Lukas HT 90 User manual
(Translation of original operating instructions)
84150612985 EN
replaces 01.2008
Edition 11.2019
Door opener
Operating instructions for rescue equipment
HT 90
JL-8
HT 99
2
Content Page
1. Dangerclassications 4
2. Productsafety 5
3. Appropriateuse 8
4. Functionaldescription 9
4.1 Description 9
4.2 Unit in detail 9
4.3 Wiring diagram 10
4.4 Control of the operating movements 10
4.5 Hydraulic supply 11
4.6 Hoses 11
5.Connecting the equipment 11
5.1 General information 11
5.2 Coupling of screwed couplings (on HT 90) 12
5.3 Coupling of Flat-Face quick-disconnect couplings (on HT 99 and JL-8) 12
6. Operation 13
6.1 Preparatory measures 13
6.2 Danger information 13
6.3 Starting points 13
6.4 Procedure 14
6.5 Retraction of the piston 14
7. Dismantlingtheequipment/deactivationfollowingoperation 15
7.1 Door opener 15
7.2 Hand pump 15
7.3 Hoses 15
8. Maintenanceandservice 16
3
Content Page
9. Repairs 17
9.1 General information 17
9.2 Preventative service 17
9.3 Repairs 18
10.Troubleshooting 20
11.Technicaldata 23
11.1 Recommendedhydraulicuids 24
11.2 Operating and storage temperature ranges 24
12.ECDeclarationofConformity 25
13.Notes 27
4
Wearahelmetwithafaceguard
Wearprotectivegloves
Wearsafetyshoes
Properrecycling
Protecttheenvironment
Readandfollowtheoperatinginstructions
Wedierentiatebetweenvariousdierentcategoriesofsafetyinstructions.Thetableshown
belowprovidesanoverviewoftheassignmentofsymbols(pictograms)andsignalwordsto
thespecicdangerandthepossibleconsequences.
1. Danger classications
Pictogram Damage /
injury to Key word Denition Consequences
Persons
DANGER! Immediatedanger Deathorsevere
injury
WARNING!
Potentially
dangerous
situation
Potentialdeathor
seriousinjury
CAUTION! Lessdangerous
situation
Minororslight
injury
Property
ATTENTION!
Riskofdamage
toproperty/
environment
Damagetothe
equipment,
damagetothe
environment,
damageto
surroundings
- NOTE
Handlingtipsand
otherimportant/
usefulinformation
andadvice
Noinjury/damage
topersons/
environment/
device
5
2. Product safety
LUKAS products are developed and manufactured to ensure the best performance and
qualitywhenusedasintended.
Thesafetyoftheoperatoristhemostimportantconsiderationinproductdesign.Furthermore,
theoperatinginstructionsareintendedtohelpinusingLUKASproductssafely.
Inadditiontotheoperatinginstructions,allgenerallyapplicable,statutoryandotherbinding
rulesforaccidentpreventionandforenvironmentalprotectionmustbecompliedwithand
instructed.
The equipment must only be operated by persons with appropriate training in the safety
aspectsofsuchequipment–otherwise,thereisadangerofinjury.
Wewouldliketopointouttoallusersthattheyshouldreadcarefullytheoperatinginstructions
andtheinstructionscontainedthereinbeforetheyusetheequipment,andthattheyshould
becarefullyfollowed.
Wealsorecommendthatyouhaveaqualiedtrainershowyouhowtousetheproduct.
WARNING / CAUTION!
Theoperatinginstructionsforthehoses,theaccessoriesandtheconnected
devicesmustalsobeheeded!
Evenifyouhavealreadyreceivedinstructionsonhowtousetheequipment,youshouldstill
readthroughthefollowingsafetyinstructionsagain.
WARNING / CAUTION!
Ensure that the accessories and connected equipment are suitable for the
maximumoperatingpressure!
Pleaseensurethatnobody
partsorclothingarecaught
betweenthevisiblymoving
parts(e.g.pistonclawand
cylinder).
Workingundersuspended
loadsisnotpermittedwhere
suchloadsarebeingliftedonly
usinghydraulicdevices.Ifthis
workisunavoidable,suitable
mechanicalsupportsarealso
required.
