HURST ML-630-SI User manual

375070085 EN
Hydraulic power unit ML-630-SI
(Original instruction manual)
replaces 11.2014
Instruction manual for rescue equipment
Edition 02.2015
Built to extend lives.™

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Content Page
1. Danger classi¿cations 5
2. Product safety 6
3. Proper use 10
4. Power unit designation 11
5. Functional description 11
5.1 General information 11
5.2 Installation of the power unit 12
5.3 Motor 13
5.4 Valves 14
5.5 Pumps 15
5.6 Frame with side sections 15
5.7 Connection to the rescue equipment 15
6. Connecting the hoses / devices 16
7. Set-up and start-up 18
7.1 Set-up 18
7.2 Start-up 18
8. Operation 20
8.1 Starting the engine 20
8.2 Turning the engine off 21
8.3 Refuelling 21
8.4 Controlling the valves 22
9. Dismantling the equipment / deactivation following operation 23
10. Tests 24
10.1 Recommended test intervals 24
10.2 Visual and function check 25
11. Maintenance and repair 26
11.1 General information 26
11.2 Service work on the hydraulic unit 27
11.3 Additional service work 29
12. Fault analysis 34

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Content Page
13. Technical data 39
13.1 Power unit 39
13.2 Noise emissions 41
13.3 Sparking plug 42
13.4 Sparking plug spanner 42
13.5 Fuel 42
13.6 Engine oil 43
13.7 Hydraulic fluid recommendation 43
13.8 Operating and storage temperature range 43
14. EC Declaration of Conformity 44
15. Notes 45

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Wear a helmet with a face guard
Wear protective gloves
Wear safety shoes
Proper recycling
Protect the environment
Read and follow operating instructions
We differentiate between various different categories of safety instructions. The table shown
below shows you an overview of the assignment of symbols (pictograms) and signal words
to the speci¿c danger and the possible consequences.
1. Danger classifications
Pictogram Damage /
injury to Key word Definition Consequences
Persons
DANGER! Immediate danger Death or severe
injury
WARNING! Potentially dangerous
situation
Potential death or
serious injury
CAUTION! Less dangerous
situation Minor or slight injury
Property
ATTENTION! Danger of damage to property/
environment
Damage to the
equipment,
damage to the
environment,
damage to
surroundings
- NOTE
Handling tips and
other important/
useful information
and advice
No injury/damage
to persons/
environment/
device

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2. Product safety
HURST products are developed and manufactured to ensure the best performance and
quality when used as intended.
Thesafetyoftheoperatoristhemostimportantconsiderationinproductdesign.Furthermore,
the operating instructions are intended to help in using HURST products 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 must only be operated by persons with appropriate training in the safety
aspects of such equipment – otherwise, there is a danger of injury.
Wewouldliketo point outto all usersthat they shouldread carefully theoperating instructions
and the instructions contained therein before they use the equipment, and that they should
carefully follow such.
We further recommend you have a quali¿ed trainer show you how to use the product.
CAUTION!
The operating instructions for the hoses, accessories and the connected
devices must also be heeded!
Even if you have already received instruction on how to use the equipment, you should still
read through the following safety instructions again.
CAUTION!
Ensure that the accessories and connected equipment are suitable for the
maximum operating pressure!
Please ensure that no body
parts or clothing get stuck
between the visibly moving
parts.
Immediately report any changes
that occur (including changes
in operating behaviour) to
the appropriate persons/
departments! If necessary, the
equipment is to be shut down
immediately and secured!
Wear protective clothing, safety
helmet with visor, safety shoes
and protective gloves.
Check the equipment for visible
Àaws or damage before and
after use.
Working under suspended
loads is not permitted where
such loads are being lifted only
by means of hydraulic devices.
If this work is unavoidable,
suitable mechanical supports
are also required.
Check all lines, hoses and
screwed connections for leaks
and externally visible damage,
and repair immediately!
Escaping hydraulic Àuid can
cause injuries and ¿res.

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In the event of malfunctions,
immediately deactivate the
device and secure it. Repair the
fault immediately.
Do not carry out any changes
(additions or conversions) to the
equipment without obtaining the
approval of HURST beforehand.
Observe all safety and danger
information on the device and in
the operating instructions.
All safety and danger
information on the device must
always be 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 mode of operation which
compromises the safety and/
or stability of the device is
forbidden!
Safety devices must never be
disabled! The maximum operating pressure set on the equipment
must not be changed!
Make sure before switching
on/starting up the device and
during its operation, that this will
put no one in danger.
Observe all intervals for
recurring tests and/or
inspections that are prescribed
or stated in the operating
instructions.
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 HURST
accessories and spare parts are
to 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
and therefore possible sparking
must be avoided when handling
the device.
Do not touch the engine and
exhaust system when running
with combustion engine pumps
because of the danger of
burning.
Motorised pumps must not be
operated in areas at risk of
explosion!
Combustion engines must not
be operated in enclosed spaces
because of the danger of
poisoning and / or smothering.

