprises a carrier, shaft and hose drum.We distinguish between: Single hose reel: - Connection of a extension hose pair - Delivery with carrier frame

Double hose reel: - Connection of two extension hose pairs - Delivery with carrier frame - Parking brake

Mounted single hose reel: - Connection of a extension hose pair - connection to the side of a unit frame

Coiling / unrolling of all models is being carried out by a hand crank, which can either be plugged in or is fix connected with the hose drum.Connection to the hydraulic pump is being carried out via screwing the connection hose pairs directly into the valve block of the pump or via connecting the connection hose pairs to the pump by using couplings.

1 Hose drum 2 Carrier 3 Extension hose pair 4 Connection hose pair 5 Mono-coupling (male) 6 Mono-coupling (female) 7 Quick-disconnect-coupling

(male) 8 Quick-disconnect-coupling

(female)

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4.3 Double hose reel

1110

1

23

4

5

67

9

8

12

13

Quick-disconnect coupling system:

The double hose reel comprises one carrier frame and one shaft with two hose drums. Two extension hose pairs or extension hoses can be connected to the reel on the device side (one extension hose per drum). Depending on the connector version, connection on the equipment side is made by one or two short return hoses and one short extension hose per extension hose or extension hose pair. These connecting hoses are attached to the connection block of the hydraulic pump or a control unit directly or by means of couplings. The double hose reel also has a parking brake for simultaneously securing both hose drums in their positions. The basic model of the double hose reel comes as a mounted / installed reel. It can be affixed directly to a D-unit frame, a frame for connection hose reels or be permanently integrated into a vehicle. The fixing elements required for the assembly are contained in the delivery.

1 Hose drum 2 Carrier 3 Extension hose pair 1 4 Extension hose pair 2 5 Supply hose A 6 Supply hose A1 7 Return hose T 8 Mono-coupling (female) 1 9 Mono-coupling (female) 2 10 Quick-disconnect-coupling

(male) 11 Quick-disconnect-coupling

(female) 12 Parking brake 13 Hand crank

Mono-coupling system:

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For easier transport of the double hose reel, an auxiliary set is available as an accessory: this is screwed onto the reel.

Auxiliary set with mono-couplings:

The mono-coupling halves included in the auxiliary set must be connected with the supply hoses / the return hose as follows: Coupling 1, connection P: supply hose A Coupling 1, connection T: return hose T

Coupling 2, connection P: supply hose A1 Coupling 2, connection T: return hose T1 (contained in the auxiliary set)

Auxiliary set with quick-disconnect-couplings:

The quick-disconnect-coupling halves included in the auxiliary set must be connected with the supply hoses / the return hose as follows:

Steckkupplungsmuffe: supply hose Steckkupplungsnippel: return hose

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4.4 Mounted single hose reel

Connecting the equipment5.

5.1 On the side of the hydraulic unit

5.2 On the side of the equipment

The mounted single hose reels are basically assembled the same as the single hose reels. The only difference is the carrier used. This is designed only for mounting onto a hydraulic unit frame. It isn’t possible to use this carrier as the basis for transport or erection. The fixing elements required for the assembly are contained in the delivery.

REMARK:The devices can be equipped with different coupling systems.They are distinguished only by the item/article number.Of course the coupling systems can also be reequipped at a later time.

There are short hoses on the side of the unit: they are connected to the pump unit. All hose assemblies are marked with a colour, enabling them to be unmistakably connected:

HD = High pressure / supply (grey) T = Return (blue)

Connection on the equipment side can be made the screwing the hose(s) directly into the connection block of the hydraulic pump or the control unit or by means of couplings.Refer to the “Repairs” chapter for the tightening torque to be used when attaching the hose lines to the connection block or the control unit.Please see also the chapter “Repairs” for the screw-in torque of the hose assemblies in the couplings.

The hose pairs of the double hose reel are also distinguished by the different-coloured antikink covers.

The extension hose pairs are on the side of the equipment: they are connected with the equipment by means of couplings. All hose assemblies are marked with a colour and have coupling halves to enable unmistakable connection:

HD = High pressure / supply (grey) T = Return (blue)

The hose pairs of the double hose reel are also distinguished by the different-coloured antikink covers.

WARNING / CAUTION!Before connecting the equipment you have to pay attention that all used components are suitable to the max operation pressure of the pump unit! In the case of doubt you have to inquire LUKAS directly!

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5.3 Coupling the mono-couplingsThe equipment is connected to the hydraulic pump via mono-coupling halves (male and female).

Before coupling, remove dust protection caps, then connect male and female, and turn the locking sleeve of the female to direction „1“ until the locking sleeve locks into place. The connection is now in place and secure. Decoupling is by turning the locking sleeve to direction „0“. The equipment can also be coupled under pressure provided the connected equipment is not activated.

REMARK:We recommend coupling the coupling halves in a pressureless state, when working in areas with low ambient temperature otherwise decoupling could need very high expenditure of force.


WARNING / CAUTION! The mono-couplings may not be screwed off the hose assemblies and / or the hose assemblies be confused!

mono-coupling halve (male)

mono-coupling halve (female)

dust protection caps

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5.4 Coupling the quick-disconnect-couplings

X

Y

The equipment is connected to the hydraulic pump via quick-disconnect-coupling halves (male and female).

Before coupling unlock the connect socket by turning the sleeve into position X. Retract sleeve and connect plug and socket. Release sleeve and turn it into position Y.Now the connection has been made and locked. Uncoupling is done in the reverse order.

WARNING / CAUTION! The quick-disconnect-couplings partly have special functions. Therefore it is not allowed to screw them off from the hoses or to exchange them!


REMARK:Coupling of the devices is only possible, when the hoses are depressurized.

CAUTION!Always connect the return line first and afterwards the supply line!

REMARK when using the quick-disconnect-coupling system:Overpressure protection of the rescue equipment(model with yellow coupling nipple on the return hose)If the equipment’s hoses are not connected to a hydraulic unit or a rescue tool, temperature increases can inadvertently cause pressure to build up in the equipment. Hence, the return hose of the equipment is equipped with a safety coupling (quick-disconnect coupling male, yellow). Unwanted overpressure (approx. 1.5 Mpa) is automatically released via this nipple: a small amount of hydraulic fluid leaks.Should an hydraulic fluid leak on the coupling male be more frequent, please contact your dealer or LUKAS itself.

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CAUTION! Always connect the return line first and then the supply line!

5.5 Direct connection of the hose reels to the hydraulic pump or the control unit

WARNING / CAUTION! Unused connections on the hydraulic equipment or the control unit must be sealed. This can be accomplished through use of a suitable coupling half, an already connected device or an appropriate threaded plug.

When making this type of connection, there is no design feature to prevent inadvertent mix-up of the connections. For this reason, when making the connections you must ensure that the supply lines on the equipment side are always connected to the supply connection of the equipment or control unit. The same applies regarding the return lines.

The hose lines are attached to the existing fittings (nipples) on the equipment or control unit by means of coupling nuts. (tightening torque MA = 40 Nm)

Operation6. 6.1 Safety notesWorld-wide, safety guidelines pertaining to the specific country are to be observed and complied with. In the Federal Republic of Germany, regular safety inspections according to the regulations of the Gesetzlichen Unfallversicherung (GUV; connoted ‘Legal accident insurance’) are mandatory.

The following are to be worn when working with the hose reel:- protective clothing, - safety helmet with visor or protective goggles, - protective gloves - and, if necessary, ear protection

WARNING / CAUTION!When working with the hose reel, those not involved must maintain an appropriate, suitable safe distance, so that they are not endangered in the event of failure of the hose.

