Lukas P 635 Operating Instructions Manual

Hydraulic power units

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Operating instructions for rescue equipment

Hydraulic power units P 635

P 635 SG

175635086 EN

Edition 03/2024

(Translation of the original operating instructions)

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Page 1 Operating instructions for rescue equipment Hydraulic power units P 635 P 635 SG 175635086 EN Edition 03/2024 (Translation of the original operating instructions)
Page 2: Table Of Contents
Content Page 1. Danger classifications 2. Product safety 3. Proper use 4. Unit designation 5. Functional description 5.1 General 5.2 Power unit design 5.3 Gasoline motor 5.4 Valves 5.5 Pumps 5.6 Frame with side parts 5.7 Connection to the rescue equipment 5.8 Hose reels 5.9 Carrying handles 5.10 Holder...
Page 3 Content Page 10. Tests 10.1 Recommended inspection intervals 10.2 Hydraulic power units with gasoline motor 10.3 Hose reels 11. Maintenance and repair 11.1 General information 11.2 Maintenance work on the hydraulic power unit 11.3 Additional service work on power unit with gasoline motor 11.4 Service work on attached hose reel 12.
Page 4: Danger Classifications
1. Danger classifications We differentiate between various different categories of safety instructions. The table shown below provides an overview of the assignment of symbols (pictograms) and signal words to the specific danger and the possible consequences. Damage/ Pictogram Keyword Definition Consequences injury to Death or severe...
Page 5: Product Safety
2. Product safety LUKAS products are developed and manufactured to ensure the best performance and quality when used as intended. The safety of the operator is the most important consideration in product design. Furthermore, the instruction manual is intended to help you use LUKAS products safely.
Page 6 (additions or conversions) to device and secure it. Repair the device without obtaining the fault immediately (or have it the prior approval of LUKAS. repaired). Observe all safety and danger All safety and danger information on the device and instructions on the device must in the instruction manual.
Page 7 If fuel is spilled on combustion Refueling while operating a motors, it must be completely combustion motor is strictly removed before starting the prohibited! motor. Keep combustion motors and Replace all damaged electrical their fuel away from ignition components (e.g. charred sources, otherwise there is a cables, etc.) immediately or risk of explosion.
Page 8 In addition to the safety instructions in these operating instructions, all generally applicable, statutory and other binding national and international accident prevention regulations must be observed, and operators must be instructed accordingly. WARNING / CAUTION / ATTENTION! This device is intended exclusively for the purpose described in the instruction manual (see chapter "Proper use").
Page 9: Proper Use
It is possible to use the power unit to supply pressure / fluid to rescue devices made by other manufacturers, however this requires a technical inspection and approval by LUKAS in each individual case.
Page 10: Unit Designation
5. Functional description 5.1 General On all LUKAS hydraulic power units, the hydraulic pump is operated with a motor. The pump conveys fluid from the hydraulic oil tank and builds up the pressure in the tool. Fluid is distributed to the connected equipment through valves.
Page 11: Power Unit Design
5.2 Power unit design P 635 SG 1 Gasoline tank 2 Hydraulic fluid tank 3 Motor with hydraulic pump 4 Connecting block with control valves 5 Speed adjusting lever 6 Pull starter 7 "TURBO" control lever 8 Mono-coupling sockets 9 Fuel tank cap...
Page 12 P 635 SG-DHR-COAX 8 Mono-coupling sockets 10 Hydraulic fluid filler cap 20 Telescopic handle (also available as an extra for retrofitting) 21 Hose reel 22 Lock (hose reel) 23 Crank (hose reel) 24 Hose guide 25 Holder P 635 SG-DHR...
Page 13: Gasoline Motor
The rescue equipment is connected to the hose assemblies. Model P 635 power units are equipped with a SIMO connecting block. The connecting block of the P 635 also has a TURBO function.
Page 14: Pumps
5.5 Pumps P 635 hydraulic power units manufactured by LUKAS are equipped with a dual-flow pump. The pump is fixed to the connecting block. Dual-flow pump for operating with SIMO valve The pump used always has two pressure stages per pump feed flow, one low pressure and one high pressure stage.
Page 15: Hose Reels
5.10 Holder LUKAS type P635 hydraulic power units with a hose reel are fitted with a holder. The holder can be adjusted to hold all LUKAS cutters and spreaders and also modified at a later time. The holder allows you to transport a power unit with equipment attached, meaning it is not necessary to detach the devices after use and store them separately.
