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. 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 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. Dismantlingtheequipment/deactivationfollowingoperation 15
7.1 Door opener 15
7.2 Hand pump 15
7.3 Hoses 15
8. Maintenanceandservice 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.Technicaldata 23
 11.1 Recommendedhydraulicuids 24
11.2 Operating and storage temperature ranges 24
12.ECDeclarationofConformity 25
13.Notes 27

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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.pistonclawand
cylinder).
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.

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
pressing,tearingorbreaking
cancausethematerialtofall
down,orsuddenremoval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
withprotectivegloves,ascut
edgescanbeverysharp.

7
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!
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.
Disposeproperlyofall
disassembledparts,oiland
left-overuid,aswellas
packagingmaterials!

8
3. Appropriate use
You can obtain accessories and replacement parts for the rescue equipment from your
authorisedLUKASdealer.
LUKASdooropenersaredesignedespeciallyforrescueservices.Theyareusedforopening
doors/forcingdoorsopentogainaccessinanemergency.
Basically,objectscanbepushedaway.
ATTENTION!
Inthiscase,youmuststrictlyobserveanyleaksinordertoavoidthreatstothe
environment.
WARNING / CAUTION!
All objects to be moved must be secured by xed supports. It must also be
ensuredthatthedooropenerscannotslipaway.
WARNING / CAUTION!
Duringoperation,payattentiontopre-stressedparts,suchasdoorcloserswhich
canbecomelooseormakeuncontrolledmovements.
WARNING / CAUTION / ATTENTION!
Nolivecablesmaybecrushed:
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 spreadingor
squashing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!
WARNING / CAUTION / ATTENTION!
Noliftingprocessesmaybecarriedoutwiththedooropener.

9
4. Functional description
4.2 Unit in detail
Thedooropenersaresingle-actinghydrauliccylinders.Extensionishydraulic,retractionis
mechanicalbyaspringreturn.
4.1 Description
HT 90
1 Femalecoupling
2 Cylinder
3 Claw
4 Base
1
2
3
4
1 Femalecoupling
2 Cylinder
3 Claw
4 Base
1
2
3
4

10
4.4 Control of the operating movements
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).
4.3 Wiring diagram
Thewiringdiagramisshownhereinsimpliedformtoenablecomprehensionofthefunction.
1 Femalecoupling
2 Cylinder
3 Claw
4 Base
1
2
3
4
JL-8

11
4.5 Hydraulic supply
4.6 Hoses
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.
Thehandpumpanddooropenerareconnectedbyhoselines.
ATTENTION!
The HT90 and HT99 door openers may only be operated with mineral oil in
accordancewithsection11.1“Recommendedhydraulicuids”.
TheJackRabbitToolJL-8mayonlybeoperatedwithmineraloilinaccordance
withsection11.1“Recommendedhydraulicuids”.
5. Connecting the equipment
5.1 General information
Afemalescrewedcouplingismountedonthedevice;itisconnectedtothehandpumpviaa
hose.Thehoseisequippedwithcouplingssothatitcanbeconnectedwithouterror.
5.1.1. Door opener HT90
5.1.2. Door opener HT99
WARNING / CAUTION / ATTENTION!
Priortoconnectingthedevices,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.
A(Flat-Face)femalequick-disconnectcouplingismountedonthedevice;itisconnectedto
thehandpumpviaahose.Thehoseisequippedwithcouplingssothatitcanbeconnected
withouterror.

12
Thedeviceisconnectedtothehydraulicpumpwithouttheriskofconnectionerrorbymeans
ofscrewedcouplinghalves(femaleandmalecounterparts).
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-Facequick-disconnectcouplinghalves(femaleandmale).
NOTE:
Couplingofthedevicesisonlypossiblewhenthehosesaredepressurised.
Removethedustcapsbeforecouplingandthenpushthemaleconnectorintothefemale
connector.Thenscrewthethreadedsleeveofthefemaleconnectorontothemalethreadon
themalecouplingandtightenhand-tight.Theconnectionisnowmade.
Uncouplingisdoneinthereverseorder.
NOTE:
Couplingofthedevicesisonlypossiblewhenthehosesaredepressurised.
Fordustprotection,thesupplieddustcapsmustberetted.
5.3 Coupling of Flat-Face quick-disconnect couplings (on HT 99
and JL-8)
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.
Ahosewitha(Flat-Face)femalequick-disconnectcouplingismountedonthedevice.Itis
coupleddirectlytothehandpump.
5.1.3. Jack Rabbit Tool JL-8