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6.3 Parking brake (applies only to double hose reels)

A

B

C

A

BC C

6.2 Start-upBefore start-up and following repairs, the hose assemblies of the hose reel must be deaerated: - Connect the hose reel to the hydraulic pump (see chapter “Connecting the equipment”).

- Switch on the hydraulic unit and pressurize the supply hoses for some time. - Switch the hydraulic unit to depressurized circulation or switch it. If necessary, you have

to top-up hydraulic fluid.

CAUTION!The working equipment has to be disconnected!

REMARK when using mono-couplings:We recommend coupling the coupling halves in a pressureless state, when working in areas with low ambient temperature otherwise decoupling could need very high expenditure of force.

REMARK when using quick-disconnect-couplings:When using quick-disconnect-couplings on extension hoses, each quick-disconnect-coupling (male) has to be connected with a quick-disconnect-coupling (female).

After the deaeration the working equipments can be reconnected to the hose reel.

REMARK when using quick-disconnect-couplings:Decouple the quick-disconnect-coupling halves.

The parking brake prevents the extension hose pairs from unrolling during transport!In order to release the parking brake, turn the knob A anti-clockwise until there is a distance of approx. 5 mm / 0.2 in. between the brake shaft B and the hose drums C.

In order to activate the parking brake, turn the knob A clockwise until brake shaft B is finger-tight with the hose drums C.

fig. 9

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6.4 Unrolling

6.5 Coiling

To unroll, pull at the extension hoses until the required length has been unrolled from the hose reel.

CAUTION!For unrolling the hose from the double hose reel, the parking brake must first of all be released. This prevents damage to the reel and the hoses.

REMARK:We recommend the use of the hand crank for coiling the hose!

- First of all, put the hand crank onto the shaft of the hose reel (except models with fix mounted hand crank).

- Check that the parking brake of the double hose reels has been released.- Aligning the hose as depicted in figure 10 simplifies coiling of the hose.

- Now, you can turn the hand crank to coil the extention hose pair. Pleasenotethatthewindingdirectiondepictedinfigure11mustalwaysbeobserved!

fig. 10

fig. 11

winding direction‚Coiling‘

hose

ellbow

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Dismantling the equipment / deactivation following 7. operation

7.1 Equipment

7.2 Hydraulic unit

7.3 HosesIf the hose reel is to be disconnected from the unit and the equipment, please proceed as follows:

On the side of the equipment (with quick-disconnect-couplings):First of all, decouple the supply hose then the return hose as described in chapter “Connecting the equipment”.Ensure that you put the dust protection caps back on to the quick-disconnect-couplings.

On the side of the equipment (with mono-couplings):Decouple the hoses as described in chapter “Connecting the equipment”.Ensure that you put the dust protection caps back on to the mono-couplings.

On the side of the hydraulic unit (with quick-disconnect-couplings):First of all, decouple the supply hose then the return hose as described in chapter “Connecting the equipment”.Ensure that you put the dust protection caps back on to the quick-disconnect-couplings.

Ensure that the extention hose pair is always properly coiled on the hose drum. Thisisusuallyguaranteedbyguidingtheextentionhosepairwithyourhand(seefigure

12) during the coiling process.

- Finally, you must put the parking brake of the double hose reel back on.

fig. 12

Basically, all used equipment must be safely stored following deactivation.

When using a LUKAS hydraulic unit with mounted hose reel, it is possible to store the equipment on a special storage device (available from the LUKAS range of accessories). It isn’t necessary to disconnect the hose assemblies from the hydraulic unit and / or the equipment.

Once work has been completed, the equipment is to be reset to its basic position.

Upon completion of work, the unit must be deactivated.

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7.4 Hose reel

On the side of the hydraulic unit (with mono-couplings):Decouple the hoses as described in chapter “Connecting the equipment”.Ensure that you put the dust protection caps back on to the mono-couplings.

On the side of the hydraulic unit (with direct connection):First of all, unscrew the supply hose then the return hose as described in chapter “Assembly of mounted hose reels onto hydraulic unit frames”.Ensure that you screw the protection caps back onto the connectors.

Maintenance and service8.

Coil the extention hose pairs onto the hose reel.Apply the parking brake on double hose reels.

Visual inspection

Hose reel• General tightness (leaks),• Operability of the hose drums,• All fastening screws are in place and tightened,• Carrier, frame and drum are undamaged,• Hand crank in place and undamaged,• Parking brake of the double hose reel in place and in working order,• Labels completely existent and legibly,

Hoses• Visual control for visible damage, • Control for leaks.• The hose connection must be tightly attached to the mounted reel, and not leak,• Couplings must be easy to couple,• Dust protection caps must be available.

Function test• Undisturbed coiling and unrolling of the extension hose pairs.• no suspicious noises.

A visual inspection is to be carried out after every use: however, at least one visual inspection is to be carried out annually. A function test is also to be carried out every three years or should there be any doubt regarding the safety or reliability of the equipment. (Please also observe the relevant valid national and international regulations pertaining to service intervals of rescue equipment). In the Federal Republic of Germany, regular safety inspections according to the regulations of the Gesetzlichen Unfallversicherung (GUV; connoted ‘Legal accident insurance’) are mandatory.

CAUTION!Clean off any dirt before controlling the equipment!

WARNING / CAUTION!In order to carry out maintenance and repair works, tools appropriate for the job and personal protecting equipment are essential.

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Assembly of mounted hose reels onto hydraulic 9. unit frames

9.1 Mounted single hose reelThe mounted single hose reel is to be mounted on the LUKAS aggregates with D-frames or mounted frames as follows:- Position the carrier of the reel to the side of the

frame such that the fastening bores of the carrier overlap with those of the frame, and use screws, washers and nuts to affix (see figure 13).

- Now connect the equipment-side hoses to the equipment’s connection block or the control unit as described in “Connecting the equipment” chapter.

fig. 13

9.2 Double hose reelThe double hose reel is to be mounted on the LUKAS aggregates with D-frames or mounting

frames as follows:- Place the reel at the “open” side of the frame such that the fixing holes in the support align

with those in the frame and then secure with the aid of bolts, lock washers, washers and threaded plate (see Fig. 15).

- Now connect the equipment-side hoses to the equipment’s connection block or the control unit as described in the “Connecting the equipment” chapter.

fig. 15

frame washer boltlock washersthreaded plate

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The auxiliary set consists of two handles, two quick-disconnect-couplings (female), one quick-disconnect-coupling (male) as well as assembly material.

Assemble the set as follows:- Slide carrying handles “B” into the

curved pieces of sheet metal “C” and fasten in place using bolts “D”, lock washers “E”, washers “F” and bars “G”. To secure properly, lock nut “H” must still be attached and tightened. (see Fig. 17)

J

K

L

N

T

T1

A

A1L

N

fig. 18

Assembly of auxiliary sets on hose reels10. 10.1 Double hose reel (auxiliary set with quick-disconnect-couplings)

10.2 Double hose reel (auxiliary set with mono-couplings)The auxiliary set consists of two handles, two mono-couplings, two antikink covers, one return hose and assembly material.

