Lukas H1 Bedienungsanleitung

Operating instructions for rescue equipment

84150012085 EN

H1 and H2 Lifting Sets (DIN 14800)

(Translation of the original operating instructions)

replaces 03.2008

Edition 03.2015

Lifting Set H1

Lifting Set H2

Content Page

1. Danger classiﬁcations 4

2. Product safety 5

3. Appropriate use 8

4. System description and overview 10

4.1 Design of the system and connection of the components 10

4.2 Commissioning and control 12

5. Lifting and lowering of loads 14

5.1 Lifting a load 14

5.2 Lowering a load 15

6. Accessories 16

6.1 Base plate 16

6.2 Extension 16

6.3 Wedge block (Expansion wedge) 16

6.4 Foot lifter 17

7. Maintenance and repair 18

7.1 General information 18

7.2 Function and load test 19

7.3 Signs 19

8. Troubleshooting 20

9. Technical data 23

9.1 Technical data of the hydraulic cylinder 23

9.2 Technical data of the Hand pump 24

9.3 Technical data of lifting set H1/H2 25

9.4 Dimensions of the transport crate 25

9.5 Operating and storage temperature ranges 25

10. Declaration of conformity 26

11. Instructions regarding disposal 27

12. Notes 27

Wear a helmet with a face guard

Wear protective gloves

Wear safety shoes

Proper recycling

Protect the environment

Read and follow the operating instructions

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.

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!

Risk 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

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.

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

be carefully followed.

We also recommend that you have a qualiﬁed trainer show you how to use the product.

WARNING / CAUTION!

The operating instructions for accessories must also be taken into account!

Even if you have already received instruction on how to use the equipment, you should still

read through the following safety instructions again.

WARNING / CAUTION!

Please ensure that the accessories you use are appropriate for the maximum

operating pressure and the performance of the rescue device!

Please ensure that no body

parts or clothing get stuck

between the visibly moving

parts.

Working under suspended

loads is not permitted where

such loads are being lifted

solely by means of hydraulic

or electro-hydraulic devices.

If this work is unavoidable,

suitable mechanical supports

are also required.

Wear protective clothing, safety

helmet with visor, safety shoes

and protective gloves.

Check the equipment for

visible ﬂaws or damage before

and after use.

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!

All bolted connections must

be checked for leaks and

externally visible damage,

which must be repaired

immediately! Escaping

hydraulic ﬂuid can cause

injuries and ﬁres.

In the event of malfunctions,

immediately deactivate the

equipment and secure it.

Repair the fault immediately.

Do not carry out any changes

(additions or conversions)

to the equipment without

obtaining the approval of

LUKAS 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.

Any mode of operation which

compromises the safety and/

or stability of the device is

forbidden!

Repairs to the equipment may

only be carried out by a trained

service technician with speciﬁc

knowledge of the device.

Safety devices must never be

disabled!

Only genuine LUKAS

accessories and spare parts

are to be used for repairs.

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.

Please note that materials can

fall off during lifting or lowering

or be slung away if a load is

suddenly released. Also take

suitable precautions of your

own.

Please ensure that you do not

become entangled in cables

and trip when working with or

transporting the device.

Please ensure that dust

protection caps are provided

for the couplings.

The equipment is ﬁlled with

hydraulic ﬂuid. This hydraulic

ﬂuid 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 ﬂuid, 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, left-over oil

and hydraulic ﬂuid as well as

packaging materials!

Protect all of the lifting set

components against humidity

and moisture

The hand pump is not suitable

for underwater applications.

The build-up of static charge

and therefore possible

sparking must be avoided

when handling the device.

Always wear protective gloves

to prevent injury when touching

torn or sharp-edged parts.

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.

3. Appropriate use

The LUKAS lifting sets are specially designed for the lifting or stabilising of heavy or movable

loads requiring lifting in order to free persons, vehicles or other objects from operations in

dangerous or catastrophic situations.