Page 16: Connecting Hose Lines / Devices
Before connecting devices ensure that all components used are suitable for the maximum operating pressure of the hydraulic power unit! In case of doubt, you must consult LUKAS directly before connecting the devices! The hose assemblies / devices are connected via quick-disconnect coupling halves (female and male) to the hydraulic pump or hose reel in such a way that they cannot be reversed.
Page 17 Remove the dust caps before coupling together. Then push the male and female parts together and turn the locking sleeve on the female coupling in the direction "1" until the locking sleeve clicks in place. The connection is now established and secured. Decoupling is accomplished by turning the locking sleeve in direction “0”.
Page 18: Setting Up And Commissioning
The power unit should be set up in a suitable location (safe location / level surface / sufficient distance from vehicles, loads, ignition sources, etc.). LUKAS power units work perfectly up to an inclination of 20°. However, in order to guarantee maximum safety and fluid withdrawal, they should be operated in a position which is as horizontal as possible.
Page 19 2. Now bleed the hydraulic power pack: 3. Open the venting plug on the pump block. Venting plug Pump block 4. Tilt the power unit back approx. 90° (see illustration) and wait until oil comes out from the bolt. 90° 90°...
Page 20: Operation
7.2.2 Commissioning (after initial filling or prior use) 1. Check the fluid level of the motor oil, the hydraulic fluid and the fuel tank. Top up, if necessary. For precise reading of the fluid levels and for filling, the hydraulic power unit should be as level as possible. 2.
Page 21: Refilling With Fuel (Only For Combustion Motors)
8.3 Refilling with fuel (only for combustion motors) The motor must be switched off prior to refueling! Procedure: 1. Open the fuel tank cap. 2. Fill the tank with fuel until the fill level is just below the filler opening. 3.
Page 22: Controlling The Valves
8.4 Controlling the valves 8.4.1 "Simultaneous operation" control valve (SIMO) P 635 SG The pump block also has a "TURBO" control lever, allowing the user to switch to the "TURBO" function (see diagram above). With this function, switching the lever supplies one of the two connections at double the feed rate.
Page 23: Hose Reels
8.5 Hose reels 8.5.1 Holding brake The holding brake is designed to prevent the pairs of hoses from unrolling during transport! To release the holding brake, pull and turn the knob 90°. To apply the holding brake, turn the knob again approx. 90° until it engages automatically. 90°...
Page 24 8.5.4 Rolling up NOTE: We recommend using the hand crank to roll up the hoses! - Move the hand crank into operating position. - Check that the holding brake on the double hose reels is released. - Align the unrolled pairs of hoses so that they can be rolled up in a straight line. Rolling up is much easier as a result.
Page 25: Telescopic Handles
8.6 Telescopic handles Power units with a hose reel are fitted with carrying handles. Power units without a hose reel can be retrofitted with one as an optional extra. You should then use this reel to transport the P635. The telescopic carrying handles are screwed directly into the frame, after first removing the sealing plugs.
Page 26: Holder
8.7 Holder Open the strap to remove a device from the holder. The device is then very easy to remove. Removing the spreader: Press the red button to release the strap. Lift the rear handle of the spreader slightly. Remove the spreader in the direction of the reel.
Page 27 Procedure (fitting and adjusting the holder): NOTE: The actions described below are required to retrofit a holder or adjust an existing one to accommodate new devices. 1. Secure each holder "A" with retaining strap to rail "C" using two screws "B". 2.
Page 28 The brackets must be adjusted depending on the size of the rescue device. Bracket "E" can be mounted on either side of rail "F". 3. Now adjust the brackets to accommodate the relevant devices. To do this, loosen the fastening screws slightly so that the brackets are easy to move. Do not unscrew the screws completely.
Page 29: Dismantling The Device/Deactivation Following Operation
9. Dismantling the device/deactivation following operation Once work has been completed, all connected equipment must be returned to the neutral position (storage position) before the power unit is shut down. You can then switch off the motor of the power unit. WARNING for power units with combustion motors! Check that the motor switch is set to the "OFF"...