Assemble the handles as follows:- Slide carrying handles “B” into the curved pieces of sheet metal “C” and fasten in place

using bolts “D”, lock washers “E”, washers “F” and bars “G”. To secure properly, lock nut “H” must still be attached and tightened. (see Fig. 17)

D

The short hose assemblies to the hydraulic pump must be equipped with quick-disconnect-couplings as follows (see figure 18):- Connect quick-disconnect-coupling (male) G to

return hose F, - Connect one quick-disconnect-coupling (female)

J to each supply hose H - All quick-disconnect-couplings must be

tightened with a torque of 35 Nm

E

FCB

G

H

fig. 17

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Assemble the return hose of the auxilary set as follows:- Remove the plug and the steel ball from the connection T1 of the reel shaft and tighten

the return hose instead (see figure 19). (torque MA = 40 Nm)

T

T1

A

A1

M1

M2

TT1

AA1

TT1

AA1

fig. 20

fig. 19

The short hose assemblies to the hydraulic pump must have be assembled with the mono-couplings as follows (see figure 20):- Put the antikink cover (blue) onto the supply

hose A and return hose T.- Put the antikink cover (grey) onto the supply

hose A1 and return hose T1.- Connect the mono-coupling (male) H1 with the

supply hose A and the return hose T.- Connect the mono-coupling (male) H2 with the

supply hose A1 and the return hose T1.

CAUTION!Take care that the port ‘T’ / ‘T1’ of the hose reel is always connected to the port ‘T’ of the mono-coupling.The hoses must be tighten onto the mono-couplings (male) with a torque of 40 Nm!

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- Following that shift the antikink cover till dead stop of the mono-coupling.

Servicing may only be carried out by the manufacturer or personnel trained by the manufacturer and by authorised LUKAS dealers.Only LUKAS spare parts may be used to replace all components (see spare parts list) since special tools, assembly advice, safety aspects, inspections might have to complied with (see also chapter “Maintenance and Service”).During assembly, ensure the complete cleanliness of all components, since dirt can damage the rescue equipment!

Repairs11.

WARNING / CAUTION!Protective clothes must be worn when repairs are being carried out, since parts of the units can also be pressurised in an idle state.

REMARK:Please always return the guarantee registration card to LUKAS Hydraulik GmbH. Only then are you entitled to the extended guarantee.

REMARK:Before you use couplings from a different company, you must contact LUKAS or an authorised dealer.

11.1 General information

CAUTION!Because LUKAS of rescue equipment are appropriate for highest achievements, only components may be exchanged, which are specified in the spare parts list of the appropriate equipment.Further components of the equipment may only be exchanged, when:- you have participated on a appropriate LUKAS service training.- you have the explicit permission of the LUKAS Service department (After inquiry,

examination for the distribution of permission. Examination in each individual case necessarily!)

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11.2.1 Care regulationsThe exterior of the equipment is to be cleaned from time to time in order to protect it from external corrosion. Oil is to be applied to the metallic surfaces.

11.2.2 Function and load test If there is any doubt regarding the safety or reliability of the equipment, a function and load test must also be performed.

11.2.3 Changingthehydraulicfluid- The hydraulic fluid must be changed after after three years at the latest. - It must always be changed whenever the hydraulic fluid for the accompanying pump

(motor / hand pump) is changed. This is to prevent the fresh hydraulic fluid from becoming contaminated by the used fluid from the rescue equipment.

Procedure:1. Change the hydraulic fluid of the pump. Please observe the separate operating instructions

for the pump being used! 2. Screw off the return hose on the pump: - With direct hose connection to the pump or control unit: completely unscrew the connection nut of the connection piece of the blue return hose. - With hose connection to the pump or control unit via mono-coupling: remove the cover from the mono-coupling (male). completely unscrew the connection nut of the blue returnhose on the mono-coupling

(male). - With hose connection to the pump or control unit via quick-disconnect coupling: completely unscrew the connection nut on the quick-disconnect-coupling of the blue return hose.3. Put the return hose into a separate collecting basin for the hydraulic fluid still in the equipment.

4. Activate the hydraulic pump and pressurize the supply hose. Pressurize the supply hose as long as it needs to scavenge the whole used hydraulic fluid out of the hose reel.

The period of pressurization depends on the length of the hose assemblies (Fluid volume in the hose reel) and the flow rate of the pump. You will find fhe fluid volume of the hose reel in the chapter ‘technical data’.

5. Switch the pump off (motor pump) / no longer activate it (e.g. hand pump) and dispose the collected hydraulic fluid properly and according to the legal specifications.

6. Reconnect the return hose to the pump: - With direct hose connection to the pump or control unit: screw the connection nut of the connection piece of the blue return hose back on. (Please observe the necessary torque of MA = 40 Nm!) - With hose connection to the pump or control unit via mono-coupling: screw the connection nut of the blue return hose back onto the mono-coupling (male). (Please observe the necessary torque of MA = 40 Nm!) Pull back the cover on the couplings as far as the limit stop. - With hose connection to the pump or control unit via quick-disconnect coupling: screw the connection nut back onto the quick-disconnect-coupling of the blue return hose. (Please observe the necessary torque of MA = 35 Nm!)

11.2 Preventative service

REMARK when using hose reels with quick-disconnect-couplings:When using hose reels with quick-disconnect-couplings on the extension hose pairs, each quick-disconnect-coupling (male) has to be connected with a quick-disconnect-coupling (female) of the same hose pair.

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11.3 Repairs11.3.1 Changing or tightening connection hosesHose assembly of the supply and/or return hose leaks or hoses are defective. Tighten the hose connections on the shaft.(CAUTION! Observe torque of MA = 40 Nm!)

11.3.2 Changing or tightening extension hose pairsHose assembly of the supply and/or return hose leaks or hose pairs are defective. Pull back the protectiv cover and tighten the hose connections on the ellbows.(CAUTION! Observe torque of MA = 40 Nm!)

7. Control and top up the hydraulic fluid level in the hydraulic pump.

REMARK when using hose reels with quick-disconnect-couplings:When using hose reels with quick-disconnect-couplings on extension hoses, they have to be disconnected again.

ellbow

protectiv cover

hose

CAUTION!Set of protectiv covers must be assembled on the reel!

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11.3.3 Mono-couplingsThe mono-couplings must be replaced in the event of:- external visible damage,- the locking device not working,- hydraulic fluid continually leaking in a coupled/uncoupled state.

Procedure:

1. Remove the cover from the couplings.

2. Loosen the connection nuts of the hose assembly and remove the coupling.

3. Position the new coupling and tighten the connection nuts of the hose assemblies with a torque of MA = 40 Nm and push the cover of the couplings back on.

WARNING / CAUTION!Never repair couplings: they are to be replaced by original LUKAS parts!

CAUTION!Take care that the port ‘T’ / ‘T1’ of the hose reel is always connected to the port ‘T’ of the mono-coupling.

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11.3.4 Quick-disconnect-couplingsThe quick-disconnect-couplings must be replaced in the event of:- external visible damage,- the locking device not working,- hydraulic fluid continually leaking in a coupled/uncoupled state.

WARNING / CAUTION!Never repair couplings: they are to be replaced by original LUKAS parts!

Procedure:

1. Loosen the connection nut of the hose assembly and remove the coupling.

2. Position the new coupling and tighten the connection nut of the hose assemblies with a torque of MA = 35 Nm.

CAUTION (side of the equipment)!The return hoses, which are screwed onto the port “T” / “T1” of the hose reel, must always be equipped with quick-disconnect-couplings (female).However the supplying hose lines must be equipped with quick-disconnect-couplings (male).

CAUTION (side of the aggregate)!The return hoses, which are screwed onto the port “T” / “T1” of the hose reel, must always be equipped with quick-disconnect-couplings (male).However the supplying hose lines must be equipped with quick-disconnect-couplings (female).

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11.3.5 Ellbows on the single and double hose reelsThe ellbows must be replaced in the event of:- external visible damage,- hydraulic fluid continually leaking on the ellbow pipes.

Procedure:

1. Remove the extension hose pairs.

2. Loosen the ellbow and remove it.

3. Position the new ellbow and tighten it with a torqu of MA = 40 Nm.

winding direction‚Coiling‘

hose

ellbow

CAUTION!Take care that the ellbows are allways mounted in the correct oriented manner (see illustration on the right).

protectiv covers

Do not forget to push the protective covers back again over the screwed-connections (siehe illustration on the left).