Wearprotectiveclothing,safety
helmetwithvisor,safetyshoes
andprotectivegloves
Checktheequipmentfor
visibleawsordamagebefore
andafteruse.
Immediatelyreportany
changesthatoccur(including
changesinoperating
behaviour)totheappropriate
persons/departments!If
necessary,theequipmentisto
beshutdownimmediatelyand
secured!
Inspectalllines,hoses,and
screwedconnectionsfor
leaksandexternallyvisible
damage.Ifnecessary,repair
immediately!Escaping
hydraulicuidcancause
injuriesandres.
6
Intheeventofmalfunctions,
immediatelydeactivatethe
equipmentandsecureit.
Repairthefaultimmediately.
Donotcarryoutanychanges
(additionsorconversions)
totheequipmentwithout
obtainingtheapprovalof
LUKASbeforehand.
Observeallsafetyanddanger
informationonthedeviceand
intheoperatinginstructions.
Allsafetyanddanger
informationonthedevicemust
alwaysbecompleteandina
legiblecondition.
Anymodeofoperationwhich
compromisesthesafetyand/
orstabilityofthedeviceis
forbidden!
Observeallintervalsfor
recurringtestsand/or
inspectionsthatareprescribed
orstatedintheoperating
instructions.
Safetydevicesmustneverbe
disabled!
Themaximumpermitted
operatingpressurenotedon
theequipmentmustnotbe
exceeded.
Makesurebeforeswitching
on/startingupthedeviceand
duringitsoperationthatthis
willputnooneindanger.
OnlygenuineLUKAS
accessoriesandspareparts
aretobeusedforrepairs.
Pleaseensurethat,when
workingwiththisequipmentor
duringtransportationofsuch,
youdon’tgetcaughtupinthe
loopedhosesandtrip.
Whenworkingclosetolive
componentsandcables,
suitablemeasuresmustbe
takentoavoidcurrenttransfers
orhigh-voltagetransferstothe
equipment.
Pleasenotethat,when
pressing,tearingorbreaking
cancausethematerialtofall
down,orsuddenremovalcan
causeittosuddenlycatapult
o:necessaryprecautions
needtobetaken.
Thebuild-upofstaticcharge
andthereforepossible
sparkingmustbeavoided
whenhandlingthedevice.
Onlytouchanybroken-oparts
withprotectivegloves,ascut
edgescanbeverysharp.
7
The generally applicable, legal and other binding national and international regulations
pertainingtothepreventionofaccidentsandprotectionoftheenvironmentapplyandareto
beimplementedinadditiontotheoperatinginstructions.
WARNING / CAUTION / ATTENTION!
The equipment is exclusively intended for the purpose stated in the operating
instructions (see chapter “Appropriate Use”).Anyotheruseis not considered intended
useThemanufacturer/supplierisnotliableforanydamageresultingfrominappropriateuse.
Theuserbearssoleresponsibilityforsuchuse.
Appropriateuseincludesobservanceoftheoperatinginstructionsandcompliancewiththe
inspectionandmaintenanceconditions.
Never work in a fatigued or intoxicated state!
Theequipmentislledwith
hydraulicuid.Thishydraulic
uidcanbedetrimentalto
healthifitisswallowedor
itsvapourisinhaled.Direct
contactwiththeskinmustbe
avoidedforthesamereason.
Also,whenhandlinghydraulic
uid,notethatitcannegatively
aectbiologicalsystems.
Whenworkingwithorstoring
theequipment,ensurethatthe
functionandthesafetyofthe
equipmentarenotimpaired
bytheeectsofsevere
externaltemperaturesorthat
theequipmentisdamagedin
anyway.Pleasenotethatthe
equipmentcanalsoheatup
overalongperiodofuse.
Makesurethereisadequate
lightingwhileworking.
Beforetransportingthe
equipment,alwaysensurethat
theaccessoriesarepositioned
insuchawaythattheycannot
causeanaccident.
Alwayskeeptheseoperating
instructionseasilyaccessible
attheplaceofoperation.
