HURST P 650 User manual

275710085 EN
Hydraulic power units P 650
(Original instruction manual)
replaces 01.2014
Instruction manual for rescue equipment
Edition 11.2014
Built to extend lives.™

2

3
1.Hazard classes 5
2.Product safety 6
3.Intended use 10
4.Labelling of the units 11
5.Functional description 11
5.1 General information 11
5.2 Structure of the units 12
5.3 Motor variants 13
5.4 Valve variants 14
5.5 Pumps 15
5.6 Frame with side parts 15
5.7 Connection to the rescue equipment 15
5.8 Hose reels 16
5.9 Carrying handle 16
5.10 Toolholder 16
6.Connection of the hose lines / devices 17
7.Set-up and start-up 19
7.1 Set-up 19
7.2 Start-up 19
8.Operation 20
8.1 Starting the motor/engine 20
8.2 Stopping the motor/engine 21
8.3 Refuelling (combustion engines only) 22
8.4 Controlling the valves 22
8.5 Hose reels 24
8.6 Telescopic carrying handles 26
8.7 Toolholder 27
9.Removing the device / deactivation following operation 32
10.Tests 33
10.1 Recommended inspection intervals 33
10.2 Hydraulic units with combustion engine 34
10.3 Hydraulic units with electric motor 35
10.4 Hose reels 36
Contents Page

4
11.Maintenance and repair 36
11.1 General information 36
11.2 Maintenance work on the hydraulic unit 37
11.3 Additional maintenance work on units with a combustion engine 39
11.4 Maintenance work on mounted hose reel 43
12.Troubleshooting 46
13.Technical data 53
13.1 Unit 53
13.2 Noise emissions 60
13.3 Sparking plug 60
13.4 Sparking plug socket 60
13.5 Fuel 60
13.6 Engine oil 61
13.7 Hydraulic fluid recommendation 61
13.8 Operating and storage temperature range 61
14.EPA Warranty 62
15. Declaration of Conformity 65
16. Notes 66
Contents Page

5
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 speci¿c hazard
and possible consequences.
1. Hazard classes
Pictogram Damage /
injury to Key word Definition Consequences
People
DANGER! Immediate danger Death or major
injury
WARNING!
Potentially
dangerous
situation
Potential death or
major injury
CAUTION! Less dangerous
situation
Minor or slight
injury
Objects
ATTENTION!
Danger of damage
to objects /
environment
Damage to the
equipment,
damage to the
environment,
damage to
surrounding
materials
- NOTE
Advice for
application and
other important /
useful information
and advice
No injury /
damage to
persons /
environment /
equipment

6
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 the product design.
Moreover, the operating instructions are intended to help the safe use of HURST 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 complied with in addition to
the operating instructions.
The device 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 carefully read and adhere to the
operating instructions before they use the equipment.
We further recommend that a quali¿ed 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 the following safety notes 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.
Immediately report any
changes that occur (including
changes in operating behavior)
to the appropriate persons/
departments! If necessary,
deactivate the device
immediately and secure
against restart!
Wear protective clothing,
safety helmet with visor, safety
shoes and protective gloves.
Inspect the device for visible
defects or damage before and
after use
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.
Check all lines, hoses and
screwed connections for leaks
and externally visible damage,
and repair immediately!
Escaping hydraulic Àuid can
cause injuries and ¿res.

7
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 prior approval from
HURST.
Observe all safety and danger
notes on the device and in the
operating instructions.
All safety and danger notes
on the device 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 mode of operation which
impairs safety and/or stability
of the device is forbidden!
Safety devices must never be
deactivated!
The maximum operating
pressure set on the equipment
must not be changed!
Before the device is switched
on/started up, and during its
operation, it must be ensured
that nobody is endangered by
the operation of the device.
Comply with all speci¿ed
dates or dates speci¿ed in
the operating instructions
pertaining to regular checks /
inspections of the equipment.
When working in the proximity
of live components and
wires, appropriate steps must
be taken to avoid current
transmission or high-voltage
discharge through the device.
Only genuine 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
with the potential consequence
of spark formation is to be
avoided when handling the
device.
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!