29

11.3.6 Changing the hose drum on the single hose reelDamaged hose drums must be immediately replaced. Before you can change the hose drums, however, you must dismantle the extension hose pairs!

Procedure (see illustration):

1. Remove fixing bolts “A”, lock washers “B” and washers “C”.2. Remove the hose drum D and replace it with a new one.

A

3. Assembly is now carried out in reverse order. Please ensure all screws are once again tightened after the hose drum has been changed.

(torque max. MA = 7 Nm)

B

C

D

30

11.3.7 Changing the hose drum on the double hose reelDamaged hose drums must be immediately replaced. Before you can change the hose drums, however, you must dismantle the extension hose pairs!


1. Remove both screws A and washer B.2. Remove the shaft with both hose drums C.3. Remove fixing bolts “D”, lock washers “E” and washers “F”.4. Remove the hose drum and replace it with a new one.

5. Assembly is now carried out in reverse order. Please ensure all screws are once again tightened after the hose drum has been changed.

(torque max. MA = 7 Nm) The screws A must be tightened with a torque of MA = 30 Nm and be secured with a screw

securing paste (e.g. Loctite 243).

D

A

B

E F C DEFC

31

11.3.8 Parking brake on the double hose reelIf the parking brake on the double hose reel is damaged / non-functional, it must be replaced


1. Remove bolts “A”, washers “B”, lock washers “C” and nuts “D”. 2. Remove the damaged parking brake D and replace it with a new one.3. Assemble screws A, washers B and nuts C, and tighten.

A

11.3.9 LabelsAll damaged and/or illegible labels (safety notices, type plate, etc.) must be renewed.

Procedure:1. Remove damaged and/or illegible labels. 2. Clean the surfaces using acetone or industrial alcohol. 3. Attach new labels.

Ensure that you attach the labels in the right position. If you are no longer sure about this, then please contact your authorised LUKAS dealer or LUKAS itself.

E

B

D

C

32

Troubleshooting12. Trouble Control Cause Solution

Equipment doesn’t move when activated

Hose assemblies connected properly?

Hose assemblies not connected

Reaffix hose assemblies or re-couple them

Does the pump unit work?

Equipment or hydraulic unit defective

See separate operating instructions for hydraulic unit or equipment.

Equipment moves slowly or jerkily when activated

Are the hoses connected correctly?

Air in the hydraulic system

Deaerete hydraulic system

Does the pump unit work?

with mono-coupling-system: Hoses cannot be coupled

Pressure too high (e.g. caused by too-high ambient temperature)

Set hydraulic pump to pressureless circulation


with mono-coupling-system: It is frequently not possible to couple hose assemblies

Control the degree of viscosity and application temperature of the used hydraulic fluid

Hydraulic fluid not adapted to the application situation

Hydraulic fluid must be replaced (see chapter “Recommended Hydraulic fluids”)


with quick-disconnect-coupling-system: Hoses cannot be coupled

Is the pump working?

Pressurized Relieve pumpCoupling defective Coupling needs to be

replaced immediately

Damages of the surface of the hydraulic hoses

Mechanical damages or contact with aggressive agents

Replace hoses

Leak in the couplings Is the coupling damaged?

coupling damaged Coupling must be replaced immediately

Hydraulic fluid leaking from the hoses or connections

Hoses defective? Leak, possible damage

Replace hoses

33

Leakage of hydraulic fluid in the inner area of the hose reel.

Hose extension pairs defective?

Hoses defective Replace hoses

Connection of the hoses tighten?

Hoses not tightened properly onto the elbows.

Tighten the screwed connection between hoses and elbow.

Leckage on the connection between elbow and shaft?

Defective elbow / defective sealing below the elbow

Replace elbow / sealing

Defective shaft Repair by an authorised dealer, by personnel specially trained by LUKAS, or by LUKAS itself

Leakage of hydraulic fluid on the connections between connection hoses and reel shaft.

Connection hoses defective?

Hoses defective Replace hoses

Connections of the hoses tighten?

Hoses / fittings not tightened properly.

Tighten the screwed connection of the hoses / fittings.

Leackage between fitting and shaft?

Fittings not tightened properly.

Tighten the screwed connection.

Sealing between fitting and shaft defective.

Replace sealing

Fitting defective Replace fitting.

Leckage on connection between hub and shaft

Sealing between hub and shaft defective.

Repair by an authorised dealer, by personnel specially trained by LUKAS, or by LUKAS itself

with mono-coupling-system: Leak in the couplings

Is the coupling damaged?


with quick-disconnect-coupling-system: Leak in the couplings

Is the coupling damaged?


Is the leak only on the coupling male (when uncoupled)?

Safety valve reacted

After pressure release there is no more leakage.

Trouble Control Cause Solution

34

If it isn’t possible to rectify the malfunctions, inform an authorised LUKAS dealer or the LUKAS customer service department immediately!The address for the LUKAS customer service department is:



Tel.: (+49) 09131 / 698 - 348Fax.: (+49) 09131 / 698 - 353

35

Technical Data13.

13.1 Generalreelidentification

DHR 20 - 66 blgr

13.2 Maximum operating pressure

70 [MPa]* = 10,153 [psi.]* 1 [MPa] = 10 [bar]

13.3 Technical data for the hose reels

This information can be found in the separate, supplemental instructions for your hose reel model.

Since all values are subject to tolerances, minor differences may occur between the data on your equipment and the data listed here!

Type of hose reelSHR = single hose reelDHR = double hose reel

Length of the extension hose

pairs in [m]

Length of the extension hose

pairs in [ft.]

Colour of the antikink cover of the extension

hose pairsbl = bluebc = blackgr = grey

At the double hose reels both of the anti-kink cover colours are specified, that means blgr signifies:antikink cover 1 = blueantikink cover 2 = grey

The max. operating pressure of all STREAMLINE-hose reels is:

36

13.4 Further technical datas of the hose reels


Oil temperature range Oil code Viscosity rating RemarksA -24 .... +30°C HL 5 VG 5B -18 .... +50°C HM 10 VG 10C -8 .... +75°C HM 22 VG 22D +5 .... +80°C HM 32 VG 32E -8 .... +70°C HF-E15 VG 15 Bio-oil

Oil temperature range Oil code Viscosity rating RemarksA -11.2 .... +86°F HL 5 VG 5B -0.4 .... +122°F HM 10 VG 10C +17.6 .... +167°F HM 22 VG 22D +41.0 .... +176°F HM 32 VG 32E +17.6 .... +158°F HF-E15 VG 15 Bio-oil


13.5 Further technical datas of the hose reelsOperating temperature [°C] / [°F] -20 … +55 -4 … +131Ambient temperature (device in operation) [°C] / [°F] -25 … +45 -13 … +113


CAUTION!Before using hydraulic fluids, which do not correspond to the above-mentioned specifications and/or are not purchased from LUKAS, you have to contact LUKAS itself!

NOTE:When hose reels with a mono-coupling are used, we recommend an oil in the viscosity class VG 10, as the force required for coupling can otherwise be very high.

37

EC Declarations of conformity14. This information can be found in the separate, supplemental instructions for your hose reel model.

38

Notes15.