Disposeproperlyofall
disassembledparts,oiland
left-overuid,aswellas
packagingmaterials!
8
3. Appropriate use
You can obtain accessories and replacement parts for the rescue equipment from your
authorisedLUKASdealer.
LUKASdooropenersaredesignedespeciallyforrescueservices.Theyareusedforopening
doors/forcingdoorsopentogainaccessinanemergency.
Basically,objectscanbepushedaway.
ATTENTION!
Inthiscase,youmuststrictlyobserveanyleaksinordertoavoidthreatstothe
environment.
WARNING / CAUTION!
All objects to be moved must be secured by xed supports. It must also be
ensuredthatthedooropenerscannotslipaway.
WARNING / CAUTION!
Duringoperation,payattentiontopre-stressedparts,suchasdoorcloserswhich
canbecomelooseormakeuncontrolledmovements.
WARNING / CAUTION / ATTENTION!
Nolivecablesmaybecrushed:
NEVER operate the rescue equipment at a higher operating pressure than
thatstatedinthechapter“Technicaldata”.Ahighersettingmaycauseproperty
damageand/orinjuries.
LUKASrescueequipmentmayonlybeusedinareasatriskofexplosionifan
explosion has been prevented by appropriate measures. You must also take
intoaccount thefact thatsparksmay becreated, forexampleby spreadingor
squashinganobject.
When working in explosive areas, all applicable legal, national
and international regulations, standards and safety rules for
avoiding explosions must be observed without restriction!
WARNING / CAUTION / ATTENTION!
Noliftingprocessesmaybecarriedoutwiththedooropener.
9
4. Functional description
4.2 Unit in detail
Thedooropenersaresingle-actinghydrauliccylinders.Extensionishydraulic,retractionis
mechanicalbyaspringreturn.
4.1 Description
HT 90
1 Femalecoupling
2 Cylinder
3 Claw
4 Base
1
2
3
4
1 Femalecoupling
2 Cylinder
3 Claw
4 Base
1
2
3
4
10
4.4 Control of the operating movements
Pressureisappliedbyahandpump.
Duetothespringforce,thepistonrodretractsagainassoonaspressurestopsbeingapplied
andthepressurecanbereleasedviathesupplyline(notblockedandnopressureapplied).
4.3 Wiring diagram
Thewiringdiagramisshownhereinsimpliedformtoenablecomprehensionofthefunction.
1 Femalecoupling
2 Cylinder
3 Claw
4 Base
1
2
3
4
JL-8
11
4.5 Hydraulic supply
4.6 Hoses
OnlyLUKAShandpumpsmaybeusedtodrivetheequipment.
If the hand pump is a dierent make, you must make sure that it complies with LUKAS
specications, otherwise potential dangers may occur, for which LUKAS cannot be held
responsible. Ensure in particular that the authorised operating pressure for LUKAS
equipmentisnotexceeded.
NOTE:
Beforeusingpumpsfromadierentmanufacturer,youmustcontactLUKASor
anauthoriseddealer.
Thehandpumpanddooropenerareconnectedbyhoselines.
ATTENTION!
The HT90 and HT99 door openers may only be operated with mineral oil in
accordancewithsection11.1“Recommendedhydraulicuids”.
TheJackRabbitToolJL-8mayonlybeoperatedwithmineraloilinaccordance
withsection11.1“Recommendedhydraulicuids”.
5. Connecting the equipment
5.1 General information
Afemalescrewedcouplingismountedonthedevice;itisconnectedtothehandpumpviaa
hose.Thehoseisequippedwithcouplingssothatitcanbeconnectedwithouterror.
5.1.1. Door opener HT90
5.1.2. Door opener HT99
WARNING / CAUTION / ATTENTION!
Priortoconnectingthedevices,ensurethatall the components
being usedaresuitableforthe maximum operating pressure
of the pump unit.Incaseofdoubt,youmust contact LUKAS
directly.
A(Flat-Face)femalequick-disconnectcouplingismountedonthedevice;itisconnectedto
thehandpumpviaahose.Thehoseisequippedwithcouplingssothatitcanbeconnected
withouterror.
