LC 99 cutter
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Content
Page
1. Danger classifications 4 2. Product safety 5 3. Appropriate use 8 4. Functional description 9 4.1 Description 9 4.2 Unit in detail 10 4.3 Wiring diagram 114.4 Control of the operating movements 11
4.5 Hydraulic supply 11
4.6 Hoses 11
5. Connecting the device 12
5.1 General information 12
5.2 Coupling of (Flat-Face) quick-disconnect coupling 12
6. Operation 13
6.1 Preparatory measures 13
6.2 Operating the cutter 13
7. Dismantling the equipment / deactivation following operation 14 7.1 Cutter 14 7.2 Hand pump 14 7.3 Hoses 14 8. Maintenance and service 15 9. Repairs 16 9.1 General information 16 9.2 Preventative service 16 9.3 Repairs 17
10. Troubleshooting 19
11. Technical data 22
11.1 Recommended hydraulic fluids 23
11.2 Operating and storage temperature ranges 23
12. EC Declaration of Conformity 24
13. Notes 26
4 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! dangerous Potentially 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. 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. WARNING / CAUTION! The operating instructions for the hoses, the accessories and the connected devices must also be heeded! Even if you have already received instructions on how to use the equipment, you should still read through the following safety instructions again. WARNING / CAUTION!
Ensure that the accessories and connected equipment are suitable for the maximum operating pressure! Please ensure that no body parts or clothing are caught between the visibly moving parts (e.g. blade arms). Working under suspended loads is not permitted where such loads are being lifted only using 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
6 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! Observe all intervals for recurring tests and/ or inspections that are prescribed or stated in the operating instructions. Safety devices must never be
disabled! The maximum permitted operating pressure noted on the equipment must not be exceeded. Make sure before switching on/starting up the device and during its operation that this will put no one in danger. Only genuine LUKAS accessories and spare parts are to be used for repairs. Please ensure that, when working with this equipment or during transportation of such, you don’t get caught up in the looped hoses and trip. 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, when cutting or spreading, tearing or breaking can cause falling material, or sudden removal of such can cause it to suddenly catapult off: necessary precautions need to be taken. The build-up of static charge and therefore possible sparking must be avoided when handling the device. Only touch any broken-off parts or the cut-off parts wearing protective gloves, since the torn / cut edges can be very sharp.
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!
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 / ATTENTION!
The equipment is exclusively intended for the purpose stated in the operating instructions (see chapter “Appropriate Use”). Any other use is not considered intended use 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.
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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.
All objects to be worked on are to be secured using stable supports or substructures.
4. Functional description
You can obtain accessories and replacement parts for the rescue equipment from your authorised LUKAS dealer. LUKAS cutters are also suitable for underwater use. ATTENTION! In this case, you must strictly observe any leaks in order to avoid threats to the environment. WARNING / CAUTION!
All objects to be worked on are to be secured using stable supports or substructures.
WARNING / CAUTION / ATTENTION!
The following may not be cut / squeezed: - live cables
- prestressed and hardened parts such as springs and spring steels,
steering columns and rollers
- tubes / hoses under gas or liquid pressure, - compound materials (steel/concrete), - 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.
4.1 Description
The device has been designed in such a way that a hydraulically operated piston closes the blades mounted opposite each other so that they can cut through objects.
10 1 Body of rescue tool 2 Handle 3 Protective cover 4 Blade 5 Flat-Face coupling 4
4.2 Unit in detail
1 3 2 54.3 Wiring diagram
4.4 Control of the operating movements
4.5 Hydraulic supply
The wiring diagram is shown here in simplified form to enable comprehension of the function. Pressure is applied by a hand pump. Due to the spring force, the piston rod retracts again as soon as pressure stops being applied and the pressure can be released via the supply line (not blocked and no pressure applied). 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.
NOTE:
Before using pumps from a different manufacturer, you must contact LUKAS or an authorised dealer.
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5. Connecting the device
5.1 General information
5.2 Coupling of (Flat-Face) quick-disconnect coupling
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.
The device is connected to the hand pump without the risk of connection error using Flat-Face quick-disconnect coupling halves (female and male). NOTE: The device can only be decoupled when the hoses are depressurised. 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. To connect the device, push the male into the female counterpart. To lock, turn the sleeve of the male counterpart by 90°. To decouple, turn the sleeve of the male counterpart by 90° again and then pull back.