39

Please dispose all packaging materials and dismantled parts properly

LUKAS Hydraulik GmbHWeinstraße 39, D-91058 ErlangenPostfach 2560, D-91013 ErlangenTel.: (+49) 0 91 31 / 698 - 0Fax.: (+49) 0 91 31 / 698 - 394e-mail: [email protected]

Made in GERMANY

© Copyright 2009 LUKAS Hydraulik GmbHSchlauchhaspeln_BA_GB_176101085_0809.indd

subj

ect t

o re

visi

on

Operating instructions

Edition 11.201084120300085 GBHand Pumps ZPH and HM


replaces 11.2009

2

3

Contents Page 1. Danger classes 4 2. Product safety 4 3. Proper use 7 4. Main components of the hand pump 8 5. Functional description 8 6. Connection options for hydraulic equipment 9 6.1 Connecting nipples 9 6.2 Quick-disconnect couplings 10 6.3 Monocouplings 11 7. Commissioning 12 7.1 Locking the pump 12 7.2 Bleeding the pump 12 8. Operation 13 8.1 Operation 13 8.2 Shut-down / Storage 14 9. Transport 14 10. Maintenance and repair 14 10.1 Basic requirements 14 10.2 Maintenance 15 10.3 Changingortoppingupthehydraulicfluid 16 10.4 Care 16 10.5 Repair 17 11. Troubleshooting 22 12. Technical data 25 12.1 Hand pump data 25 12.2 Hydraulicfluidrecommendation 28 12.3 Operating and storage temperature ranges 28 13. EC Declaration of Conformity 29 14. Notes 30

4

Wear helmet with face guard

Wear protective gloves

Wear safety shoes

We distinguish between various categories of safety instructions. The table shown below shows you the overview, via the assignment of symbols (pictograms) and signal words, of the concrete danger and the possible consequences.

Danger classes1.


hum

anDANGER! Immediate danger Death or major injury



CAUTION! Less dangerous situation Minor or slight injury

devi

ce

ATTENTION!Danger of damage


Damage to the equipment, damage to the environment,

damage to surrounding materials

- NOTE





Product safety2. LUKAS products are developed and produced in order to ensure the best performance and quality with proper use.The safety of the operator is the most important consideration in the product design. In addition, the operating instructions are to help in using the LUKAS products safely.In addition to the operating instructions, all generally applicable, statutory and other binding rules for accident prevention and for environmental protection must be heeded and disseminated.The device must only be operated by educated persons who are trained in safety technology, since otherwise there is a risk of injury.We advise all users before using the device to carefully read through the operating instructions and to follow the instructions contained therein without exception.

Proper recycling

Protect the environment

Read and follow operating instructions

5

We also recommend that you get instructed by a qualified trainer in the use of the product.

WARNING / CAUTION!The operating instructions for the hoses, the accessories and the connected devices must also be heeded!

Even if you have already received instruction, you should read the following safety instructions again.

Make sure that no body parts or clothing get between the openly visible moving parts of the device.

Immediately report changes that occur (including changes in operating behaviour) to the appropriate persons/departments! If necessary, immediately shut down and secure the device!

Wear protective clothing, protective helm with visor, safety shoes and protective gloves.

Check the device for visible defects or damage before and after use.

Working under loads is prohibited if they are raised exclusively with hydraulic devices. If this work is unavoidable, sufficient mechanical supports are additionally required.

Check all lines, hoses and screwed connections for leaks and externally visible damages and repair immediately! Escaping hydraulic fluid can lead to injuries and fires.

In the event of malfunctions, shut down the device immediately and secure it. You should have the malfunction repaired immediately.

Do not make any changes (add-ons or conversions) on the device without the approval of LUKAS.

Heed all safety instructions and hazard warnings on the device and in the operating instructions.

All safety instructions and hazard warnings on the device are to be kept intact and in a legible condition.

Make sure that all safety covers are present on the device and in proper working condition.

Any work procedure that detracts from the safety and/or stability of the device should be abandoned!

Safety equipment must never be disabled!

The maximum permissible operating pressure must not be changed.

6

Before switching on/engaging the device or while operating the device, it must be ensured that no one is endangered by the operation of the device.

Observe all intervals that are prescribed or specified in the operating instructions for recurring tests and/or inspections.

When working in the vicinity of live components and lines, take appropriate measures for preventing current transfers or high voltage flashovers to the device.

For repairs only original LUKAS accessories and spare parts are to be used.Make sure that you do not get caught in the hose loops and trip when working with or transporting the device.

Prevent electrostatic discharge, which has the possible consequence of spark formation, when handling the device.

When the hand pumps are set up, care needs to be taken that they are not impaired by extremely strong temperature changes.

The device is filled with hydraulic fluid. These hydraulic fluids can be detrimental to health if they are swallowed or their vapours are inhaled. Direct contact with the skin should be avoided for the same reason. Also, when handling hydraulic fluids, note that they can negatively affect biological systems.

When operating and/or storing the device, make sure that the function and the safety of the device are not impaired by strong external temperature differences or that the device is damaged. Keep in mind that the device can also heat up when it is continuously used.

Make sure there is adequate lighting while working.

Before transporting the device, always check to see that the accessories are positioned securely to prevent the possibility of an accident.

Always keep these operating instructions easily accessible at the site where the device is used.

Make sure you properly dispose of all removed parts, leftover hydraulic fluid, leftover oil and packing materials.

In addition to the safety instructions of these operating instructions, all generally applicable, statutory and otherwise binding national and international rules for accident prevention need to be heeded and disseminated!

7

WARNING / CAUTION / ATTENTION!The device is specified exclusively for the purpose represented in the operating instructions (see Chapter "Proper use"). Any use that differs or goes beyond this is considered improper. The manufacturer/supplier shall not be held liable for damages resulting from improper use. The risk shall be borne solely by the user.Proper use also includes heeding the operating instructions and complying with the inspection and maintenance requirements.

Never work in a fatigued or intoxicated state!

Proper use3.

You can obtain accessories and replacement parts for the devices from your authorised LUKAS dealer!

The LUKAS hand pump is used for the operation of LUKAS devices.They can be used as an additional or replacement drive source along with the LUKAS hydraulic unit (e.g. in areas at risk for explosion).Use with equipment of other manufacturers is possible, but requires technical testing and approval of LUKAS on a case-by-case basis.

WARNING / CAUTION / ATTENTION!Always note the product limitations with respect to operating pressure, load limit values and operating conditions. The operating pressure should not be higher than the lowest maximum operating pressure of any system components.

The operating pressure should NEVER be set higher than that which is specified in the "Technical Data" chapter. A higher setting may cause property damage and/or injuries.

Make sure that the usable capacity of the hand pump (see chapter "Technical Data") is sufficient for operating the connected cylinders or devices. The required hydraulic fluid operating quantity can be found in the chapter "Technical Data" or in the operating instructions of the devices to be operated.

8

Main components of the hand pump4.

Functional description5. All LUKAS hand pumps of this series are two-speed, i.e. they have two operating speeds: • A high speed in the low pressure range (LP) for fast extension of the cylinder or device

while unloaded • A low speed in the high pressure range (HP) for controlled extension of the cylinder or

device while loadedThe switch from low pressure (LP) to high pressure (HP) is automatic at the factory setting for changeover pressure (see chapter "Technical Data").

1 Drain valve 2 Bleeding / Filling cap 3 Pump lever 4 Tank 5 Lock 6 Connecting nipples 7 Sealing caps 8 quick-disconnect couplings (optional) 9 Connecting block for monocoupling (optional) 10 Monocoupling (optional) 11 Front foot plate (optional) 12 Rear foot plate (optional) 13 Base plate (optional)

3

1

1

1

2

13

4

5

5

5

6

7

8

9

10

12

11

1

5

9

Connection options for hydraulic equipment6. ATTENTION!Make sure to store all plugs, screw plugs and/or dust caps in a way that prevents them from getting dirty or lost.After completion of the work, seal off all lines using screw plugs and/or dust caps to prevent contamination of the hand pump.When connecting lines to the hand pump, we recommend positioning it vertically so that the ports point upward. This reduces the danger of hydraulic fluid escaping.