12
Thedeviceisconnectedtothehydraulicpumpwithouttheriskofconnectionerrorbymeans
ofscrewedcouplinghalves(femaleandmalecounterparts).
5.2 Coupling of screwed couplings (on HT 90)
The device is connected to the hand pump without the risk of connection error using
Flat-Facequick-disconnectcouplinghalves(femaleandmale).
NOTE:
Couplingofthedevicesisonlypossiblewhenthehosesaredepressurised.
Removethedustcapsbeforecouplingandthenpushthemaleconnectorintothefemale
connector.Thenscrewthethreadedsleeveofthefemaleconnectorontothemalethreadon
themalecouplingandtightenhand-tight.Theconnectionisnowmade.
Uncouplingisdoneinthereverseorder.
NOTE:
Couplingofthedevicesisonlypossiblewhenthehosesaredepressurised.
Fordustprotection,thesupplieddustcapsmustberetted.
5.3 Coupling of Flat-Face quick-disconnect couplings (on HT 99
and JL-8)
Toconnectthedevice,pushthemaleintothefemalecounterpart.Tolock,turnthesleeveof
themalecounterpartby90°.
Todecouple,turnthesleeveofthemalecounterpartby90°againandthenpullback.
Ahosewitha(Flat-Face)femalequick-disconnectcouplingismountedonthedevice.Itis
coupleddirectlytothehandpump.
5.1.3. Jack Rabbit Tool JL-8
13
6. Operation
6.1 Preparatory measures
6.1.1 Inspection of the hand pump
Seeseparateoperatinginstructionsforthecorrespondinghandpump.
6.2 Danger information
Beforeoperatingthedooropener, you should ensure that no participants or persons not
involvedareputatriskfromthemovementofthepistonrodorfromyingfragments.Also
avoid unnecessary damage to property belonging to others, objects not involved by the
cylinderpistonsoryingfragments.
Holding the device by the piston rod during operation is strictly
forbidden.
6.3 Starting points
Doorswithsingleprotection:Lockingplateanddoorhinges.
Doorswithmultipleprotection:Lockingplate,doorhingesandifnecessaryoneachlockingpin.
14
6.4 Procedure
WARNING / CAUTION / ATTENTION!
- Ifthedeviceslipsometalorstone,thereisariskofsparks.
- Thedooropenermustbeheldrmlytopreventinjurybyfallingdownwhen
thedoorisforcedopen.
- Thereisariskofinjuryintheareaofdoorsthatspringopenorareforcedopen.
Whenattachingthedevice,itmustbepressedrmlyandasdeeplyaspossibleintothedoor
gapwiththeclawsordriventhroughtheanvil(seepicture).
Anvil
Whenworkinginpotentiallyexplosiveenvironments,sparkingmustbeavoided.
6.5 Retraction of the piston
Whenretractingthepiston,makesurethatthebase(item4)isloweredbetweentheclaw
(item3).Turnthebaseifnecessary.
WARNING / CAUTION!
Whenretractingthepiston,thereisariskofcrushingbetweentheclawand
thebase.
15
7. Dismantling the equipment /
deactivation following operation
7.1 Door opener
Attheendofthework,thedooropenersmustberetracteduntiltheyreachtheendposition.
Thisrelieveshydraulicandmechanicalstressonthedevice.
NOTE:
When door openers are in storage, uctuations in ambient temperature can
cause the pistons to move slightly. This physical phenomenon is due to the
dieringexpansionoftheenclosedhydraulicuid.
7.2 Hand pump
7.3 Hoses
Aftercompletingthework,thehandpumpmustbedepressurised.
Firstdecouplethepressurehose,thenthereturnhoseasdescribedinchapter“Connecting
theequipment”.
Makesurethatyoureplacethedustprotectioncapsonthecoupling.
16
8. Maintenance and service
ATTENTION!
Cleanoanydirtbeforecheckingthedevice!
WARNING / CAUTION / ATTENTION!
Toperformmaintenanceandrepairs,personalprotectionequipmentappropriate
fortheworkisanabsoluterequirement.