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.
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 ¿re
when using combustion
engines, ensure suf¿cient
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 quali¿ed
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 Àat 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 inÀuences
of extreme temperatures.
The device is ¿lled with
hydraulic Àuid. These hydraulic
Àuids can be harmful to your
health if swallowed or if their
vapors inhaled. Direct contact
with the skin is to be avoided
for the same reason. Please
also note that hydraulic Àuids
can also have a negative
effect on biological systems.
When working with or storing
the device, ensure that the
function and the safety of the
device are not impaired by the
effects of extreme external
temperatures or that the
device is damaged in any way.
Please note that the device
can also heat up over a long
period of use.
Ensure adequate lighting
when you are working.
Before transporting the
device, always ensure that the
accessories are positioned
such that they cannot cause
an accident.
Always keep these operating
instructions within reach where
the device is used.
Ensure the proper disposal of
all removed parts, leftover oil,
hydraulic Àuid and packaging
materials.

9
WARNING / CAUTION / ATTENTION!
The device is to be used exclusively for the purpose stated in the operating instructions
(see chapter "Intended Use"). Any form of use beyond this is not considered intended
use. The manufacturer / supplier is not liable for any resulting damages. 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 de¿nition of intended use.
Never work when you are overtired or intoxicated!
WARNING / CAUTION!
Should you sustain an injury while working with the hydraulic unit, clean the
wound immediately and seek medical attention!
If hydraulic Àuid enters your eye, rinse immediately several times with clear, clean
water and seek medical attention!
You should also seek medical attention after ingesting hydraulic Àuid!

10
3. Intended use
You can obtain accessories and replacement parts for the rescue apparatus from your
authorized HURST dealer!
WARNING / CAUTION / ATTENTION!
Always observe the safety notes of these operating instructions with regard to
place of installation and type of installation!
Type P 650 units manufactured by HURST are not explosion-proof!
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.
The P650 power units were not developed for being operated without hoses or devices
(operating time < 15 minutes).
CAUTION!
When selecting a device for connection, remember that the maximum possible
useable volume of the hydraulic Àuid is limited.
The maximum total volume of hydraulic Àuid required by all connected devices
must not exceed the maximum possible useable volume of the unit!
Due to the limited useable volume, a maximum of 2 rescue rams can be
connected for reasons of safety (only at maximum ¿ll quantity).
Type R424 cylinders are an exception to the rule, however.
Two of these cylinders should never be coupled and operated
simultaneously!
NOTE:
Always register your hydraulic unit on the HURST website. This is the only way
to guarantee your extended warranty cover.
You must always contact HURST or an authorized dealer before using couplings
from another manufacturer.
CAUTION!
The P 650 power units were not developed for being operated without hoses
or devices (operating time < 15 minutes).

11
-
4. Labelling of the units
P650 4 G
Coding for
hydraulic units
Type group
Valve variants
Motor variants
DHR
Speci¿cations
(e.g. DHR = with
integral reels)
Valve variants:
S = Simultaneous mode
4 = 4POWER mode
Motor variants:
E = Electric motor (operation via mains supply)
G = Gasoline engine
The hydraulic pump on all HURST hydraulic units is always operated by a combustion
engine or electric motor. The pump conveys Àuid from the reservoir and builds up hydraulic
pressure. The distribution of the Àuid is controlled by mounted valves.
Two versions of type P650 unit are available:
1. small frame without reel
2. large frame with mounted reel
The telescopic carrying handles are an optional accessory for the ¿rst version and can
always be retro¿tted.
The telescopic carrying handles and the toolholder are an optional accessory for the second
version and can always be retro¿tted.
5. Functional description
5.1 General information
ES
with electric starter
-
NOTE:
A hose reel is only included with the second version and cannot be retro¿tted
at a later date!