6.1 Connecting nipples The hose lines are connected via fittings to the hydraulic pump.

1.2.

1. First remove the closure caps from the fittings.

2. Then, you can connect the hose lines to the fittings and tighten them with a tightening torque of MA = 40 Nm.

ATTENTION!The return hose must always be connected at the "T" port of the connection block.The supply hose line must instead be connected at the "P" port.

A pressure connection "P" and a return connection "T" with a G1/4“ thread are available for connecting directly to the pump.To connect equipment, appropriate connectors (connecting nipples, quick-disconnect couplings or monocouplings) must be attached. On some of the LUKAS hand pumps offered, one of these connection options is supplied with the pump and is already fitted.Obviously, the connection options fitted can be replaced by others. However, you must contact an authorised LUKAS dealer or contact LUKAS directly.

Additionally, LUKAS hand pumps can be fitted with various accessories (e.g. a baseplate), to adapt the hand pump to the individual application.You can obtain the appropriate accessory and any necessary replacement parts for the hand pumps from your authorised LUKAS dealer.

10


Before connecting the couplings, remove the dust cap, then pull back and hold the locking sleeve of the female coupling (Position X). Push the male and female couplings together and release the locking sleeve. Finally, turn the locking sleeve into Position Y. The connection is then made and secured. Decoupling is done in the reverse sequence.

WARNING / CAUTION / ATTENTION! To some extent the quick-disconnect couplings have special functions and therefore must not be unscrewed and/or interchanged!

X

Y


NOTE:Coupling the equipment is only possible if the hoses are depressurised.

6.2 Quick-disconnect couplings

ATTENTION!Always connect the return line first and then the supply line!

11

6.3 Monocouplings

Male coupling Female coupling

Dust caps

Before coupling, remove dust caps, then connect male and female couplings and turn locking sleeve of the female coupling in direction "1" until the locking sleeve latches. The connection is then made and secured. The decoupling is accomplished by turning the locking sleeve in direction "0".The coupling of the devices under pressure is also possible, assuming the connected equipment is not turned on.

NOTE:We recommend, when ambient temperatures are low and extension hoses are used, connecting the coupling halves in a depressurised state because decoupling may otherwise require a very large exertion of force.


WARNING / CAUTION / ATTENTION! The monocouplings must not be unscrewed and/or the hose lines reversed!

The hose lines are connected via monocoupling halves (female and male) to the hydraulic pump in such a way that they cannot be reversed.

12

NOTE:With the LUKAS hand pump, a little idle stroke may occur when the unit is first used in the high pressure range.However, this idle stroke independently stops after a device is operated 2-3 times.

7.1 Locking the pump

ATTENTION! The hand pump should be as close to horizontal as possible, because otherwise the usable amount changes!

The oil fill plug must always be unscrewed one turn before starting operation of the hand pump! This enables the aeration and bleeding of the hydraulic tank. After the work is completed but before transport, the oil fill plug should be retightened!

Commissioning7.

7.2 Bleeding the pump 1. Open the discharge valve.2. Open the oil fill screw plug on the tank container and check the oil fill level. The oil fill

level should come up to approximately 1-2 cm below the top edge of the oil reservoir.3. In this state, work the pump handle several times.

Hand wheel

Unlock: Lock:

ATTENTION! Always push the locking lever fully to the end position, both when locking and when unlocking!When locking the hand pump, the pump lever must always be in the home position (end position against the pump body)!

13

NOTE:To bleed connected equipment, make sure that the highest point of the connected devices are below the level of the pump.Before operating the pump, you should also open the oil fill screw plug. Only in this way can any trapped air escape the hydraulic system when the pump is operated. You should operate the connected equipment several times without load.When you do this, also follow the separate operating instructions of the connected devices.

WARNING / CAUTION! Under certain circumstances, the pump handle can "kick back". Make sure that your body remains to the side of the pump.

ATTENTION! Never attach an extension to the pump handle that does not belong to the device. These extensions usually cause the pump to become unstable during operation.

Operation8.

NOTE:In order to limit the required force in high pressure operation, we recommended using short strokes with the pump handle. The greatest pumping effect is produced in the last 5 degrees of the stroke.

Should you use a female quick-disconnect-coupling as the port, quick stop may be triggered if the discharge valve is opened too quickly (turning counter-clockwise), i.e. the check valve incorporated in the male quick-disconnect coupling blocks the return flow of oil while the connection between pump and female quick-disconnect coupling is depressurised. This is provided as a safety function in case the connection between the female quick-disconnect-coupling and pump starts to leak and the pressure drops abruptly. In this case, the "quick stop" prevents, for example, an abrupt drop in the load when an hydraulic cylinder is operated. In order to release the quick stop again, more pressure must first be supplied to the device. Then, the pressure can be decreased again by slowly opening the discharge valve.

Procedure:1. Close discharge valve on the hand pump completely (rotate clockwise).2. Connect the return line of the device at the return port "T" and then the high pressure line

at the pressure port "P".3. Move the locking lever into the operating position (unlock).4. Supply the device with hydraulic fluid or pressurise by operating the pump lever (up and

down movements).5. To reduce the pressure of the device, slowly open the discharge valve of the hand pump

(turn counter-clockwise). In this way, you can meter the pressure reduction precisely.

8.1 Operation

14

Transport9.

8.2 Shut-down / Storage To shut down or store the pump, seal all hydraulic connections with the associated screw plugs or dust caps.After sealing the hydraulic ports, open the drain screw (not up to the stop!) to depressurise the pump.Then carefully clean the external dirt off of the hand pump.In addition, with a longer storage time, the outside of the device should be cleaned and all visible mechanical moving parts need to be oiled.

ATTENTION! After completion of the work but before transport, check to make sure the oil fill screw plug is screwed in tightly!Make sure the pump is not stored in a damp environment.

The pump lever is used as a carrying handle! Special pumps may be the exception in this case. These pumps are custom-assembled for each customer; therefore, there may be a different transport device or none! In these cases, please refer to your authorised dealers or LUKAS directly. The lever must be locked for transport, as described in the chapter "Locking the pump".

Maintenance and repair10.

Service work may only be performed by the device manufacturer, or by personnel trained by the device manufacturer, and authorised LUKAS dealers.All components must be replaced with original LUKAS spare parts, which are listed in the spare parts list, because in this context even required special tools, assembly instructions, safety aspects and/or checks absolutely must be taken into consideration. During the assembly work, pay particular attention to the cleanliness of all components because dirt can damage the equipment!

10.1 Basic requirements

WARNING / CAUTION / ATTENTION!To perform maintenance and repairs, personal safety equipment appropriate for the work is an absolute requirement (incl. shields).Assembly and repair work on the pump may only be performed if the entire hydraulic system is depressurised!Couplings should not be repaired; they should be replaced with original LUKAS parts!

NOTE:Always send the warranty card back to LUKAS Hydraulik GmbH.

You should always contact LUKAS or an authorised dealer before using couplings from a different company.

Do not perform any repairs without the corresponding LUKAS spare parts list, because necessary tightening torques for screw connections and/or in some cases also important additional information are listed there.

15

The equipment is subject to very high mechanical stresses. Therefore, a visual inspection needs to be made after each use, at least once per month (if continually used, once per week). In this way, early signs of wear are recognisable so that damage to the device can be avoided by prompt replacement of these worn parts. Also check regularly to make sure that all attachment screws are tightened (observe any applicable tightening torque specifications).At least once a year (if continually used, once every half year) or if there is a doubt about the safety or reliability, a functional check should also be performed (for this purpose, also heed the corresponding applicable national and international specifications related to the maintenance intervals of the devices).