6.1 Preparatory measures
6. Operation
6.2 Operating the cutter
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.
6.2.1 Cutting
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7. Dismantling the equipment /
deactivation following operation
7.1 Cutter
7.2 Hand pump
At the end of the work, the cutter must be retracted until it reaches its end position. This relieves hydraulic and mechanical stress on the device. NOTE: When cutters are in storage, fluctuations in ambient temperature can cause the pistons to move slightly. This physical phenomenon is due to the expansion of the enclosed hydraulic fluid.
7.3 Hoses
After completing the work, the hand pump must be depressurised. Decoupling is carried out as described in the chapter “Connecting the device”. Ensure that you put the dust protection caps back on to the couplings.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. Persons not involved in the work must keep well clear (at least 5m).
WARNING / CAUTION!
Do not reach between the blades. Do not cut live cables.
Do not cut any pre-stressed parts (springs, vehicle steering rods, shock absorbers), cut parts can jump away uncontrolled.
Do not cut hardened parts.
The cutter may only be operated with a hand pump, under no circumstances may it be operated with a motor pump unit. The operating pressure must not exceed 700 bar.
8. Maintenance and service
ATTENTION!
Clean off any dirt before checking the device!
WARNING / CAUTION / ATTENTION!
To perform maintenance and repairs, personal protection equipment appropriate for the work is an absolute requirement.
Inspections to be carried out:
Visual inspection Cutter • Cylinder and piston rod undamaged and not deformed, • Correct fit of the blades, • Blades are free from damage, deformation and nicks, • Correct and firm fit of dowel pins on the blades, • General tightness (leaks), • Mobility of swivel connection, • Labels complete and legible, • Couplings must be easy to couple, • Dust protection caps must be present.Hoses (see also operating instructions for hose lines)
• Visual inspection for visible damage, • Check for leaks, • Check date of manufacture (note the 10-year replacement period). Operational check • Piston can be fully extended and retracted (see chapter “Technical Data”), • Flawless extension and retraction, • No suspicious noises during the procedure, • No leaks. 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).
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9. Repairs
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.
9.1 General information
Servicing may only be carried out by the manufacturer or personnel trained by the manufacturer and by authorised LUKAS dealers.
Only LUKAS spare parts may be used to replace all components (see spare parts list), as special tools and compliance with assembly instructions, safety aspects and inspections are required (see also chapter “Maintenance and Servicing”).
During assembly, ensure that all components are particularly clean, since dirt can damage the rescue equipment!
WARNING / CAUTION / ATTENTION!
Protective clothes must be worn when repairs are being carried out as the device may also be pressurised when not in operation.
NOTE:
Always register your device on the LUKAS Hydraulik GmbH website. This is the only way to guarantee your extended warranty cover.
NOTE:
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
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”.
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. 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. 7. De-aerate as described in Chapter “First operation”. 8. Re-connect the hand pump.
9.3 Repairs
9.3.1 Replacing the cutting jaws
- Close drain valve. (Turn hand wheel slightly clockwise).
- Operate the pump lever until both cutting jaws (1) are almost touching; the fixing bolt (2) on the movable cutting jaw is now accessible. - Carefully knock out fixing bolt (2) with a drift punch and hammer. - Remove defective cutting jaws (1) and insert the new ones. - Drive the fixing bolt back in. - Replace defective bolts. - Open discharge lever again.
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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 MA = 45 Nm (33.2 lbf x ft)A = 45 Nm (33.2 lbf x ft) (use Teflon tape).
9.3.4 Decals
All damaged and/or illegible labels (safety notices, type plate, etc.) must be replaced. Procedure: 1. Remove damaged and/or illegible decals. 2. Clean surfaces with acetone or industrial alcohol. 3. Affix new decals. Take care to affix the labels in the correct positions. If this is no longer known, you should ask your authorised LUKAS dealer or contact LUKAS directly.9.3.3 Replacing the protective cover
- Remove rounded head screw - Remove old protective cover - Fit new protective cover
10. Troubleshooting
Fault
Check
Cause
Solution
Cylinder does not extend, extends too slowly or stops when extending. Check the hydraulic fluid level in the hand pump supplying the fluid. Insufficient hydraulic fluid in the hand pump. Refill the hydraulic fluid. Check that the pressure relief valve on the hand pump is closed. Pressure relief valve on the hand pump open. Close the pressure relief valve on the hand pump. Check that all couplings are fully tightened. Hydraulic coupling
loose. Tighten hydraulic coupling. Air in hydraulic
system. Vent hydraulic system in accordance with section 6.1.