Page 30: Tests
An appropriate workshop and personal protective equipment is absolutely necessary when carrying out inspection, maintenance and repair work. (when necessary also use screens). LUKAS offers a suitable test kit for testing the function of the hydraulic power units. (For more detailed information, please refer to the LUKAS range of accessories or contact your LUKAS dealer.) 10.1 Recommended inspection intervals...
Page 31: Functional Check
• All required accessories (e.g. spark plug, spark plug spanner and fuel can) are present. Functional check • Unconventional or noticeable noises are heard during operation, • Cable starter fully functional, • Motor switch functional, • Test for maximum load. NOTE: Use the LUKAS test kit, including testing instructions, for the functional check.
Page 32: Hose Reels
11. Maintenance and repair 11.1 General information LUKAS P 635 hydraulic power units require only limited maintenance. No special training is required for maintenance work, but knowledge of the function of the power units, the legal safety regulations and the handling of the required tools is a basic requirement.
Page 33: Maintenance Work On The Hydraulic Power Unit
Other power unit components may only be replaced if: - You have participated in an appropriate LUKAS service training course. - You have the express permission of LUKAS customer service (permission will be verified on request - each case requires individual assessment!)
Page 34: Changing Labels
1. Remove damaged and/or illegible labels. 2. Clean surfaces with industrial alcohol. 3. Affix new labels. Take care to affix the labels in the correct positions. If this is no longer known, you should contact your authorized LUKAS dealer or LUKAS directly.
Page 35: Additional Service Work On Power Unit With Gasoline Motor
• Check the spark plug, clean if necessary / set the electrode gap of the spark plug You must carry out the following maintenance measures every 200 operating hours: • Replace spark plug • Replace air filter (The following maintenance work should be carried out by an authorized dealer, LUKAS directly or the motor manufacturer.) You must carry out the following maintenance measures every 300 operating hours: • Replace spark plug and filter element •...
Page 36 11.3.1 Replacing and cleaning the air filter NOTE: It is very important to keep the air filter in good condition. Incorrect installation, incorrect maintenance or unsuitable filter inserts will cause damage and wear to the motor. Always keep the air filter element clean. Procedure: 1.
Page 37 11.3.2 Replacing, cleaning and adjusting the spark plug Procedure: In order to ensure a good performance, the spark plug must have a correct electrode gap and be free from deposits. 1. Detach the spark plug connector and remove any dirt near the spark plug. 2.
Page 38: Service Work On Attached Hose Reel
11.4 Service work on attached hose reel A visual inspection of the fitted hoses and couplings must be carried out after each use or once every six months. If damage or leaks are visible, the components must be replaced. If a screw connection is leaking, check whether it is tightened correctly first of all.
Page 39 3. Screw the new hose lines onto the manifolds with a torque of = 40 Nm. Remember to push the protective hoses "B" back over the screw connections. The protective hose set must be fitted to the reel! 4. Roll up the hose lines again. 5.
Page 40 - hydraulic fluid is constantly escaping in the coupled and/or uncoupled state. WARNING / CAUTION / ATTENTION! The repairing of couplings is not permitted, they must be replaced with original LUKAS parts! Procedure for couplings on the valve block: 1. First, empty the hydraulic tank as described in the chapter "Changing the hydraulic fluid”.
Page 41 Procedure for hose line couplings (double hose): 1. First, empty the hydraulic tank as described in the chapter "Changing the hydraulic fluid”. 2. Pull the kink protection back from the couplings. 3. Loosen the union nuts on the hose line and remove the coupling. ATTENTION! Ensure that connection "T1"/"T2" on the pump block is always connected to connection "T"...
Page 42 Procedure for hose line couplings (mono-hose): 1. First, empty the hydraulic tank as described in the chapter "Changing the hydraulic fluid”. 2. Undo the hose line union screw. Remove the coupling and O-ring. If required, remove any remnants of threadlocker from the thread of the union screw. 3.
Page 43: Troubleshooting
Have the motor set to the altitude of application of the hydraulic unit by an authorized dealer, engine manufacturer or LUKAS directly (only if the unit is scheduled for frequent use at this altitude) Check air filter Air filter dirty...
