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Summary of Contents for Lukas LC 99
- Page 1 Operating instructions for rescue equipment LC 99 cutter 84150643186 EN Edition 06.2019 (Translation of original operating instructions)
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Page 2: Table Of Contents
Content Page 1. Danger classifications 2. Product safety 3. Appropriate use 4. Functional description 4.1 Description 4.2 Unit in detail 4.3 Wiring diagram 4.4 Control of the operating movements 4.5 Hydraulic supply 4.6 Hoses 5. Connecting the device 5.1 General information 5.2 Coupling of (Flat-Face) quick-disconnect coupling 6. Operation 6.1 Preparatory measures 6.2 Operating the cutter... - Page 3 Content Page 10. Troubleshooting 11. Technical data 11.1 Recommended hydraulic fluids 11.2 Operating and storage temperature ranges 12. EC Declaration of Conformity 13. Notes...
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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 Key word Definition Consequences injury to Death or severe DANGER! Immediate danger injury Potentially Potential death or WARNING! dangerous serious injury situation Less dangerous Minor or slight CAUTION! situation injury Damage to the equipment, Risk of damage damage to the ATTENTION! to property/ environment, environment damage to surroundings Handling tips and No injury/damage other important/... -
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 operating instructions are intended to help in using LUKAS products safely. In addition to the operating instructions, all generally applicable, statutory and other binding rules for accident prevention and for environmental protection must be complied with and instructed. 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 be carefully followed. We also recommend that you have a qualified trainer show you how to use the product. - Page 6 In the event of malfunctions, Do not carry out any changes immediately deactivate the (additions or conversions) equipment and secure it. to the equipment without Repair the fault immediately. obtaining the approval of LUKAS beforehand. Observe all safety and danger All safety and danger information on the device and information on the device in the operating instructions. must always be complete and in a legible condition. Any mode of operation which Observe all intervals compromises the safety and/ for recurring tests and/ or stability of the device is or inspections that are forbidden! prescribed or stated in the operating instructions. Safety devices must never be The maximum permitted disabled! operating pressure noted on the equipment must not be exceeded. Make sure before switching Only genuine LUKAS on/starting up the device and accessories and spare parts during its operation that this are to be used for repairs. will put no one in danger. Please ensure that, when working with this equipment or during transportation of such, you don’t get caught up...
- Page 7 The equipment is filled with When working with or storing hydraulic fluid. This hydraulic the equipment, ensure that the fluid can be detrimental to function and the safety of the health if it is swallowed or equipment are not impaired its vapour is inhaled. Direct by the effects of severe contact with the skin must be external temperatures or that avoided for the same reason. the equipment is damaged in Also, when handling hydraulic any way. Please note that the fluid, note that it can negatively equipment can also heat up affect biological systems. over a long period of use. Make sure there is adequate Before transporting the lighting while working. equipment, always ensure that the accessories are positioned in such a way that they cannot cause an accident. Always keep these operating Ensure the proper disposal of instructions easily accessible all removed parts, left-over oil at the place of operation. and hydraulic fluid as well as packaging materials! The generally applicable, legal and other binding national and international regulations pertaining to the prevention of accidents and protection of the environment apply and are to be implemented in addition to the operating instructions.