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Keep combustion engines and
their fuels away from sources
of ignition since otherwise there
will be a danger of explosion.
All damaged electrical
components e.g. scorched
cables, etc. are to be replaced
immediately!
In order to prevent the danger
of ¿re, you should ensure
adequate ventilation when
operating combustion engines
and you must keep a safety
distance of at least 1m (39.4 in.)
to walls and other screens.
Damage to electrical
components must only
be repaired by a quali¿ed
electrician in compliance with
all applicable national and
international safety guidelines
and regulations.
Make sure that the combustion
engines are always standing on
as Àat and horizontal a surface
as possible to prevent fuel from
leaking out.
When setting up the units, you
must make sure that they are
not impaired by the inÀuences
of extreme temperatures.
The equipment is ¿lled with
hydraulic Àuid. This hydraulic
Àuid can be detrimental to
health if it is swallowed or its
vapour is inhaled. Direct contact
with the skin must be avoided
for the same reason. Also,
when handling hydraulic Àuid,
note that it can negatively affect
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 severe
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.
Make sure there is adequate
lighting while 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 easily accessible at
the place of operation.
Ensure the proper disposal of
all removed parts, leftover oil,
hydraulic Àuid and packaging
materials.
If you spill any fuel when using
combustion engines, you
must remove the spilled fuel
completely before starting the
engine.
Refuelling whilst the engine is
running is strictly prohibited!

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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.
WARNING/CAUTION!
The device is intended exclusively for the purpose stated in the operating instructions
(see chapter "Proper Use"). Any other use is not in accordance with its designated
use. The manufacturer/supplier is not liable for any damages resulting from improper use.
The user bears sole responsibility for such use.
Proper use includes observance of the operating instructions and compliance with the
inspection and maintenance conditions.
Never work in a fatigued or intoxicated state!
WARNING/CAUTION!
If you still injure yourself on the hydraulic unit, clean the wound immediately and
consult a doctor to have it attended to!
If you get hydraulic Àuid in your eye, rinse it immediately several times with clear,
clean water and consult a doctor!
Also, if you swallow hydraulic Àuid you should consult a doctor!

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3. Proper use
You can obtain accessories and replacement parts for the rescue apparatus from your
authorised HURST dealer!
WARNING/CAUTION!
The safety instructions in this operating instruction manual concerning the site of
erection and type of erection must always be observed!
HURST hydraulic units are specially designed to supply HURST rescue equipment with
hydraulic Àuid so that this equipment can be used to rescue victims of road, rail or air traf¿c
accidents as well as from buildings.
Their use for supplying pressure / Àuid to rescue equipment of other manufacturers is
possible, yet requires the technical inspection and approval by HURST in each individual
case.
ATTENTION!
When selecting the units to connect to the unit, bear in mind that the maximum
possible useable volume of hydraulic Àuid is limited.
The sum of the max. required operating volume (hydraulic Àuid) of all connected
equipment must not exceed the maximum possible usable volume of the power
unit!
NOTE:
Always register your hydraulic unit on the HURST Jaws of Life internet site. This
is the only way to guarantee your extended warranty cover.
Before you use couplings from a different company, you must contact HURST
or an authorised dealer.
HURST ML-630 units are not explosion protected!
When using the equipment in explosion-risk areas you must make sure that
operation of the unit does not trigger an explosion!
The responsibility for explosion prevention or for ruling out work with the ML-630
rests with the operator of the device or with the person responsible at the place
of use.
When working in areas at risk of explosion, all applicable legal,
national and international regulations, standards and safety rules
for avoiding explosions must be observed without limitation!
The equipment should not come into contact with acids or alkalis. If this is
unavoidable, clean the equipment immediately afterwards with a suitable cleaning
agent.
CAUTION!
The ML-630 power units were not developed for being operated without hoses
or devices (operating time < 15 minutes).

