Operating Instructions
Rescue Tools
Rescue Sets including
LH 1/0,5-70; HT 90; LC 75/40
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84150/6108-85 D
Ausgabe 12.2004
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1 Cuttert LC 75/40
2 Screw coupling socket SKM1
3 Screw coupling plug SKN2
4 Door opener HT 90
5 Hand pump LH 1/0,5 PN 700
6 Transport case
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1 Basic operation and designated use of the machine
1.1 The machine has been built in accordance with state-of-the-art standards and the recognized
safety rules. Nevertheless, its use may constitute a risk to life and limb of the user or of third parties,
or cause damage to the machine and to other material property.
1.2 The machine must only be used in technically perfect condition in accordance with its
designated use and the instructions set out in the operation manual, and only by safety-conscious
persons who are fully aware of the risks involved in operating the machine. Any functional disorders,
especially those affecting the safety of the machine/plant, should therefore be rectified immediately!
1.3 The machine is exclusively designed for the use described in the operating manual. Using the
machine for purposes other than those mentioned in the manual, such as driving and controlling
other pneumatic systems, is considered contrary to its designated use. The manufacturer/supplier
cannot be held liable for any damage resulting from such use. The risk of such misuse lies entirely
with the user.
Operating the machine within the limits of its designated use also involves observing the
instructions set out in the operating manual and complying with the inspection and maintenance
directives.
2 Organizational measures
2.1 The operating manual must always be at hand at the place of use of the machine!
2.2 In addition to the operating instructions, observe and instruct the user in all other generally
applicable legal and other mandatory regulations relevant to accident prevention and environmental
protection.
This also applies for wearing protective clothing, helmet with visor or goggles and protective gloves.
2.3 In order to avoid innjuries, the machine must only be operated by a specially trained operator
who has undergone a safety training.
2.4 Observe all safety instructions and warnings attached to the machine. Make sure that safety
instructions and warnings attached to the machine are always complete and perfectly legible.
2.5 Never make any modifications, additions or conversions which might affect safety without the
supplier's approval. This also applies to the installation and adjustment of safety devices and
valves.
2.6 Spare parts must comply with the technical requirements specified by the manufacturer.
Spare parts from original equipment manufacturers can be relied to do so. It is only allowed to use
original LUKAS spare parts of LUKAS system components.
2.7 Replace hydraulic hoses at the specified or adequate intervals, even if no defects are detected
which might affect safety. This must be done after 10 years, at the latest!
2.8 Adhere to prescribed intervals or those specified in the operating manual for routine checks
and inspections.
2.9 Make sure to dispose properly of packing material and dismounted parts!
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3 General safety instructions
3.1 In the event of malfunctions, stop the machine immediately and lock it. Have any defects rectified
immediately.
3.2 Before starting up or setting the machine in motion and during operation of the machine make
sure that nobody is at risk.
3.3 Before transporting the machine always check that the accessories have been safely stowed
away.
3.4 Make sure that there is enough lighting during work.
3.5 Avoid any operation that might be a risk to machine stability.
3.6 Check the machine at least after every operation for obvious damage and defects. Report any
changes (incl. changes in the machine’s working behaviour) to the competent organization /person
immediately. If necessary, stop the machine immediately and lock it. All lines, hoses and screwed
connections have to be checked for leaks and obvious damage. Repair damage immediately.
Splashed oil may cause injury and fire.
3.7 All safety equipment has to be checked for completeness and flawless condition:
- instruction markings and warning signs (safety instructions)
- check safety cover (e.g. motor-safety covers, heat protection etc.) if they are available and if they
are in good condition.
3.8 Working under loads is not allowed if they are only lifted by hydraulic cylinders. If the work is
indispensable sufficient mechanical supports are needed additionally.
3.9 Do not stress hoses mechanically (pulling, buckling etc.).
4 Instructions for maintenance and service
4.1 For the execution of maintenance and service work, tools and workshop equipment adapted
to the task on hand are absolutely indispensable.
Work on the hydraulic system must be carried out only by personnel having special knowledge and
experience with hydraulic equipment.
4.2 Before putting into operation clean the machine, especially connections and threaded unions,
of any traces of oil, fuel or preservatives before carrying out maintenance/repair. Never use
aggressive detergents. Use lint-free cleaning rags and pay attention that the components are
meticulously clean during reassembling after repair.
4.3 During dismantling of machines it is necessary to collect the outrunning hydraulic liquids
completely, so that they cannot reach the ground. They have to be disposed properly according to
the instructions.
4.4 Always tighten any screwed and thread connections that have been loosened during
maintenance and repair. Observe the stipulated torques.
4.5 Work on the electrical system or equipment may only be carried out by a skilled electrician
himself or by specially instructed personnel under the control and supervision of such electrician
and in accordance with the applicable electrical engineering rules.
4.6 The electrical equipment of machines is to be inspected and checked at regular intervals.
Defects such as loose connections or scorched cables must be rectified immediately.
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4.7 Aggressive material (acid, lye, solvent, vapour) can damage the machine. It is necessary to
clean the whole machine if it must be exceptionally operated under such conditions or gets into
touch with these materials. Additionally, the machine must be checked as described under 3.6.