ATTENTION!Clean the device before checking for dirt!Do not use any aggressive agents for cleaning; it could cause damage to the equipment.

Because LUKAS devices are designed for the highest performance, only components may be replaced that are listed in the spare parts lists of the corresponding device.Additional components of the equipment may only be replaced if:- You have participated in a corresponding LUKAS service training course.- You have the express permission of LUKAS customer service (by

request, check on the grant of permission. A check is necessary in each individual case).

10.2 Maintenance Before performing maintenance work, clean the hand pump thoroughly.After performing the maintenance work, you should carefully coat all metallic parts with oil to prevent any corrosion.

Checks (Maintenance measures):

Perform a visual inspection of the hand pump at least once per month; in the case of continuous use, once a week.

Visual inspectionHand pump• are all hydraulic connections still tightened,• generally sealed, no leaks present (oil "sweat" has no effect on the operation),• is damage to pump housings, valve blocks or attachment parts recognisable, especially

on the moving parts such as the piston rods,• are all fluid levels within the prescribed tolerances,• are all non-moving parts firmly attached,• is there no corrosion,• free movement of the pump lever, the locking mechanism and the hand wheels (check in the depressurised state),• the couplings are easy to couple (if attached),• are dust caps in place,• are identification plate, all control decals, instruction decals, labels and warnings present

and legible.

16

NOTE:In this test, an idle time of approximately 2 minutes needs to be observed and the hand pump needs to be reloaded to operating pressure.The resulting max. operating pressure must not drop by more than 5% after 10 seconds.A test pressure gauge is available from the LUKAS line of accessories.

Perform an operational check of the hand pump at least once a year; in the case of continuous use, once every half year.

Operational check• no suspicious noises,• tests at maximum load. Execution: Place the hand pump on a solid base to operate. Then, connect a test manometer to the

supply hose line. Release the pump lever lock and close the discharge valve. Then, the pressurisation to operating pressure corresponding to the specification on the identification plate occurs.

10.3 ChangingortoppingupthehydraulicfluidThe hydraulic fluid should be changed if dirty at least once a year. When the hand pump is operated in an especially dusty environment, we recommend changing the fluid at least once every six months.

ATTENTION!Add hydraulic fluid only if the hand pump is disconnected from the lines or the equipment operated with the pump is hydraulically depressurised. Otherwise, after filling the entire hydraulic system could contain more hydraulic fluid than the tank can hold.

Procedure:1. Open the bleed/fill cap on the tank.2. Add hydraulic fluid until the fluid level comes up to 1-2 cm below the top edge of the oil

tank.3. Bleed the hand pump as described in the chapter "bleeding the pump".4. Check the fluid level again and close the tank again at the correct fluid level with the

vent/fill cap on the tank. Should the tank no longer be sufficiently full after bleeding, start the fill procedure again at item 2.

NOTE:Should the fluid level in the tank still not be reached after repeated refilling (during maintenance), we recommend searching for leaks in the hydraulic system.

10.4 Care If possible, do not store the hand pump in a damp or extremely dusty environment in order to ensure a long service life. If this is unavoidable, you should perform more frequent maintenance and/or shield the pump from these effects if possible.Regularly coat all metal parts with oil to prevent any corrosion.

17

10.5 Repair ATTENTION!Because LUKAS devices are designed for the highest performance, only components may be replaced that are listed in the spare parts lists of the corresponding device and whose replacement is described here.Additional components of the equipment may only be replaced if:- You have participated in a corresponding LUKAS service training course.- You have the express permission of LUKAS customer service (by

request, check on the grant of permission. A check is necessary in each individual case!).

10.5.1 Base plate replacementThe base plate must be replaced if external damage is present that represents a danger for user and device upon further use. In particular, the base plate must be replaced if the stability of the hand pump can no longer be ensured.

Procedure:1. Remove screws A and B and also washers C and D.

2. Remove base plate E and replace it with a new one.3. Refit the base plate in the reverse order.

A

C

D

B

E

18

10.5.3 Removing tank for cleaning, replacing the tank or the seals

The tank should be cleaned at least once per year in order to remove the accumulated dirt.The tank must be replaced if there is any external damage that impairs the safety of the device.The tank seals must be replaced if there are any leaks at the junction points of the tank.

Procedure:1. Remove base plate as described in the chapter "Replacing

base plate".2. Empty tank by removing the screw plug (item D) and emptying

the tank.

D

2. Remove foot plate C or D and replace it with a new one.3. Refit the foot plates in the reverse order.

10.5.2 Foot plate replacementThe foot plates must be replaced if external damage is present that represents a danger for user and device upon further use. In particular, the foot plates must be replaced if the stability of the hand pump can no longer be ensured.

Procedure:1. Remove screws A or B.

Front foot plate: Rear foot plate:

C

A

D

B

19

Removing the ZPH1/HM1 1l tank:3. Remove the nut (item E) and sealing ring situated under it (item F).4. Remove the tank, the seals (item G), the cover (item R) and the filter (item H). On the

rescue hand pumps, the intake pipe (item J), the threaded rod (item K), the washer (item L), the O-ring (item M), the serrated washers (items N, O and P) and the bracket (item Q) must also be removed.

6. The assembly is done in reverse order. Replace all damaged parts with new ones. The tightening torque of the nuts is 40 Nm.

Removing the ZPH1/HM1 5l and 12l tanks:3. Remove the screws (item R) and the lock washers under them (item S).4. Remove the tank, the O-rings (items T and U), the serrated washer (item V) and the filter

(item W).

6. The assembly is done in reverse order. Replace all damaged parts with new ones. The tightening torque for the screws is 10 Nm.

SR

W V T U

F EN Q NGOLMH P G R

KTank

JPump head

20

10.5.4 Couplings

WARNING / CAUTION / ATTENTION!Couplings should not be repaired; they should be replaced with original LUKAS parts!

10.5.4.1 Monocouplings The monocouplings must be replaced if:- exterior damage is present,- the lock does not function,- in the coupled and/or decoupled state, hydraulic fluid continuously escapes.

Procedure for installation in the valve block:1. Unscrew coupling from connection plate.2. Screw new coupling into the connection plate with a torque of MA = 40 Nm.

Removing the ZPH3 tank:3. Remove the screws (items A and B) and the lock washers under them (items C and D).4. Remove the tank, the O-rings (items E and F), the serrated washer (item G) and the filter

(item H).

5. The assembly is done in reverse order. Replace all damaged parts with new ones. The tightening torque for screws "A" is 24 Nm, and for screws "B" is 10 Nm.

FEH BD

CA Tank

G

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10.5.4.2 Quick-disconnect couplings The quick-disconnect-couplings should be replaced if:- exterior damage is present,- the lock does not function,- in the coupled and/or decoupled state, hydraulic fluid continuously escapes.

Procedure:1. Unscrew and remove coupling.2. Screw in new screw-on male coupling and tighten with a torque of MA = 35 Nm.

ATTENTION!The return port must always be equipped with a female quick-disconnect-coupling.The supply port should instead be equipped with a male quick-disconnect-coupling.

10.5.5 DecalsAll damaged and/or illegible decals (safety instructions, identification plate, etc.) must be replaced.

Procedure:1. Remove damaged and/or illegible decals.2. Clean surfaces with acetone or industrial alcohol.3. Adhere new decals.

Make sure to adhere the decals in the correct positions. If this is no longer known, you should consult your authorised LUKAS dealer or contact LUKAS directly.

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Troubleshooting11. Problem Cause Remedy

Connected device does not move, moves only slowly or moves intermittently.



Discharge valve open Close discharge valve.Hose line not properly connected or damaged


Load on the device too high

Use a different device.