12
5.2 Structure of the units
1
2
3
4
5
6
7
8
9
10
10
11 12
13
14
14 1515
1 Hydraulic Àuid reservoir
2 Gasoline tank
3 Engine with hydraulic
pump
4 Connecting block with
control valves
5 Engine switch
6 Electric starter button
7 Pull cord starter
8 Valve control lever
9 "TURBO" control lever
10 Mono-couplings
11 Hydraulic Àuid ¿ll cap
12 Gasoline ¿ll cap
13 Frame
14 Side panel
15 Rubber buffer
16 ON/OFF switch for
electric motor
17 Telescopic carrying
handle
(also optionally available
for retro¿tting)
18 Hose reel
19 Crank handle (hose reel)
20 Lock (hose reel)
21 Hose guide
22 Toolholder
10 21
21
17
18
18 20
19
16
17
22
11
12
17

13
5.3 Motor variants
WARNING / CAUTION / ATTENTION!
For all motor variants, also comply with the separate operating instructions of
each motor manufacturer.
5.3.1 Electric motor
These 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 Àuctuations do not occur, as these have a
direct inÀuence 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 chapter entitled „Technical data".
NOTE:
Not all the technical details of the engine installed in HURST units correspond
to the engine described in the separate operating instructions provided by the
manufacturer. Components such as the gasoline tank have been modi¿ed to
guarantee the safety of the overall hydraulic unit because the unit is used for
rescue operations.
However, it is important that you observe all safety regulations and operating,
maintenance and storage instructions included in the separate manual
accompanying the engine without fail because they are unaffected by any
adaptations made by HURST.
If the battery discharges completely after a period of inactivity, you must start the unit using
the cord pull starter and allow the unit to operate until almost a complete tank of fuel has
been consumed. The battery will then be fully charged.
If the battery is still not charged after the unit consumes a full tank of fuel, the causes may
include the following:
- the contacts (connector) have come loose and must be connected again.
- the battery is defective and must be replaced.
- the generator or engine is damaged. In this case, contact HURST customer service
directly.
5.3.2 Gasoline engine
These hydraulic units are equipped with a combustion engine driven by the fuel "gasoline /
gasoline".
Units can be ¿tted with both an electric starter and a pull cord starter, or a pull cord starter
only. It is only possible to determine the unit version from the item number and unit name or
the designation printed on the unit.
The integral generator charges the starter battery automatically while the engine is operating.
NOTE:
Using an extremely long electrical connection cable may reduce the output
resistance and the power supply to the motor. The performance of the motor will
be affected as a result.

14
5.4 Valve variants
The valves are always permanently installed in a connecting block. This block is integrated
directly in the hydraulic unit. Both hose lines (pressure and return) are always connected to
the connecting block. The units are ¿tted either with a SIMO or a 4POWER connecting block.
Both connecting blocks also have a TURBO function.
More speci¿cally, this means that there are always 2 device connections linked internally to
one another. A shift lever gives you the option of supplying hydraulic Àuid to both connected
devices simultaneously or supplying double the quantity to one device (= TURBO function).
Supplying double the quantity of Àuid increases the operating speed of the connected device.
The hoses and devices are always connected to the connecting block via mono-couplings.
On units with a hose reel, only the connection hoses between the hose reel and connecting
block are screwed in position.
CAUTION!
When operating several pieces of rescue equipment with one unit, ensure that
the usable volume of hydraulic Àuid in the reservoir is greater than the maximum
possible operating Àuid volume of all connected rescue equipment.
5.4.1 "Simultaneous mode" (SIMO) control valve
This valve enables the connection of two dual-acting hydraulic devices. The valve allows
you to operate two devices simultaneously and independently of one another or supply a
larger quantity of hydraulic Àuid to one device. Supplying a larger quantity of hydraulic Àuid
increases the operating speed of the relevant device.
There are three switches available. The two smaller switches can be used to depressurize the
individual connections. The large switch is responsible for controlling the TURBO function.
5.4.2 "4POWER mode" control valve
This valve enables the connection of four dual-acting hydraulic devices. The valve allows
you to operate four devices simultaneously and independently of one another or supply a
larger quantity of hydraulic Àuid to a maximum of two devices. Supplying a larger quantity of
hydraulic Àuid increases the operating speed of the relevant devices. The TURBO function
can only be connected between the points either side of the large switch because the device
connections are linked internally.
There are six switches available. The four smaller switches can be used to depressurize
the individual connections. The large switches are responsible for controlling the TURBO
function.
The switches and connections are labelled to make them easier to assign to one another.