Check the cylinder
for damage. Cylinder piston jams. Have the damage repaired by an authorised dealer, by personnel specially trained by LUKAS, or by LUKAS itself. Cylinder extends, but does not maintain the pressure. Check that all connections are fully tightened. Leaky connection. Tighten loose connection. Check the cylinder
for leaks. Leaking seals. Have the leaks repaired by an authorised dealer, by personnel specially trained by LUKAS, or by LUKAS itself.
Internal leakage of
the hand pump. Have the hand pump serviced by an authorised dealer, by personnel specially trained by LUKAS or by LUKAS directly.
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Fault
Check
Cause
Solution
Cylinder does not retract, only partially retracts or retracts more slowly than usual. Check that the pressure relief valve on the hand pump is fully open. Pressure relief valve on the hand pump partly closed. Fully open the pressure relief valve on the hand pump. Check the hydraulic fluid level in the hand pump supplying the fluid. Too much hydraulic fluid in the hand pump. Drain hydraulic fluid. Check that all couplings are fully tightened. Hydraulic coupling
loose. Tighten hydraulic coupling.
Air in hydraulic
system. Vent hydraulic system in accordance with section 6.1.
Check the cylinder
for damage. Cylinder return spring is broken or other damage is present on the cylinder. Have the damage repaired by an authorised dealer, by personnel specially trained by LUKAS, or by LUKAS itself. Device doesn’t perform at its given power. Check the hydraulic fluid level in the pump supplying the fluid. Insufficient hydraulic fluid in the hand pump. Top up hydraulic fluid, de-aerate. Device’s cutting behaviour has deteriorated. Check cutting
inserts for damage. Mechanical damage due to cutting of materials that are too hard.
Replace cutting inserts.
Hose line cannot be
coupled. Check that the pressure relief valve on the hand pump is open.
Pressure is too
high. Open the pressure relief valve on the hand pump. Coupling defective. Coupling must be
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 - 353Fault
Check
Cause
Solution
Hydraulic fluid leak on the hose line or its inserts.
Are the hoses
defective? Leak, possible damage. Replace hose line. Damage on the
surface of the hose line.
Check hose line for
external damage. Mechanical damage or contact with aggressive agents.
Replace hose line.
Leak on the
22 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!
11. Technical data
* 1 MPa = 10 bar ** Volume of hydraulic fluid required in the hand pump to operate the device 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
Dimensions L x W x H
(w/o connection hoses) [mm][in.] 12.0 x 5.51 x 4.84305 x 140 x 123
min. cutting opening [mm] 38
[in.] 1.50
max. cutting force (rear end
of cutting surface)
[kN] 77
[lbf.] 17310
weight incl. hydraulic fluid
[kg] 3.0
[lbs.] 6.61
max. operating pressure [Mpa] * 70
[psi.] 10000
volume
(of hydraulic fluid) [cm³] **[gal.-US] 0.01246
11.2 Operating and storage temperature ranges
Operating temperature [°C] -20 … +55
Storage temperature (device not in operation) [°C] -30 … +60
Operating temperature [°F] -4 … +131
Storage temperature (device not in operation) [°F] -22 … +140
11.1 Recommended hydraulic fluids
Mineral oil DIN ISO 6743-4 for LUKAS hydraulic equipment and others
Oil temperature range Oil code Viscosity rating Remarks
A -20 .... +55°C HM 10 VG 10
Oil temperature range Oil code Viscosity rating Remarks
A -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.
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LUKAS
Hydraulik GmbH
A unit of IDEX Corporation
Weinstrasse 39, D-91058 Erlangen, Germany
Tel.: (+49) 0 91 31 / 698 - 0Fax.: (+49) 0 91 31 / 698 - 394 e-mail: [email protected] www.lukas.com
Made in GERMANY
© Copyright 2019 LUKAS Hydraulik GmbH cutter _manual_84150643186_LC99_en.indd Subject to changes
Please duly dispose of all packaging materials and removed items.
