HURST P 630 SG User manual

275070085 EN
Hydraulic power unit P 630 SG
(Original instruction manual)
replaces 07.2020
Instruction manual for rescue equipment
Edition 05.2021
Built to extend lives.™

2
Content Page
1. Dangerclassications 4
2. Productsafety 5
3. Intendeduse 9
4. Powerunitdesignation 10
5. Functionaldescription 10
5.1 General information 10
5.2 Installation of the power unit 11
5.3 Motor 12
5.4 Valves 13
5.5 Pumps 14
5.6 Frame with side sections 14
5.7 Connection to the rescue equipment 14
6. Connectingthehoses/devices 15
6.1 Coupling the mono-couplings 15
7. Set-upandcommissioning 17
7.1 Set-up 17
7.2 Commissioning 17
8. Operation 19
8.1 Starting the engine 19
 8.2 Turningtheengineo 20
8.3 Refuelling 20
8.4 Controlling the valves 21
9. Dismantlingtheequipment/deactivationfollowingoperation 22
10.Tests 23
10.1 Recommended test intervals 23
10.2 Visual and function check 24
11.Maintenanceandrepair 25
11.1 General information 25
11.2 Service work on the hydraulic unit 26
11.3 Additional service work 28

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Content Page
12.Faultanalysis 33
13.Technicaldata 38
13.1 Power Unit 38
13.2 Noise emissions (sound pressure level) 40
13.3 Sparking plug 40
13.4 Sparking plug spanner 40
13.5 Fuel 40
13.6 Engine oil 41
 13.7 Hydraulicuidrecommendation 41
13.8 Operating and storage temperature range 41
14.Notes 42

4
 Wearahelmetwithafaceguard
 Wearprotectivegloves
 Wearsafetyshoes
 Properrecycling
 Protecttheenvironment
 Readandfollowoperatinginstructions
Wedi󰀨erentiatebetweenvariousdi󰀨erent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 classications
Pictogram Damage /
injury to Key word Denition 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

5
2. Product safety
HURST 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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.
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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
aws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uidcan
causeinjuriesandres.

6
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at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inuences
ofextremetemperatures.
Theequipmentislledwith
hydraulicuid.Thishydraulic
uid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uid,
notethatitcannegativelya󰀨ect
biologicalsystems.
Whenworkingwithorstoring
theequipment,ensurethatthe
functionandthesafetyofthe
equipmentarenotimpaired
bythee󰀨ects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uid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!

8
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uidinyoureye,rinseitimmediatelyseveraltimeswithclear,
cleanwaterandconsultadoctor!
Also,ifyouswallowhydraulicuidyoushouldconsultadoctor!

9
3. Intended 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uidsothatthisequipmentcanbeusedtorescuevictimsofroad,railorairtra󰀩c
accidentsaswellasfrombuildings.
Their use for supplying pressure / uid 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uidislimited.
Thesumofthemax.requiredoperatingvolume(hydraulicuid)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di󰀨erentcompany,youmustcontactHURST
oranauthoriseddealer.
HURSTP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P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P630powerunitswerenotdevelopedforbeingoperatedwithouthoses
  ordevices(operatingtime<15minutes).

10
4. Power unit designation
P 630 S G
Codingforhydraulic
powerunits
Typegroup
Valvevariants
Motorvariants
Valve variants:
 S = Simultaneousoperation
Motor variants:
 G = Gasolineengine
InthecaseofallHURSThydraulicpowerunits,thehydraulicpumpisoperatedwithamotor.
Thepumpconveystheuidfromthehydraulicoiltankandbuildsupthepressureinthetool.
Fluidisdistributedtotheconnectedequipmentthroughcontrolvalves.
The P 630 SG is a power unit with frame and with a gasoline engine and simultaneous
operation.
5. Functional description
5.1 General information

11
5.2 Installation of the power unit
175
4
3
9
10
2
11
12
13
14 15
1 Gasolinetank
 2 Hydraulicuidtank
 3 Enginewithhydraulicpump
 4 Connectingblockwith
controlvalves
 5 Speedadjustinglever
 7 Cable-pullstarter
 9 "TURBO"controllever
10 Mono-coupling(female)
11 Fueltankcap
12 Fillercaphydraulicuid
13 Frame
14 Rubberbu󰀨er
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

12
5.3 Motor
WARNING/CAUTION!
 See also the separate operating instructions of each engine manufacturer
accompanyingthedelivery.
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 specic 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a󰀨ectedbyadjustmentsmadebyHURST.
HONDA motors have a main switch that must be activated to switch the power unit on and
o.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P630unitsareequippedwithaSIMOconnectingblock.
TheconnectingblockoftheP630SGalsohasaTURBOfunction.
Witha“TURBO”controllever,eitherbothconnecteddevicescanbesuppliedsimultaneously
withhydraulicuid,orasingledevicecanbesuppliedwithdoublethevolume(=TURBO
function). 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.
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 uidin thepower unitis greaterthan the
maximumpossibleoperatinguidvolumeofallconnectedrescueequipment.

14
TheHURSThydraulicpowerunitsmodelP630areequippedwithaSIMOconnectingblock.
Thepumpisrigidlyconnectedtotheconnectingblock.
 Double-owpumpforoperatingwithSIMOvalve
Thepumpusedalwayshastwopressurestagesperpumpfeedow,onelowpressureand
onehighpressure.
 Low-pressurelevel(LP) = upto14MPa*
 High-pressurelevel(HP)= upto70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P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inuences,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specic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)!

15
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.
6.1 Coupling the mono-couplings
0
1
0

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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 commissioning
7.1 Set-up
7.2 Commissioning
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/atsurface/su󰀩cientdistance
fromvehicles,loads,sourcesofignition,etc.).
HURSTunitsworkperfectlyatanangleofupto20°.However,inordertoguaranteemaximum
safetyanduidwithdrawal,theyshouldbeoperatedinashorizontalapositionaspossible.
ATTENTION!
Nevermixupthefuelandhydraulicuid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uid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uid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

18
4.Nowbleedthehydraulicpowerunit:
5.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uid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P 630 SG

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7.2.3 Commissioning(aftertherstllingorpriortouse)
1.Check the uid level of the engine oil, the hydraulic uid and the fuel tank. Top up if
necessary. For precise reading o󰀨 of the uid 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uid.
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!
B
A
8.1 Starting the engine
8. Operation

20
Theenginemustbeswitchedo󰀨forrefuelling!
Procedure:
1. Openthefueltankcap.
2. Fillthetankwithfueluntilthelllevelisjustbelowthelleropening.
3. Closethefueltankagainwiththefueltankcap.
WARNING/CAUTION!
Besurenotto spillfuel.Inparticular,hotenginepartsmustnotcomeinto
contactwithfuel;dangerofreotherwise!
Iffuelisspilled,itmustbecleanedupimmediatelywithasuitableabsorbent
cloth.Indoingso,becarefulnottoburnyourselfononeofthehotengine
parts!Theusedclothmustthenbecleanedordisposedofaccordingtothe
relevantprovisionsandguidelines!
8.3 Refuelling
1.SettheON/OFFswitchtotheOFFposition.
2.Whentheenginehascometoastandstill,closethe
fueltap.
For more details on switching o the engine, please refer to the separate operating
instructions of the engine manufacturer!
CAUTION!
Nevertouchhotengineparts:thiscouldresultinsevereburns!
8.2 Turning the engine o󰀨