Air in the hydraulic system Bleed system as described in the chapter “Bleeding the pump”.


Connected device moves, but does not hold pressure or does not render the specified performance.

Hose line not properly connected or damaged


Leaking seal Locate the leak and have the hand pump serviced by an authorised dealer, by personnel specially trained by LUKAS or by LUKAS directly.

Internal leakage of the pump

Have the hand pump serviced by an authorised dealer, by personnel specially trained by LUKAS or by LUKAS directly.

Device does not move back into the starting position, moves incompletely back toward the starting position or moves more slowly into the starting position than normal.

Discharge valve closed Open discharge valve.Fluid level in the hydraulic tank too high


Loose hydraulic coupling Check all couplings and retighten them.

Enclosed air in the system Bleed pump as described in the chapter “Bleeding the pump”.

Line length too long Use shorter lines.Use hydraulic fluid with a different, more suitable viscosity.


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Connected device not reaching its limit position


Add hydraulic fluid up to max. fill level.Attention: move the device back into the base position before adding fluid!

Usable hydraulic fluid quantity of the pump is insufficient

Use a different device with a usable quantity below the maximum usable quantity of the pump.

Connected device does not achieve its power-related performance data

Max. permissible operating pressure of the pump is not reached

Replace pressure control valve or have it recalibrated by an authorised dealer or directly by LUKAS.

Fluid leaks on the hydraulic fluid tank (especially at the refill tap)

Due to return flow of the hydraulic fluid from the device, the maximum fill quantity of the tank is exceeded


Seals defective Replace seal.Hydraulic fluid with milky cloudiness

Water or condensation water in the system

Perform hydraulic fluid change immediately.

In the case of a monocoupling system: Hose lines cannot be coupled

They are under excessive pressure (e.g. due to excessive ambient temperature)

Open discharge valve and bleed device.


In the case of a monocoupling system: Hose lines frequently cannot be coupled

Hydraulic fluid of the application situation not adapted

Hydraulic fluid needs to be changed (see the chapter “Hydraulic fluid recommendation” for more information).


In the case of a quick-disconnect coupling system: Hose lines cannot be coupled

System is under pressure Open discharge valve and bleed device.


In the case of a monocoupling system: Leakage at the couplings



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In the case of a quick-disconnect coupling system: Leakage on the male coupling

Safety valve has responded (in the decoupled state)

After depressurisation, no further leakage occurs.

Male coupling defective Male coupling should be replaced immediately.

In the case of a quick-disconnect coupling system: Leakage at the female coupling

Female coupling defective Female coupling should be replaced immediately.

Hydraulic fluid escaping from the hoses or at the joints

Leakage, possible damage Replace hoses.


Mechanical damage or contact with aggressive media

Replace hoses.

If the defects cannot be remedied, notify an authorised LUKAS dealer or contact LUKAS Customer Service directly!The address of LUKAS customer service is:



Phone: (+49) 09131 / 698 - 348Fax.: (+49) 09131 / 698 - 353


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Technical data12. Because all values are subject to tolerances, there cannot be any differences between the data of your device and the data of the following tables!

12.1 Hand pump data

12.1.2 Dimensions

ZPH 1A / 1 PN500rounded usable volume of the hydraulic fluid

tankin [l]

max. operating pressure in [bar](1 MPa = 10 bar)

12.1.1 Pump identification

Model series

FOptional

attachmentse.g.

F = with foot plates (not for HM1)

NOTE:Hand pumps in model series HM1 are generally fitted with a base plate.

NOTE:On hand pumps with the optional foot plate attached, the height H increases by 6 mm.

ZPH1 and HM1:

ZPH 1 HM 1(1l Tank) (5l Tank)

L[mm] 621 628 623

[in.] 24.4 24.7 24.5

B[mm] 112 164 200

[in.] 4.4 6.5 7.9

H[mm] 195 195 215

[in.] 7.7 7.7 8.5

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ZPH3:ZPH 3

(4l Tank) (8l Tank)

L[mm] 762 762

[in.] 30 30

B[mm] 150 230

[in.] 5.9 9.1

H[mm] 231 231

[in.] 9.1 9.1

12.1.3 Fill quantity - Usable quantity

Tank size Usable quantity Max.fillquantity(according to pump identification)

1 [l] 1,1 [l] 1,3 [l]0.29 [gal.-US] 0.34 [gal.-US]

4 [l] 4,0 [l] 5,3 [l]1.06 [gal.-US] 1.40 [gal.-US]

5 [l] 4,5 [l] 5,0 [l]1.19 [gal.-US] 1.32 [gal.-US]

8 [l]8,0 [l] 10,5 [l]

2.11 [gal.-US] 2.77 [gal.-US]

12.1.4 Delivery quantity

Pump type Delivery quantity per piston stroke

Low pressure LP High pressure HP

ZPH 1A 10 [cm³] 1,6 [cm³]0.61 [cu. in.] 0.10 [cu. in.]

ZPH 3 10,8 [cm³] 4,2 [cm³]0.66 [cu. in.] 0.26 [cu. in.]

HM 1 10 [cm³] 1,6 [cm³]0.61 [cu. in.] 0.10 [cu. in.]

12.1.5 Max. operating pressure

NOTE:You can take the max. operating pressure from the pump identification.

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12.1.6 Change-over pressure LP - HP

*) 1 [MPa] = 10 [bar]

Pump type Change-over pressure

ZPH 1A 10 [MPa]*1,450 [psi.]

ZPH 3 18 [MPa]*2,611 [psi.]

HM 1 10 [MPa]*1,450 [psi.]

12.1.7 Weight

Total weight

Weight(Pump head)

Weight(Tank)

Weight(Accessories)= + +

Pump type Weight(Pump head)

ZPH 1A 4,6 [kg]10.1 [lbs.]

ZPH 3 3,7 [kg]8.2 [lbs.]

HM 1 4,7 [kg]10.4 [lbs.]

Tank size Weight(according to pump

identification) (Tank)

1 [l] 1,4 [kg]3.1 [lbs.]

4 [l] 4,4 [kg]9.7 [lbs.]

5 [l] 4,0 [kg]8.8 [lbs.]

8 [l] 6,2 [kg]13.7 [lbs.]

Accessories Weight

Base plate 1,28 [kg]2.83 [lbs.]

Foot plate (front) 0,18 [kg]0.40 [lbs.]

Foot plate (rear) 0,07 [kg]0.15 [lbs.]

Connecting nipples 0,04 [kg]0.09 [lbs.]

Quick-disconnect coupling, female

0,29 [kg]0.64 [lbs.]

Quick-disconnect coupling, male

0,12 [kg]0.26 [lbs.]

Monocoupling 0,73 [kg]1.61 [lbs.]

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12.3 Operating and storage temperature ranges

Operating temperature [°C] / [°F] -20 … +55 -4 … +131Ambient temperature (device in operation) [°C] / [°F] -25 … +45 -13 … +113


12.2 Hydraulicfluidrecommendation





ATTENTION!Before using hydraulic fluids that do not correspond to the aforementioned specifications and / or are not purchased from LUKAS, you must contact LUKAS!

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EC Declaration of Conformity13.

30

Notes14.

31

© Copyright 2010 LUKAS Hydraulik GmbHZPH_HM_BA_GB_84120300085_1110.indd

Please properly dispose of all packing materials and removed parts.

Sub

ject

to re

visi

on

LUKAS Hydraulik GmbHWeinstraße 39, D-91058 ErlangenPostfach 2560, D-91013 ErlangenPhone: (+49) 0 91 31 / 698 - 0Fax.: (+49) 0 91 31 / 698 - 394e-mail: [email protected]

Made in GERMANY

Documents

48562712 Lukas Hydraulic Power Pack