5 Safety instructions for hydraulic hoses
All instructions as to safe use of hydraulic hoses can be found in the booklet 84150/8056-85
delivered with the hoses.
6 Application
6.1 General
The hand pump LH 1/0,5 is designed as a two-stage pump which is used for the operation of oil
hydraulic single acting cylinders. It is designed for a maximum system pressure of 700 bar.
Warning
Always check product limitations regarding pressure ratings, load capacities, and set-up
requirements. The system operating pressure must not exceed the pressure rating of the lowest
rated component in the system.
Warning
NEVER set the relief valve to a higher pressure than the maximum rated pressure of the pump.
Higher settings may result in equipment damage and/or personal injury.
7 Applications
The mini cutter with hand pump is meant for cutting in confined spaces or where access is difficult,
e.g. steering-wheel spokes or pedals in vehicles which are severely deformed as a result of an
accident.
In the industrial and trade field, steel rods, screws, etc. can be cut.
8 Connecting the pump
Mini cutter and hand pump are to be connected according to following Scheme:
8.1 Connection of the screw cpouplers
The device is connected to the hydraulic pump with the screw couplers (plug and socket), there
being no risk of mix-up.
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Before coupling, remove the dust protection covers. Push the threaded sleeve back and connect
plug and socket in this position. Screw the threaded sleeve onto the thread on the plug and tighten
it by hand.
Now the parts are connected and locked. Decoupling is done in the reverse order.
9 Operation of Hand pump
The pump can be used both in horizontal and vertical position,
i.e. with the pump head downwards.
Pumps
Make sure that the drain valve is closed (turn lever clock-wise).
Return flow of oil will be allowed by opening of drain valve (turn
lever anti-clockwise).
drain valve
9.1 Venting the mini cutter
Use the pump to drive out the unloaded piston half way. The pump has to be placed higher than
the tool which has to be vented. Now open the drain valve of the pump for retracting the piston by
spring retraction.
The oil reservoir filler cap must be open. The retracting piston presses the air back into the oil
reservoir via the maximum-pressure-hose. The air escapes through the open fillercup.
10 Operation
10.1 Door opener HT 90
10.1.1Points of application:
Doors with single protection: locking furniture and hinge plates.
Doors with multiple protection: locking furniture, hinge plates and
at each locking bolt, if required.
10.2 Cutter LC 75/40
10.2.1Cutting
The knives must be applied in a right angle to the
object to be cut.
Actuate the pump lever til the work piece is cut
through.
After the cutting performance open drain valve by
turning the lever to the left. The movable cutting
blade returns to its initial position.
10.3 Uncoupling pump and working tool
Before uncoupling the pump from the working tool, make sure (by opening the drain valve) that there
is no pressure and that the piston is completely retracted.
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10.4 Operating: Safety instructions
When operating rescue devices, wear protective clothing • helmet with visor or goggles • protective
gloves.
During operation of this rescue device, parts of the object worked on with this device may break
away and endanger people standing nearby. Onlookers must be kept at a safety clearance of at
least 5 m.
10.4.1 Door opener HT 90
When applying the unit, the claws must be pressed or beaten into the door crack as hard and deep
as possible.
When working in an environment which involves the risk of explosions, sparks must be avoided
when the claws are pushed into the door gap!
Attention! There is the risk of sparks, if the device gets in contact with metal or stone!
The door opener must be held tight to prevent injuries by the falling device when the door breaks
open.
Attention! There is the danger of injuries in the area doors breaking open.
10.4.2 Cutter LC 75/40
Attention!
- Do not reach in between the cutter arms!
- Live cables must not be cut apart.
- Cutting objects under tension (shock absorbers, springs, track rods) is prohibited since cutoff parts of these objects might jerk away unpredictably which exposes the operator and other
persons to a high risk of injury.
- Hardened objects such as spring steel and steering pillars must not be cut.
The cutting equipment may only be operated in conjunction with a hand pump, and under no
circumstances is it to be driven by a motor pump. The operating pressure must not exceed 700
bar max.
11 Servicing and Maintenance
Oil should be changed once a year. In case of frequent use or operation in particularly dusty
environment, oil should be changed every six months.
11.1 Adding Oil to the Pump
Attention!
Always add oil with cylinders fully retracted (extended if pull cylinders) or the system will contain
more oil than the reservoir can hold.
- Remove vent/fill cap from reservoir.
- Fill reservoir only to level mark shown on pump.
- Remove air from system if necessary. See 9.1.
Recheck oil level after removing air.
- Return vent/fill cap to proper position.
- Make sure no dirt gets into the oil reservoir or into the
pump, as this will cause malfunction.
- To extend pump life and improve performance,
lubricate the beam pin A, cross pin B and piston
head C regulary, using roller bearing grease.
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B
A
C
11.2 Maintenance of the working tools
11.2.1 LH1/0,5-70
To guarantee safety and operational function of the rescue tool it is definitely necessary to make
a visual inspection after each operation at least once a year if tool has not been used.