Inspections to be carried out:
Visual inspection
Door opener
• Cylinderandpistonrodundamagedandnotdeformed,
• Correctandrmtofclawandbase,
• Clawandbasearefreefromdamage,deformationandnicks,
• Generaltightness(leaks),
• Mobilityofswivelconnection,
• Labelscompleteandlegible,
• Couplingsmustbeeasytocouple,
• Dustprotectioncapsmustbepresent.
Hoses (see also operating instructions for hose lines)
• Visualinspectionforvisibledamage,
• Checkforleaks,
• Checkdateofmanufacture(notethe10-yearreplacementperiod).
Operational check
• Pistoncanbefullyextendedandretracted(seechapter“TechnicalData”),
• Flawlessextensionandretraction,
• Nosuspiciousnoisesduringtheprocedure,
• Noleaks.
Thedevicesaresubjecttoveryhighmechanicalstress.Therefore,avisualinspectionmust
becarriedoutaftereveryuseandatleastonceayear.Theseinspectionsenabletheearly
detectionof wear andtear, which meansthatpunctual replacement ofthis wearing parts
preventsbreakagesfromoccurring.Every3yearsorwhentheremightbedoubtsregarding
thesafetyorreliabilityoftheunit,anadditionalfunctioncheckistobecarriedout(inthis
connection,complywiththeapplicablenationalandinternationalregulationswithregardto
themaintenanceintervalsofrescueequipment).
17
9.2.1 Care instructions
Theexterioroftheequipmentistobecleanedfromtimetotimeinordertoprotectitfrom
externalcorrosion.Oilistobeappliedtothemetallicsurfaces.
9.2.2 Function and load test
Ifthereisanydoubtregardingthesafetyorreliabilityoftheequipment,afunctionandload
testmustalsobeperformed.
9. Repairs
9.1 General information
Servicing may only be carried out by the manufacturer or personnel trained by the
manufacturerandbyauthorisedLUKASdealers.
OnlyLUKASsparepartsmaybeusedtoreplaceallcomponents(seesparepartslist),as
specialtoolsandcompliancewithassemblyinstructions,safetyaspectsandinspectionsare
required(seealsochapter“MaintenanceandServicing”).
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
devicesmayalsobepressurisedwhennotinoperation.
NOTE:
AlwaysregisteryourdeviceontheLUKASHydraulikGmbHwebsite.Thisisthe
onlywaytoguaranteeyourextendedwarrantycover.
NOTE:
You should always contact LUKAS or an authorised dealer before using
couplingsfromanothermanufacturer.
ATTENTION!
BecauseLUKASrescueequipmentsareappropriateforhighestachievements,
onlycomponentsmaybeexchanged,whicharespeciedinthesparepartslist
oftheappropriateequipment.
Othercomponentsinthedevicemayonlybereplacedif:
- YouhaveparticipatedinanappropriateLUKASservicetrainingcourse.
- You have the explicit permission of LUKAS Customer Service (on request,
vericationthatpermissionmaybegranted.Tobecheckedineachindividual
case!)
9.2 Preventative service
Afunctionaltestmustbecarriedoutafterrepairs:
Extendthedevice2-3timesintheunloadedstatesothatanyairpresentcanescapefrom
thesystem.
18
ATTENTION!
Alwaysreplacethehydraulicuidoveraliquidcollectioncontaineranddispose
ofthecollecteduidinapropermanner.
ATTENTION!
The hydraulic uid must be completely replaced if the application conditions
(ambienttemperatures)changesubstantially.Whenselectingasuitablehydraulic
uid,pleaserefertothechapter“Recommendedhydraulicuids”.
9.2.3 Replacing the hydraulic uid
- Thehydraulicuidmustbereplacedafterapprox.200deployments,butafterthreeyears
atthelatest,
- Itmustalwaysbechangedwheneverthehydraulicuidfortheaccompanyinghandpump
ischanged.Thisistopreventthefreshhydraulicuidfrombecomingcontaminatedbythe
useduidfromtherescueequipment.