The lifting cylinders can also be used in all types of dangerous situations for the shifting or

lifting of objects to rescue buried or trapped persons or to recover any type of heavy object

(vehicles, devices, etc.).

Buildings in danger of collapsing or heavy vehicles in danger of crashing can be temporarily

secured and stabilised.

Thanks to the cylinder's low design, the lifting sets can be particularly well used for initial

lifting at low clearance heights between the object and the ﬂoor. The cylinder extensions can

additionally be used to increase the initial height of the stroke.

The cylinder unit of the lifting set is suitable for underwater applications. The hand pump

requires an air exchange through the tank cover of the hydraulic ﬂuid container.

Additional safety instructions:

• Never use hydraulic cylinders without a base plate (stability). Use hard wood

spacers if possible to provide additional stability of the load.

• Never use more than one extension per cylinder (risk of buckling with multiple

arrangements).

• Always load the hydraulic cylinder in the centre (in the direction of the cylinder axis)!

Exception: Use of the foot lifter according to instructions.

• Work with a support bar when using the foot lifter (see Accessories section).

Screw the foot lifter on in reverse for loads with low internal strength and use it

without the support bar. Use suitable underlays or support bars to provide additional

support if necessary.

• Always lay the hoses to be free of twists and kinks!

• Pay extremely close attention to the moving load during the lifting and lowering

processes!

• Always provide additional mechanical support to raised loads!

• No bystanders are allowed in the hazard zone!

WARNING / CAUTION / ATTENTION!

The system is exclusively intended for the purpose stated in the operating instructions

(see section "Appropriate Use"). Any other use is not considered appropriate.

The manufacturer/supplier is not liable for any damage resulting from inappropriate use.

The user bears sole responsibility for such use.

Appropriate 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 / ATTENTION!

The following may not be pressurised or squeezed:

- electric cables

- prestressed and hardened parts such as springs, spring steels,

steering columns and rollers

- tubes or containers under gas or liquid pressure

- explosive bodies such as airbag cartridges

The internally set operating pressure may only be directly changed after

consultation with LUKAS. A change in settings may result in damage to property

and/or injuries.

The H1and H2 lifting sets are not explosion protected!

When using the equipment in explosive areas you must rule out any chance of

the equipment causing an explosion.

The responsibility for explosion prevention or for prohibiting work with a lifting set

rests with the operator of the device or with the person responsible at the place

of use.

When working in explosive areas, all applicable legal, national

and international regulations, standards and safety rules for

avoiding explosions must be observed without restriction!

The lifting set should not come into contact with acids or alkalis. If this is

unavoidable, clean the equipment immediately afterwards with a suitable cleaning

agent.

You can obtain other accessories and replacement parts for the lifting sets from your

authorised LUKAS dealer!

WARNING / CAUTION!

Always ensure that the surroundings of the object to be lifted remain stable and

are secured against accidental shifting by sustainable supports or substructures.

4. System description and overview

4.1 Design of the system and connection of the components

A LUKAS lifting set generally includes a hydraulic hand pump which serves as a drive for

one or two single-acting hydraulic cylinders. Operating the hand pump presses hydraulic

ﬂuid into the cylinder or cylinders, causing the cylinder piston to extend and lift an attached

load. The reset spring in the cylinder causes the cylinder to retract in the idle stroke or it is

retracted under loading by the force exerted by the attached load.

The components are joined together by connection hoses and couplings.

The accessories make it possible to optimally use the cylinders in any position desired at

the site.

The cylinders are controlled by the pump movement on the hand pump. The drain valve

must be closed to build up pressure. The hand wheels (distributor stop valves) must be open

when two cylinders are operated with 2-way distributors. A hydraulic load holding function

is provided when the isolating valves (distributors) are closed. You should also secure the

system mechanically when the cylinders are continuously loaded (under load).

33a3b

Connection of two (2)

cylinders using the distributor

valve

Connection of one (1)

cylinder directly to the pump

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