15
HURST hydraulic units are equipped with a double-Àow or four-Àow pump depending on the
type. The pumps are permanently connected to the connecting block.
Double-Àow pump for operation with SIMO valve
Four-Àow pump for operation with 4POWER valve
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 (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 in the pump.
The maximum pressure is limited by a pressure limiting valve.
5.5 Pumps
*) 1 MPa = 10 bar
5.6 Frame with side parts
A surrounding frame is ¿tted to all the hydraulic units described here, without exception.
The frame and the side parts are designed to protect the unit from external inÀuences (e.g.
dirt, damage, etc.), to attach accessories (e.g. toolholders) and as a means of transporting
the unit by the frame itself or the optional carrying handles.
The starter equipment and accelerator cable regulator on units with a combustion engine are
mounted on the frame or side parts.
5.7 Connection to the rescue equipment
Connection with the rescue equipment is via extension hose pairs or hose reels. These are
available in various lengths and colored bend protections.
Different colors distinguish the individual hose lines in a hose pair.
(For specific details, please consult the HURST range of accessories or contact your
HURST dealer).
WARNING / CAUTION / ATTENTION!
For reasons of safety, the pressure set on this valve must not be adjusted
(without direct authorization from HURST)!

16
5.8 Hose reels
The hose reels were designed to store extension hose pairs leading between the hydraulic
supply and the working equipment (hose pairs are included in the delivery as standard).
The extension hose pairs are connected to the hose reels and rolled onto the drums.
A hose reel with extension hose pairs can cover long distances between the hydraulic supply
and the working equipment, allowing you to keep the hydraulic unit on a vehicle, for example.
The possibility of rolling up and unrolling the hose allows you to adapt the hose length
accordingly and reduce the amount of unnecessary or potentially dangerous excess hose
lying on the ground.
The extension hose pairs are easier to transport and store when fully rolled up.
Moreover, the hose reels on type P650 units are equipped with a hose guide that facilitates
easier rolling up and unrolling.
The unit is connected to the working equipment via couplings.
CAUTION!
In order to avoid potential losses in pressure, the length of the extension hose
lines must not exceed 30 m!
5.9 Carrying handle
Type P650 HURST hydraulic units can be ¿tted with optional carrying handles. The P650
can be transported more ergonomically using the carrying handles.
NOTE:
Only 2 of the 4 connections can be connected to the hose reel on type
P 650 4G units.
There are 2 coupling connections located between the two reel drums for the
remaining two connections. The lower of the two connections is extendable to
allow easier coupling. It also engages easily in the end positions.
The switches and connections are labelled to make them easier to assign to one
another.
5.10 Toolholder
Type P650 HURST hydraulic units with a hose reel could be ¿tted with a toolholder.
The toolholder is usually designed to attach a SP310 spreader and a type S5xx cutter.
Needless to say, it is possible to adapt the mount to accommodate all HURST cutters and
spreaders as well as modify it at a later date.
The toolholder allows you to transport a unit with devices still attached.
You no longer have to detach and store devices separately after use. You only have to wind
the hose lines onto the reels and position the devices on the toolholder again.
Devices secured to the unit do not pose a risk during transport.