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Page 8: Appropriate Use
3. Appropriate use LUKAS cutters have been specially designed to rescue or retrieve the bodies of victims of road, rail or aircraft accidents or to be used during rescue operations from buildings. They serve the purpose of freeing injured people in accidents e.g. by cutting pedals or spokes. -
Page 9: Functional Description
- explosive bodies such as air bag cartridges. NEVER operate the rescue equipment at a higher operating pressure than that stated in the chapter “Technical data”. A higher setting may cause property damage and/or injuries. LUKAS rescue equipment may only be used in areas at risk of explosion if an explosion has been prevented by appropriate measures. You must also take into account the fact that sparks may be created, for example by cutting an object. When working in explosive areas, all applicable legal, national and international regulations, standards and safety rules for avoiding explosions must be observed without restriction. -
Page 10: Unit In Detail
4.2 Unit in detail 1 Body of rescue tool 2 Handle 3 Protective cover 4 Blade 5 Flat-Face coupling... -
Page 11: Wiring Diagram
4.5 Hydraulic supply Only LUKAS hand pumps may be used to drive the equipment. If the hand pump is a different make, you must make sure that it complies with LUKAS specifications, otherwise potential dangers may occur, for which LUKAS cannot be held responsible. Ensure in particular that the authorised operating pressure for LUKAS equipment is not exceeded. -
Page 12: Connecting The Device
5.1 General information WARNING / CAUTION / ATTENTION! Prior to connecting the device, ensure that all the components being used are suitable for the maximum operating pressure of the pump unit. In case of doubt, you must contact LUKAS directly. A Flat-Face coupling is mounted on the device which is connected to the hand pump via a hose line. The hose is equipped with couplings so that it can be connected without error. 5.2 Coupling of (Flat-Face) quick-disconnect coupling The device is connected to the hand pump without the risk of connection error using Flat-Face quick-disconnect coupling halves (female and male). -
Page 13: Operation
6. Operation 6.1 Preparatory measures 6.1.1 Commissioning Before commissioning and after repairs, the equipment must be de-aerated. Procedure: The piston is extended when free from load by operating the hand pump. The hand pump must be positioned higher than the device being de-aerated. Then the drain valve on the hand pump is opened so that the cylinder retracts via the spring return. The sealing cap on the oil tank must be open. The air is pressed back into the oil tank by the retracting piston via the hose line and escapes through the sealing cap. If the pistons move jerkily when retracting, the de-aeration process must be repeated. 6.1.2 Inspection of the hand pump See separate operating instructions for the corresponding hand pump. 6.2 Operating the cutter 6.2.1 Cutting The blades must be positioned at a 90° angle to the object to be cut. Operate the pump lever until the object to be cut is cut through. After cutting, open the discharge lever to the left. The movable cutting jaw returns to its initial position. 6.2.2 Decoupling of pump and device Before separating the pump from the device, make sure by opening the drain valve, that there is no pressure and that the device’s piston is fully retracted. -
Page 14: Dismantling The Equipment / Deactivation Following Operation
6.2.3 Operation: Safety instructions The following must be worn when working with the rescue equipment: • Uniform or protective clothing, • Safety helmet with visor or protective goggles, • Protective gloves. The particular effect of the force of the rescue equipment during operation could cause pieces to break off or separate, posing a danger to persons. Measures must be taken to ensure that neither operators nor persons not involved in the work are put in danger. -
Page 15: Maintenance And Service
8. Maintenance and service The device is subject to very high levels of mechanical stress. Therefore, a visual inspection must be carried out after every use and at least once a year. These inspections enable the early detection of wear and tear, which means that punctual replacement of this wearing parts prevents breakages from occurring. Every 3 years or when there might be doubts regarding the safety or reliability of the unit, an additional function check is to be carried out (in this connection, comply with the applicable national and international regulations with regard to the maintenance intervals of rescue equipment). -
Page 16: Repairs
You should always contact LUKAS or an authorised dealer before using couplings from another manufacturer. ATTENTION! Because LUKAS rescue equipments are appropriate for highest achievements, only components may be exchanged, which are specified in the spare parts list of the appropriate equipment. Other components of the device may only be replaced if: - You have participated in an appropriate LUKAS service training course. - You have the explicit permission of LUKAS Customer Service (on request, verification that permission may be granted. To be checked in each individual case!) 9.2 Preventative service 9.2.1 Care instructions The exterior of the equipment is to be cleaned from time to time in order to protect it from external corrosion. Oil is to be applied to the metallic surfaces. 9.2.2 Function and load test If there is any doubt regarding the safety or reliability of the equipment, a function and load test must also be performed. -
Page 17: Repairs
9.2.3 Replacing the hydraulic fluid - The hydraulic fluid must be replaced after approx. 200 deployments, but after three years at the latest. - It must always be changed whenever the hydraulic fluid for the accompanying hand pump is changed. This is to prevent the fresh hydraulic fluid from becoming contaminated by the used fluid from the rescue equipment. ATTENTION! Always replace the hydraulic fluid over a liquid collection container and dispose of the collected fluid in a proper manner. ATTENTION! The hydraulic fluid must be completely replaced if the application conditions (ambient temperatures) change substantially. When selecting a suitable hydraulic fluid, please refer to the chapter “Recommended hydraulic fluids”. Procedure: 1. Retract the cutter fully and depressurise the hydraulic system. 2. Remove the coupling on the cutter. 3. Drain off the hydraulic fluid. 4. Flush 5. Reassemble the coupling. 6. Connect hand pump with fresh hydraulic fluid. - Page 18 9.3.2 Flat Face quick-disconnect coupling The quick-disconnect couplings must be replaced if: - there is external damage, - the lock does not work, - hydraulic fluid continues to leak in the coupled and/or uncoupled state. WARNING / CAUTION / ATTENTION! Never repair couplings: they must be replaced by genuine LUKAS parts! Procedure: 1. Dismantle the coupling from the swivel screw connection of the cutter. 2. Install a new coupling on the swivel screw connection of the cutter and tighten with a torque of M A = 45 Nm (33.2 lbf x ft) A = 45 Nm (33.2 lbf x ft) (use Teflon tape). 9.3.3 Replacing the protective cover - Remove rounded head screw - Remove old protective cover - Fit new protective cover - Retighten the rounded head screw with M A = 0.5 Nm (0.37 lbf x ft).