Procedure:
1. Retractthedooropenerfullyanddepressurisethehydraulicsystem.
2. Removethecouplingonthedooropener.
3. Drainothehydraulicuid.
4. Flush
5. Reassemblethecoupling.
6. Connecthandpumpwithfreshhydraulicuid.
7. De-aerateasdescribedinChapter“Firstoperation”.
8. Re-connectthehandpump.
9.3 Repairs
9.3.1 Replacing the hose (on JL-8)
Hoseconnectionleakingorhosedefective.
Procedure:
1. Removethecouplingfromthehoseline.
2. Removethehoselinefromthecylinderofthedooropener.
3. Mountanewhoselineonthecylinderofthedooropenerandtightenwithatorqueof
MA=40Nm(use Teon tape).
4. ReassemblecouplingonthehoselineandtightenwithatorqueofMA=40Nm
(use Teon tape).
19
9.3.2 Flat Face quick-disconnect couplings (on JL-8)
Thequick-disconnectcouplingsmustbereplacedif:
-thereisexternaldamage,
-thelockdoesnotwork,
-hydraulicuidcontinuestoleakinthecoupledand/oruncoupledstate.
WARNING / CAUTION / ATTENTION!
Neverrepaircouplings:theymustbereplacedbygenuineLUKASparts!
WARNING / CAUTION / ATTENTION!
Neverrepaircouplings:theymustbereplacedbygenuineLUKASparts!
Procedure:
1. Removethecouplingfromthehoseline.
2. MountthenewcouplingonthehoselineandtightenwithatorqueofMA=40Nm
(use Teon tape).
9.3.3 Screwed couplings (on HT90)
Thescrewedcouplingsmustbereplacedif:
-thereisexternaldamage,
-thelockdoesnotwork,
-hydraulicuidcontinuestoleakinthecoupledand/oruncoupledstate.
Procedure:
1. Dismantletheswivelscrewconnectionofthedooropener.
2. Mountnewcouplingontheswivelscrewconnectionofthedooropenerandtightenwith
atorqueofMA=50Nm.
9.3.4 Flat Face quick-disconnect couplings (on HT 99)
Thequick-disconnectcouplingsmustbereplacedif:
-thereisexternaldamage,
-thelockdoesnotwork,
-hydraulicuidcontinuestoleakinthecoupledand/oruncoupledstate.
WARNING / CAUTION / ATTENTION!
Neverrepaircouplings:theymustbereplacedbygenuineLUKASparts!
Procedure:
1. Dismantletheswivelscrewconnectionofthedooropener.
2. Mountcouplingonswivelscrewconnectionofthedooropenerandtightenwithatorque
ofMA=45Nm(use Teon tape).
20
10. Troubleshooting
Fault Check Cause Solution
Cylinderdoesnot
extend,
extendstooslow-
lyorstopswhen
extending
Checkthehydrau-
licuidlevelinthe
pumpsupplyingthe
uid.
Insucienthydrau-
licuidinthehand
pump.
Rellthehydraulic
uid.
Checkthatthe
pressurereliefvalve
onthehandpumpis
closed.
Pressurereliefvalve
onhandpumpopen.
Closethepressure
reliefvalveonthe
handpump.
Checkthatall
couplingsarefully
tightened.
Hydrauliccoupling
loose.
Tightenhydraulic
coupling.
Airinhydraulicsys-
tem.
Venthydraulicsys-
teminaccordance
withsection6.1.
Checkthecylinder
fordamage.
Cylinderpistonjams. Havethedamage
repairedbyan
authoriseddealer,by
personnelspecially
trainedbyLUKAS,
orbyLUKASitself.
9.3.5 Decals
Alldamagedand/orillegiblelabels(safetynotices,typeplate,etc.)mustbereplaced.
Procedure:
1. Removedamagedand/orillegibledecals.
2. Cleansurfaceswithacetoneorindustrialalcohol.
3. Axnewdecals.
Takecaretoaxthelabelsinthecorrectpositions.Ifthisisnolongerknown,youshouldask
yourauthorisedLUKASdealerorcontactLUKASdirectly.
This manual suits for next models
3
Table of contents