Page 44 (home position)? the power unit LUKAS directly The motor is running, Check hose line Hose line not properly Check connection but the connected connected or damaged...
Page 45 (to end position) Pump unit defective Have repaired by authorized dealers or LUKAS directly Air in the hydraulic Bleed the hydraulic system system Plug coupling sleeve Replace the plug defective...
Page 46 LUKAS directly Pump block defective Have repaired by authorized dealers or LUKAS directly Connected device For remedy, see...
Page 47 "Hydraulic fluid recommendation") Leak at the couplings Coupling defective Coupling must be replaced immediately Leakage at the drive Shaft seal defective Repair by an authorized shaft of the hydraulic dealer, by personnel pump specially trained by LUKAS, or by LUKAS itself...
Page 48 Shaft defect Repair by an authorized dealer, by personnel specially trained by LUKAS, or by LUKAS itself Hydraulic fluid Connecting hoses Hoses defective Replace hoses leak from the defective?
Page 49 In case of faults which affect the combustion motor, please also observe the instructions in the separate operating instructions of the motor manufacturer. Contact an authorized LUKAS dealer or the LUKAS Customer Service Department directly if the malfunctions cannot be rectified!
Page 50: Technical Data
NOTE: The following tables contain only the most important technical data for normal approval. Further information about your device is available directly from LUKAS on request. The limitation of the maximum filling quantity of the hydraulic tank results from the "operability on an incline" prescribed in the standards.
Page 51 Power units with hose reel (double hose): Power units with hose reel (mono-hose):...
Page 52 13.1.2 Technical data P 635 SG Device type P 635 SG Item number 81-53-44 Motor type 4-stroke gasoline motor [kW] Motor power rating [HP] [rpm] Speed 3600 [rpm.] [l/min] 2 x 0.6 Feed rate, simultaneous (HP) [gal.-US/min] 2 x 0.16 [l/min] 1 x 1.2...
Page 53 13.1.3 Technical data P 635 SG-DHR Device type P 635 SG-DHR Item number 81-54-51 Motor type 4-stroke gasoline motor [kW] Motor power rating [HP] [rpm] Speed 3600 [rpm.] [l/min] 2 x 0.6 Feed rate, simultaneous (HP) [gal.-US/min] 2 x 0.16 [l/min] 1 x 1.2...
Page 54 13.1.4 Technical data P 635 SG-DHR-COAX Device type P 635 SG-DHR-COAX Item number 81-54-52 Motor type 4-stroke gasoline motor [kW] Motor power rating [HP] [rpm] Speed 3600 [rpm.] [l/min] 2 x 0.6 Feed rate, simultaneous (HP) [gal.-US/min] 2 x 0.16 [l/min] 1 x 1.2...
Page 55 13.1.5 Technical data P 635 SG-DHR10-COAX Device type P 635 SG-DHR10-COAX Item number 81-54-54 Motor type 4-stroke gasoline motor [kW] Motor power rating [HP] [rpm] Speed 3600 [rpm.] [l/min] 2 x 0.6 Feed rate, simultaneous (HP) [gal.-US/min] 2 x 0.16 [l/min] 1 x 1.2...
Page 56: Noise Emissions (Acoustic Pressure Level)
Explanation of dual digit noise emission values according to DIN EN 13204:2016-12 Serial number of the machine, operating conditions and other characteristic properties: Model ...P 635 SG, P 635 SG-DHR, P 635 SG-DHR-COAX, type ...81-53-44, 81-54-51, 81-54-52, 81-54-54 maximum working pressure ...700 bar, motor speed ..3600 rpm...
Page 57: Spark Plug
13.3 Spark plug BPR6ES (NGK) Spark plug type: W20EPR-U (DENSO) 13.4 Spark plug wrench Universal joint spark plug wrench with wrench size 16 mm (5/8 inch) 13.5 Fuel Unleaded gasoline Fuel: ROZ 91 to ROZ 98...
Page 58: Motor Oil
13.6 Motor oil 13.7 Hydraulic fluid recommendation Oil for LUKAS hydraulic devices, mineral oil DIN ISO 6743-4 and others Oil temperature range Oil designation Viscosity class Note -20 ..+55°C HM 10 VG 10 Oil temperature range Oil designation Viscosity class...
Page 60: Ec Declaration Of Conformity
14. EC Declaration of Conformity...
Page 63: Instructions Regarding Disposal
15. Instructions regarding disposal Please dispose of all packaging materials and removed items correctly. Electrical equipment, accessories and packaging should always be disposed of in an environmentally compatible way. Only for EU countries: Do not dispose of electrical equipment with your household waste! According to the European Directive 2012/19/EC governing electrical and electronic waste and their application in national legislation, old electrical equipment must be separately collected and recycled in an environmentally...
Page 64 WARNING / CAUTION / ATTENTION! Before connecting devices ensure that all components used are suitable for the maximum operating pressure of the hydraulic power unit! In case of doubt, you must consult LUKAS directly before connecting the devices! LUKAS Hydraulik GmbH...

This manual is also suitable for:

P 635 sgP 635 sg-dhrP 635 sg-dhr-coax