13
6. Operation
6.1 Preparatory measures
6.1.1 Inspection of the hand pump
   Seeseparateoperatinginstructionsforthecorrespondinghandpump.
6.2 Danger information
Beforeoperatingthedooropener, you should ensure that no participants or persons not
involvedareputatriskfromthemovementofthepistonrodorfromyingfragments.Also
avoid unnecessary damage to property belonging to others, objects not involved by the
cylinderpistonsoryingfragments.
Holding the device by the piston rod during operation is strictly
forbidden.
6.3 Starting points
Doorswithsingleprotection:Lockingplateanddoorhinges.
Doorswithmultipleprotection:Lockingplate,doorhingesandifnecessaryoneachlockingpin.

14
6.4 Procedure
WARNING / CAUTION / ATTENTION!
- Ifthedeviceslipso󰀨metalorstone,thereisariskofsparks.
- Thedooropenermustbeheldrmlytopreventinjurybyfallingdownwhen
thedoorisforcedopen.
- Thereisariskofinjuryintheareaofdoorsthatspringopenorareforcedopen.
Whenattachingthedevice,itmustbepressedrmlyandasdeeplyaspossibleintothedoor
gapwiththeclawsordriventhroughtheanvil(seepicture).
Anvil
Whenworkinginpotentiallyexplosiveenvironments,sparkingmustbeavoided.
6.5 Retraction of the piston
Whenretractingthepiston,makesurethatthebase(item4)isloweredbetweentheclaw
(item3).Turnthebaseifnecessary.
WARNING / CAUTION!
Whenretractingthepiston,thereisariskofcrushingbetweentheclawand
thebase.

15
7. Dismantling the equipment /
deactivation following operation
7.1 Door opener
Attheendofthework,thedooropenersmustberetracteduntiltheyreachtheendposition.
Thisrelieveshydraulicandmechanicalstressonthedevice.
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
di󰀨eringexpansionoftheenclosedhydraulicuid.
7.2 Hand pump
7.3 Hoses
Aftercompletingthework,thehandpumpmustbedepressurised.
Firstdecouplethepressurehose,thenthereturnhoseasdescribedinchapter“Connecting
theequipment”.
Makesurethatyoureplacethedustprotectioncapsonthecoupling.

16
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
Door opener
• Cylinderandpistonrodundamagedandnotdeformed,
• Correctandrmtofclawandbase,
• Clawandbasearefreefromdamage,deformationandnicks,
• 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devicesaresubjecttoveryhigh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).

17
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. Repairs
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
devices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in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
Afunctionaltestmustbecarriedoutafterrepairs:
Extendthedevice2-3timesintheunloadedstatesothatanyairpresentcanescapefrom
thesystem.

18
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dooropenerfullyanddepressurisethehydraulicsystem.
2. Removethecouplingonthedooropener.
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 hose (on JL-8)
Hoseconnectionleakingorhosedefective.
Procedure:
1. Removethecouplingfromthehoseline.
2. Removethehoselinefromthecylinderofthedooropener.
3. Mountanewhoselineonthecylinderofthedooropenerandtightenwithatorqueof
MA=40Nm(use Teon tape).
4. ReassemblecouplingonthehoselineandtightenwithatorqueofMA=40Nm
(use Teon tape).

19
9.3.2 Flat Face quick-disconnect couplings (on JL-8)
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!
WARNING / CAUTION / ATTENTION!
Neverrepaircouplings:theymustbereplacedbygenuineLUKASparts!
Procedure:
1. Removethecouplingfromthehoseline.
2. MountthenewcouplingonthehoselineandtightenwithatorqueofMA=40Nm
(use Teon tape).
9.3.3 Screwed couplings (on HT90)
Thescrewed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.
Procedure:
1. Dismantletheswivelscrewconnectionofthedooropener.
2. Mountnewcouplingontheswivelscrewconnectionofthedooropenerandtightenwith
atorqueofMA=50Nm.
9.3.4 Flat Face quick-disconnect couplings (on HT 99)
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swivelscrewconnectionofthedooropener.
2. Mountcouplingonswivelscrewconnectionofthedooropenerandtightenwithatorque
ofMA=45Nm(use Teon tape).

20
10. Troubleshooting
Fault Check Cause Solution
Cylinderdoesnot
extend,
extendstooslow-
lyorstopswhen
extending
Checkthehydrau-
licuidlevelinthe
pumpsupplyingthe
uid.
Insu󰀩cienthydrau-
lic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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sys-
tem.
Venthydraulicsys-
tem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.
9.3.5 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.