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4. Power unit designation
ML 630 SI
Coding for hydraulic
power units
Type group
Valve variants
Valve variant:
SI = Simultaneous operation
In the case of all HURST hydraulic power units, the hydraulic pump is operated with a motor.
The pump conveys the Àuid from the hydraulic oil tank and builds up the pressure in the tool.
Fluid is distributed to the connected equipment through control valves.
The ML-630-SI is a power unit with frame and with a gasoline engine and simultaneous
operation.
5. Functional description
5.1 General information

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5.2 Installation of the power unit
175
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10
2
11
12
13
14 15
1 Gasoline tank
2 Hydraulic Àuid tank
3 Engine with hydraulic pump
4 Connecting block with
control valves
5 Speed adjusting lever
6 Carrying handle
7 Cable-pull starter
8 Valve control lever
9 "TURBO" control lever
10 Mono-coupling (female)
11 Fuel tank cap
12 Filler cap hydraulic Àuid
13 Frame
14 Rubber buffer
15 Side panel
16 Air ¿lter
17 Choke
18 Fuel tap
19 ON/OFF switch (engine
switch)
22 Engine oil ¿ller cap/dipstick
23 Fill level indicator
Equipment back
16
17 18 19
23
22

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5.3 Motor
WARNING/CAUTION!
See also the separate operating instructions of each engine manufacturer
accompanying the delivery.
5.3.1 Gasoline engine
These hydraulic units are equipped with a combustion engine driven by the fuel "gasoline".
The power units are equipped with a cable-pull starter with which the engine is started.
(For specific details, please consult the separate operating instructions of the engine
manufacturer!)
NOTE:
The engine installed in the HURST power units does not match every detail of
the engine described in the manufacturer's separate operating instructions.
Nevertheless, it is important that you follow all safety rules and operating,
maintenance and storage instructions in the separate engine instructions as
absolute since they are not affected by adjustments made by HURST.
HONDA motors have a main switch that must be activated to switch the power unit on and
off. The speed adjusting lever on these power units has two switch positions.
Switch position 1 (standard): Speed 3000 1/min " " and
Switch position 2: Speed 3800 1/min " ".
The setting is adjusted by moving the speed adjusting lever.

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5.4 Valves
Both valves of the power unit in the pump block are ¿xed in place. The pump block is fully
integrated into the hydraulic power unit. The hose assemblies (pressure line (grey) and
return (blue)) must be connected to the pump block. The rescue equipment is connected
to the hose assemblies. Model ML-630 units are equipped with a SIMO connecting block.
The connecting block of the ML-630-SI also has a TURBO function.
With a switching lever, either both connected devices can be supplied simultaneously with
hydraulicÀuid,orasingledevice can be suppliedwithdoublethevolume(=TURBOfunction).
By supplying at double the feed rate, the speed of the connected device is increased.
The hoses are connected with the connecting block via mono-couplings.
5.4.1 Control valve "simultaneous operation" (SIMO)
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 that two devices can be supplied with pressure
simultaneously and independently of each other. Without impairing the work output, it
enables work with two devices simultaneously and independently of each other.
ATTENTION!
When operating several pieces of rescue equipment with one unit, ensure
that the usable volume of hydraulic Àuid in the power unit is greater than the
maximum possible operating Àuid volume of all connected rescue equipment.

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The HURST hydraulic power units model ML-630 are equipped with a SIMO connecting
block. The pump is rigidly connected to the connecting block.
Double-Àow pump for operating with SIMO valve
The pump used always has two pressure stages per pump feed Àow, one low pressure and
one high pressure.
Low-pressure level (LP) = up to 14 MPa*
High-pressure level (HP)= up to 50 MPa*
The changeover from low pressure to high pressure is carried out automatically by the pump.
This system is secured with a pressure limiting valve. Therefore, the maximum permissible
system pressure cannot be exceeded.
5.5 Pumps
*) 1 MPa = 10 bar)
5.6 Frame with side sections
The ML-630 hydraulic power unit is mounted within a frame.
The frame and side panels are also used, despite the robust design, to protect the power unit
from external inÀuences, such as for example, dirt or damage.
5.7 Connection to the rescue equipment
Connection to the rescue equipment is via extension hose pairs or via hose reels. They are
supplied in various lengths.
(For specific details, please consult the HURST range of accessories or contact your
HURST dealer.)
WARNING/CAUTION!
For safety reasons, the pressure set on this valve must not be adjusted (without
the approval of HURST directly)!

