Lukas LC 99 User manual

84150643186 EN
LC 99 cutter
(Translation of original operating instructions)
Operating instructions for rescue equipment
Edition 06.2019

2
Content Page
1. Dangerclassications 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 11
4.4 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

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10.Troubleshooting 19
11.Technicaldata 22
 11.1 Recommendedhydraulicuids 23
11.2 Operating and storage temperature ranges 23
12.ECDeclarationofConformity 24
13.Notes 26
Content Page

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 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di󰀨erentiatebetweenvariousdi󰀨erentcategoriesofsafetyinstructions.Thetableshown
belowprovidesanoverviewoftheassignmentofsymbols(pictograms)andsignalwordsto
thespecicdangerandthepossibleconsequences.
1. Danger classications
Pictogram Damage /
injury to Key word Denition 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

5
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qualied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aws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!
Inspectalllines,hoses,and
screwedconnectionsfor
leaksandexternallyvisible
damage.Ifnecessary,repair
immediately!Escaping
hydraulicuidcancause
injuriesandres.

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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o󰀨:
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-o󰀨
partsorthecut-o󰀨parts
wearingprotectivegloves,
sincethetorn/cutedgescan
beverysharp.

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Theequipmentislledwith
hydraulicuid.Thishydraulic
uid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
uid,notethatitcannegatively
a󰀨ectbiologicalsystems.
Whenworkingwithorstoring
theequipment,ensurethatthe
functionandthesafetyofthe
equipmentarenotimpaired
bythee󰀨ects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uid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.
Never work in a fatigued or intoxicated state!

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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.
Applications:

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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.
The“open”movementisperformedbyspringforcewhenthehydraulicpressureisremoved.

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 1 Bodyofrescuetool
 2 Handle
 3 Protectivecover
 4 Blade
 5 Flat-Facecoupling
4
4.2 Unit in detail
13
2
5

11
4.3 Wiring diagram
4.4 Control of the operating movements
4.5 Hydraulic supply
4.6 Hoses
Thewiringdiagramisshownhereinsimplied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 di󰀨erent make, you must make sure that it complies with LUKAS
specications, 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di󰀨erentmanufacturer,youmustcontactLUKASor
anauthoriseddealer.
ATTENTION!
TheLC99cuttermayonlybeoperatedwithmineraloilinaccordancewithsection
11.1Recommendedhydraulicuids.
Thehandpumpandthecutterareconnectedbyhoselines.

12
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.

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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
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.

14
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,uctuationsinambienttemperaturecancausethe
pistonstomoveslightly.Thisphysicalphenomenonisduetotheexpansionof
theenclosedhydraulicuid.
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 e󰀨ect of the force of the rescue equipment during operation could cause
pieces to break o󰀨 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.

15
8. Maintenance and service
ATTENTION!
Cleano󰀨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toftheblades,
• Bladesarefreefromdamage,deformationandnicks,
• Correctandrmt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).

16
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specied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,
vericationthatpermissionmaybegranted.Tobecheckedineachindividual
case!)
9.2 Preventative service

17
ATTENTION!
Alwaysreplacethehydraulicuidoveraliquidcollectioncontaineranddispose
ofthecollecteduidinapropermanner.
ATTENTION!
The hydraulic uid must be completely replaced if the application conditions
(ambienttemperatures)changesubstantially.Whenselectingasuitablehydraulic
uid,pleaserefertothechapter“Recommendedhydraulicuids”.
9.2.3 Replacing the hydraulic uid
- Thehydraulicuidmustbereplacedafterapprox.200deployments,butafterthreeyears
atthelatest.
- Itmustalwaysbechangedwheneverthehydraulicuidfortheaccompanyinghandpump
ischanged.Thisistopreventthefreshhydraulicuidfrombecomingcontaminatedbythe
useduidfromtherescueequipment.
Procedure:
1. Retractthecutterfullyanddepressurisethehydraulicsystem.
2. Removethecouplingonthecutter.
3. Draino󰀨thehydraulicuid.
4. Flush
5. Reassemblethecoupling.
6. Connecthandpumpwithfreshhydraulicuid.
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xingbolt(2)onthemovablecuttingjawisnowaccessible.
- Carefullyknockoutxingbolt(2)withadriftpunchandhammer.
- Removedefectivecuttingjaws(1)andinsertthenewones.
- Drivethexingboltbackin.
- Replacedefectivebolts.
- Opendischargeleveragain.
NOTE:
Deformedorbrokencuttingjawscannotberepairedbygrinding.

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uid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 Teon 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. A󰀩xnewdecals.
Takecaretoa󰀩x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
- RetightentheroundedheadscrewwithMA=0.5Nm(0.37lbfxft).

19
10. Troubleshooting
Fault Check Cause Solution
Cylinderdoesnot
extend,extendstoo
slowlyorstopswhen
extending.
Checkthe
hydraulicuidlevel
inthehandpump
supplyingtheuid.
Insu󰀩cient
hydraulicuidin
thehandpump.
Rellthehydraulicuid.
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.

20
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uidlevel
inthehandpump
supplyingtheuid.
Toomuch
hydraulicuidin
thehandpump.
Drainhydraulicuid.
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uid
levelinthepump
supplyingtheuid.
Insu󰀩cient
hydraulicuidin
thehandpump.
Topuphydraulicuid,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
replacedimmediately.