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Page 19: Troubleshooting
Hydraulic coupling Tighten hydraulic couplings are fully loose. coupling. tightened. Air in hydraulic Vent hydraulic system in system. accordance with section 6.1. Check the cylinder Cylinder piston Have the damage for damage. jams. repaired by an authorised dealer, by personnel specially trained by LUKAS, or by LUKAS itself. Cylinder extends, but Check that all Leaky connection. Tighten loose connection. does not maintain the connections are pressure. fully tightened. Check the cylinder Leaking seals. Have the leaks repaired for leaks. by an authorised dealer, by personnel specially trained by LUKAS, or by LUKAS itself. Internal leakage of Have the hand pump the hand pump. - Page 20 Air in hydraulic Vent hydraulic system in system. accordance with section 6.1. Check the cylinder Cylinder return Have the damage for damage. spring is broken repaired by an authorised or other damage dealer, by personnel is present on the specially trained by cylinder. LUKAS, or by LUKAS itself. Device doesn’t Check the Insufficient Top up hydraulic fluid, de- perform at its given hydraulic fluid hydraulic fluid in aerate. power. level in the pump the hand pump. supplying the fluid. Device’s cutting Check cutting Mechanical Replace cutting inserts. behaviour has inserts for damage.
- Page 21 Check Cause Solution Hydraulic fluid leak Are the hoses Leak, possible Replace hose line. on the hose line or its defective? damage. inserts. Damage on the Check hose line for Mechanical Replace hose line. surface of the hose external damage. damage or contact line. with aggressive agents. Leak on the Is the coupling Coupling defective. Coupling must be couplings. damaged? replaced immediately. Contact an authorised LUKAS dealer or the LUKAS Customer Service Department directly if the malfunctions cannot be rectified. The address for the LUKAS Customer Service department is: LUKAS Hydraulik GmbH Weinstrasse 39, D-91058 Erlangen, Germany Tel.: (+49) 09131 / 698 - 348 Fax.: (+49) 09131 / 698 - 353...
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Page 22: Technical Data
11. Technical data Because all values are subject to tolerances, there may be minor differences between the data for your device and the data in the following tables! NOTE: The following tables contain only the technical data required for standard acceptance. Additional data concerning your unit can be obtained from LUKAS on request. Device type LC 99 Item number 81-85-10 [mm] 305 x 140 x 123 Dimensions L x W x H (w/o connection hoses) [in.] 12.0 x 5.51 x 4.84 [mm] min. -
Page 23: Recommended Hydraulic Fluids
11.1 Recommended hydraulic fluids 11.1.1 Recommended hydraulic fluids Mineral oil DIN ISO 6743-4 for LUKAS hydraulic equipment and others Oil temperature range Oil code Viscosity rating Remarks -20 ..+55°C HM 10 VG 10 Oil temperature range Oil code Viscosity rating Remarks -4.0 ..+131°F HM 10 VG 10 Recommended range of viscosity: 10...200 mm²/s (10…200 cSt.) Supplied with HM 10 DIN ISO 6743-4. ATTENTION! Before using hydraulic fluids which do not correspond to the above-mentioned specifications and/or are not purchased from LUKAS, you must contact LUKAS itself. 11.2 Operating and storage temperature ranges Operating temperature [°C]... -
Page 24: Ec Declaration Of Conformity
12. EC Declaration of Conformity... -
Page 26: Notes
13. Notes... - Page 28 A unit of IDEX Corporation Weinstrasse 39, D-91058 Erlangen, Germany Tel.: (+49) 0 91 31 / 698 - 0 Fax.: (+49) 0 91 31 / 698 - 394 e-mail: lukas.info@idexcorp.com www.lukas.com Made in GERMANY cutter _manual_84150643186_LC99_en.indd © Copyright 2019 LUKAS Hydraulik GmbH...
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