Remark for maintenance:
Use oiled towel for protection against corrosion at outside of the pump.
11.2.2 HT 90
Special points of inspection are all parts for load holding function, e.g. links, bolts and hoses, to be
checked on damages.
11.2.3 LC 75/40
Take special care to inspect the C-frame of the cutter and the cutter blades on cracks or material
deformations.
12 Replacement of Cutting Blades on Cutter
Close drain valve on the hand pump (tighten hand wheel
smoothly clockwise)
Operate the pump lever until the two cutting blades 1
nearly touch; the fastening clamping sleeve 2 of the
movable cutting blade is now accessible.
Carefully remove the fastening clamping sleeve 2 using a
hammer and punch.
Remove the defective cutting blades 1 and replace with
new ones.
Hammer the fastening clamping sleeve back. Replace
defective fastening clamping sleeves.
Open drain valve again.
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Note:
Deformed or broken cutting blades must not be resharpened.
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13 Troubleshooting
Problem Cause Solution
Cylinder does not Oil level in pump reservoir is Add oil according to the operating instructions on 1 1.1
advance, advances low
slowly or advances Drain valve open Close drain valve
in spurts Loose hydraulic coupler Check that all couplers are fully tightened
Load is too heavy Do not attempt to cut more than rated tonnage
Air trapped in system Remove air according to the instructions on 9.1
Cylinder piston binding Check for damage to cylinder; have cylinder by an
authorized dealer or LUKAS themselves
Cylinder advances Leaking connection Check that all connections are tight and leak free
but does not hold Leaking seals Local leaks and have equipment serviced by an authorized
pressure dealer or LUKAS themselves
Internal leakage in the pump Have pump serviced by an authorized dealer or LUKAS
themselves
Cylinder does not Drain valve closed Open drain valve
retract, retracts p art Pump reservoir is over-filled Drain oil to level mark. See instructions for adding oil 11.1
way , or retracts more Loose hydraulic coupler Check that all couplers are fully tightened
slowly than normal Air trapped in system Remove air according to the instructions on 9.1
Hose diameter too narrow Use larger diameter hydraulic hose
Cylinder retraction spring Have cylinder serviced by an authorized dealer or LUKAS
broken or other cylinder themselves
damage
If the defects cannot be repaired, contact an authorised LUKAS dealer or the LUKAS service
department. The address:
LUKAS Hydraulik GmbH, Weinstraße 39, D-91058 Erlangen, Pf 2560, D-91013 Erlangen, service
phone 09131/698 348; fax 09131/698 353.
14 Technical data
14.1 Hand pump
Type LH 1/0,5-70
Order no. HR 1494 63203
Working pressure (MPa)* 70
Oil capacity / usable oil cap. (l) 0.7 / 0.45
Oil delivery LP / HP (cm3) 6 / 0.8 per piston stroke
Automatic switch-over (MPa)* 2
Dimensions l x w x h (mm) 345 x 100 x 140
Weight incl. hydr. oil (kg) 4.2
* 1 MPa =10bar
+4
-1
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0.5
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14.2 Cutter
Type LC 75/40
Order no. 84150/6431
Cutting force (kN) 76
Blade opening (mm) 40
Cutting width (mm) 38
Cutting depth (mm) 40
Operating pressure (MPa)* 70
Dimensions l x w x h (mm) 216 x 51 x 76
Weight (kg) 3
* 1 MPa =10bar
14.3 Door opener
Type HT 90
Order no. 84150/6129
Spreading force (kN) 90
Stroke (mm) 100
Operating pressure (MPa)* 70
Dimensions l x w x h (mm) 410 x 280 x 125
Weight (kg) 5.7
* 1 MPa =10bar
14.4 Oil recommendations
For LUKAS hydraulic devices, use mineral oil in accordance with DIN 51 524 and others
Range of oil temperature Viscosity rating Remarks
A - 24 ... + 30 °C HL 5
B - 18 ... + 50 °C HLP 10
C - 8 ... + 75 °C HLP 22
D + 5 ... + 80 °C HLP 32
E - 8 ... + 70 °C HF - E 15 biodegradable
Recommended viscosity range: 10 ... 200 mm²/s, delivered with HLP 10 to DIN 51 524
14.5 Hoses
Bending radius Rmin = 38 mm
Burst resistance safety factor: burst pressure / max. operating pressure, min. 4 : 1
Temperature resistance - 40°C ... + 100°C
Operating medium Mineral oil according to DIN 51524
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14.6 Others
Working temperature -20 ... +55°C
Ambient temperature (power pack in operation) -24 ... +45°C
Storage temperature (power pack not in operation) -30 ... +60°C
LUKAS Hydraulik GmbH
A Unit of IDEX Corporation
Weinstraße 39, 91058 Erlangen • Germany
Postfach 2560, 91013 Erlangen • Germany
Telefon +49 (0) 9131 698-0 • Telefax +49 (0) 9131 698-394
E-mail: info@lukas.de
84150_6108_85_e.P65 Subject to revision
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© Copyright 2004 LUKAS Hydraulik GmbH
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