17
CAUTION!
When connecting the hose lines / devices, always ensure that the connection
components are not soiled. Clean beforehand if necessary!
WARNING / CAUTION / ATTENTION!
Before connecting equipment, make sure that allthecomponents
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. Connection of the hose lines / devices
Male coupling Female coupling
Dust protection caps
The hose lines / devices are connected to the hydraulic pump or hose reel via mono-coupling
halves (male and female) without any risk of confusion.

18
B
AC
C
Before coupling, remove the dust protection caps, then connect male and female couplings
and turn the locking sleeve of the female coupling in direction "1" until the locking sleeve
latches. The connection has now been made and locked. Decoupling is accomplished by
turning the locking sleeve in direction "0".
Coupling of the hose lines when under pressure is also possible, assuming the connected
equipment is not turned on.
NOTE:
We recommend connecting the coupling halves in a depressurized state
when working in areas with low ambient temperature and using extension hose
assemblies / hose reels, otherwise the coupling may require the application of a
great deal of force.
For dust protection, the supplied dust caps must be re¿tted.
Fitting the dust protection caps:
The "A" dust protection caps 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 "C"
pins. Screw the dust protection caps to the limit stop to ¿x in the female couplings.

19
7. Set-up and start-up
7.1 Set-up
7.2 Start-up
WARNING / CAUTION / ATTENTION!
Combustion engine units and 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 / Àat surface / suf¿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 Àuid withdrawal, they should be operated in as level a position as possible.
Please proceed as follows:
1. First of all, check the Àuid levels in the unit.
Top off the Àuids to the top of the reservoir to reach maximum level. If possible, the
hydraulic unit should be positioned on a level surface when the Àuid levels are checked
and the reservoirs ¿lled.
CAUTION!
Always ¿ll fuel and hydraulic Àuid into the correct reservoir otherwise the unit
may sustain damage!
2. On hydraulic units with an electric motor, connect the plug to the power supply at this
point.
3. Then vent the hydraulic unit. Set all levers on the control valves to the neutral position
(see chapter "Operation"). The actual venting is carried out in the units in a different
manner, depending on the drive motor:
a) Gasoline engine:
- Detach all connectors from the sparking plugs (on the back of the unit).
- Slowly turn the engine over with the starter rope several times.
- Then replace the sparking plug connector.
b) Electric motor (mains power operation):
- Switch the motor on and then off again after approx. 10 seconds, repeat
this procedure several times. (Before switching back on,
the motor must be at a standstill!)
NOTE:
Before commissioning the unit for the ¿rst time or after longer periods of inactivity,
the starter battery must be connected and the engine oil checked (units with a
combustion engine)! Replenish the engine oil if necessary!
HURST units are delivered without engine oil for reasons of safety!

20
8. Operation
CAUTION!
The control levers on the hydraulic unit must be shifted to neutral position before
the motor/engine is started to prevent connected hydraulic equipment from
moving unexpectedly.
Levers on units with a Toolholder should only be shifted back after you have
removed the devices from the mount and intend to start work.
8.1 Starting the motor/engine
NOTE:
If the engine refuses to start after several attempts, repeat the procedure
described above with the engine switch set to the "ON" position.
3. When the engine starts, keep hold of the handle on the pull cord starter and allow it to
return to its starting position.
4. Allow the engine to warm up for 20 to 30 seconds and then set the engine switch to the
"ON" position (if previously set to "CHOKE").
Starting procedure:
1. Set the engine switch to the "CHOKE" position
( ) (if the engine is already warm or the ambient
temperature is high, start the engine with the
switch in the "ON" position.)
2. Starting with electric starter:
Press the starter button
Starting with pull cord starter:
Slowly pull the handle on the pull cord starter
beyond the compression point (resistance is felt).
Allow to return to the starting position and pull
again quickly all the way out.
8.1.1 Gasoline engines
Before 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 off the relevant Àuid.
This procedure means that the pump can slowly draw Àuid in and be well vented. The
hydraulic Àuid reservoir is equipped with automatic venting, which means no further
venting measures are required.
4. Check the Àuid levels in the reservoirs again. If necessary, top off the Àuid.
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.