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ATTENTION!
When connecting the hose assemblies / units, always ensure that the connection
components are not dirty. Clean prior to use if necessary!
WARNING/CAUTION!
Before connecting the equipment, make sure that all the
components used are suitable for the maximum operating
pressure of the hydraulic unit! In cases of doubt, you must
consult HURST directly before connecting the equipment!
6. Connecting the hoses / devices
Mono-coupling
halve (male) Mono-coupling
halve (female)
Dust protection caps
The hose lines / units 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 swapped over.
Coupling the mono-couplings

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B
AC
C
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 has been made and locked. Decoupling is
accomplished by turning the locking sleeve in direction "0".
Coupling of the hose assemblies when under pressure is also possible, assuming that the
connected equipment is not turned on.
NOTE:
We recommend connecting the coupling halves in a depressurised state
when working in areas with low ambient temperature and using extension hose
assemblies / hose reels, as otherwise the coupling may require the application
of a great deal of force.
For dust protection, the supplied dust caps must be re¿tted.
Using the dust protection caps:
The dust protection caps "A" have two external grooves "B". The dust protection caps must
be inserted in the female coupling in such a way that the grooves can be guided over the pins
"C". Screw in the dust protection caps to the stop to ¿x in the female couplings.

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7. Set-up and start-up
7.1 Set-up
7.2 Start-up
WARNING/CAUTION!
Because of possible spark formation, combustion engine units and electrical
equipment cannot be used in an explosion-risk area. 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 (secure location / Àat surface / suf¿cient distance
from vehicles, loads, sources of ignition, etc.).
HURSTunitsworkperfectlyatanangleofupto20°.However,inordertoguaranteemaximum
safety and Àuid withdrawal, they should be operated in as horizontal a position as possible.
ATTENTION!
Never mix up the fuel and hydraulic Àuid tanks when ¿lling the tank; this can
damage the power unit!
NOTE:
The engine oil level must be inspected before the ¿rst commissioning or after
longer periods of storage. First ¿ll the engine or top up the engine oil!
For safety reasons, HURST power units do not contain engine oil upon delivery!
7.2.1 First commissioning - Power unit without engine oil, hydraulic fluid and gasoline.
1. Pour in the engine oil according to the instructions
in the scope of delivery included with the separate
manufacturer operating instructions regarding the ¿ller
opening (engine oil ¿ller cap, see chapter "Installation of
the power unit").
2. Pour hydraulic oil into the hydraulic Àuid tank until the ¿ll
level indicator in the viewing window is between MIN/
MAX (see illustration on the right). The upper mark
shows the absolute ¿ll level when connecting additional
equipment with increased usable volume. The resulting
¿ll quantity is up to 3.0 l.
3. Pour fuel (gasoline) into the tank until the ¿ll level is just
below the ¿ller opening. If the power unit is resting on
an inclined surface, do not ¿ll the tank to its maximum
capacity.
Hydraulic oil
¿ll level indicator

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4. Now bleed the hydraulic power unit:
5. Set all levers of the distributor valve to circulation at static pressure (see also the chapter
"Valves"). Open and remove the tank cap so that air enters the tank.
6. Open the venting plug on the pump block, tilt the power unit backwards by approx. 45°
(see illustration) and wait until oil comes out from the bolt.
7. When oil comes out at the venting plug, the air has been removed from the pump. First
close the venting plug and then return the power unit to the level.
8. Check the Àuid levels. Top up if necessary.
9. Now connect the extension hoses and/or hose reels (unless already connected to the
unit) and/or couple the rescue equipment.
Venting plug
Pump block ML-630-SI

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7.2.3 Commissioning (after the first filling or prior to use)
1. Check the Àuid level of the engine oil, the hydraulic Àuid and the fuel tank. Top up if
necessary. For precise reading off of the Àuid levels and for ¿lling, the hydraulic unit
should be as level as possible.
2. Now connect the extension hoses and/or hose reels (unless already connected to the unit)
and/or couple the rescue equipment.
Before starting the combustion engine, check that the fuel tank is full and that the engine oil
level is within the permitted tolerances. If necessary, top up the relevant Àuid.
1. Open the gasoline tap
2. Set the ON/OFF switch to the ON position.
3. Move the lever from switching position A to switching
position B (choke) when starting cold
4. Pull the cable-starter.
5. When the motor is running, switch the lever back to
position A.
For the detailed procedure for starting the
combustion engine, please see the
separate operating instructions of the engine manufacturer!
ATTENTION!
The control levels on the hydraulic power unit should always be switched to the
neutral position (de-pressurised) prior to starting the engine in order to prevent
unwanted movements of connected hydraulic equipment and to start the power
unit without hydraulic load.
B
A
8.1 Starting the engine
8. Operation