Lukas H1 User manual

Operating instructions for rescue equipment
84150012085 EN
H1 and H2 Lifting Sets (DIN 14800)
(Translation of the original operating instructions)
replaces 03.2008
Edition 03.2015
Lifting Set H1
Lifting Set H2

2

3
Content Page
1. Danger classifications 4
2. Product safety 5
3. Appropriate use 8
4. System description and overview 10
4.1 Design of the system and connection of the components 10
4.2 Commissioning and control 12
5. Lifting and lowering of loads 14
5.1 Lifting a load 14
5.2 Lowering a load 15
6. Accessories 16
6.1 Base plate 16
6.2 Extension 16
6.3 Wedge block (Expansion wedge) 16
6.4 Foot lifter 17
7. Maintenance and repair 18
7.1 General information 18
7.2 Function and load test 19
7.3 Signs 19
8. Troubleshooting 20
9. Technical data 23
9.1 Technical data of the hydraulic cylinder 23
9.2 Technical data of the Hand pump 24
9.3 Technical data of lifting set H1/H2 25
9.4 Dimensions of the transport crate 25
9.5 Operating and storage temperature ranges 25
10. Declaration of conformity 26
11. Instructions regarding disposal 27
12. Notes 27

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!
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.
The generally applicable legal and other binding regulations pertaining to the prevention of
accidents and protection of the environment apply and are to be complied with in addition to
the operating instructions.
The equipment must only be operated by persons with appropriate training in the safety
aspects of such equipment – otherwise, there is a danger of injury.
We would like to point out to all users that they should read carefully the operating instructions
and the instructions contained therein before they use the equipment, and that they should
be carefully followed.
We also recommend that you have a qualified trainer show you how to use the product.
WARNING / CAUTION!
The operating instructions for accessories must also be taken into account!
Even if you have already received instruction on how to use the equipment, you should still
read through the following safety instructions again.
WARNING / CAUTION!
Please ensure that the accessories you use are appropriate for the maximum
operating pressure and the performance of the rescue device!
Please ensure that no body
parts or clothing get stuck
between the visibly moving
parts.
Working under suspended
loads is not permitted where
such loads are being lifted
solely by means of hydraulic
or electro-hydraulic devices.
If this work is unavoidable,
suitable mechanical supports
are also required.
Wear protective clothing, safety
helmet with visor, safety shoes
and protective gloves.
Check the equipment for
visible flaws or damage before
and after use.

6
Immediately report any
changes that occur (including
changes in operating
behaviour) to the appropriate
persons/departments! If
necessary, the equipment is to
be shut down immediately and
secured!
All bolted connections must
be checked for leaks and
externally visible damage,
which must be repaired
immediately! Escaping
hydraulic fluid can cause
injuries and fires.
In the event of malfunctions,
immediately deactivate the
equipment and secure it.
Repair the fault immediately.
Do not carry out any changes
(additions or conversions)
to the equipment without
obtaining the approval of
LUKAS beforehand.
Observe all safety and danger
information on the device and
in the operating instructions.
All safety and danger
information on the device must
always be complete and in a
legible condition.
Any mode of operation which
compromises the safety and/
or stability of the device is
forbidden!
Repairs to the equipment may
only be carried out by a trained
service technician with specific
knowledge of the device.
Safety devices must never be
disabled!
Only genuine LUKAS
accessories and spare parts
are to be used for repairs.
Make sure before switching
on/starting up the device and
during its operation that this
will put no one in danger.
Observe all intervals for
recurring tests and/or
inspections that are prescribed
or stated in the operating
instructions.
When working close to live
components and cables,
suitable measures must be
taken to avoid current transfers
or high-voltage transfers to the
equipment.
Please note that materials can
fall off during lifting or lowering
or be slung away if a load is
suddenly released. Also take
suitable precautions of your
own.
Please ensure that you do not
become entangled in cables
and trip when working with or
transporting the device.
Please ensure that dust
protection caps are provided
for the couplings.

7
The equipment is filled with
hydraulic fluid. This hydraulic
fluid can be detrimental to
health if it is swallowed or
its vapour is inhaled. Direct
contact with the skin must
be avoided for the same
reason. Also, when handling
hydraulic fluid, note that it can
negatively affect biological
systems.
When working with or storing
the equipment, ensure that
the function and the safety
of the equipment are not
impaired by the effects of
severe external temperatures
or that the equipment is
damaged in any way. Please
note that the equipment can
also heat up over a long
period of use.
Make sure there is adequate
lighting while working.
Before transporting the
equipment, always ensure that
the accessories are positioned
in such a way that they cannot
cause an accident.
Always keep these operating
instructions easily accessible
at the place of operation.
Ensure the proper disposal of
all removed parts, left-over oil
and hydraulic fluid as well as
packaging materials!
Protect all of the lifting set
components against humidity
and moisture
The hand pump is not suitable
for underwater applications.
The build-up of static charge
and therefore possible
sparking must be avoided
when handling the device.
Always wear protective gloves
to prevent injury when touching
torn or sharp-edged parts.
The generally applicable, legal and other binding national and international regulations
pertaining to the prevention of accidents and protection of the environment apply and are to
be implemented in addition to the operating instructions.

8
3. Appropriate use
The LUKAS lifting sets are specially designed for the lifting or stabilising of heavy or movable
loads requiring lifting in order to free persons, vehicles or other objects from operations in
dangerous or catastrophic situations.
The lifting cylinders can also be used in all types of dangerous situations for the shifting or
lifting of objects to rescue buried or trapped persons or to recover any type of heavy object
(vehicles, devices, etc.).
Buildings in danger of collapsing or heavy vehicles in danger of crashing can be temporarily
secured and stabilised.
Thanks to the cylinder's low design, the lifting sets can be particularly well used for initial
lifting at low clearance heights between the object and the floor. The cylinder extensions can
additionally be used to increase the initial height of the stroke.
The cylinder unit of the lifting set is suitable for underwater applications. The hand pump
requires an air exchange through the tank cover of the hydraulic fluid container.
Additional safety instructions:
• Never use hydraulic cylinders without a base plate (stability). Use hard wood
spacers if possible to provide additional stability of the load.
• Never use more than one extension per cylinder (risk of buckling with multiple
arrangements).
• Always load the hydraulic cylinder in the centre (in the direction of the cylinder axis)!
Exception: Use of the foot lifter according to instructions.
• Work with a support bar when using the foot lifter (see Accessories section).
Screw the foot lifter on in reverse for loads with low internal strength and use it
without the support bar. Use suitable underlays or support bars to provide additional
support if necessary.
• Always lay the hoses to be free of twists and kinks!
• Pay extremely close attention to the moving load during the lifting and lowering
processes!
• Always provide additional mechanical support to raised loads!
• No bystanders are allowed in the hazard zone!
WARNING / CAUTION / ATTENTION!
The system is exclusively intended for the purpose stated in the operating instructions
(see section "Appropriate Use"). Any other use is not considered appropriate.
The manufacturer/supplier is not liable for any damage resulting from inappropriate use.
The user bears sole responsibility for such use.
Appropriate use includes observance of the operating instructions and compliance with the
inspection and maintenance conditions.
Never work in a fatigued or intoxicated state!

9
WARNING / CAUTION / ATTENTION!
The following may not be pressurised or squeezed:
- electric cables
- prestressed and hardened parts such as springs, spring steels,
steering columns and rollers
- tubes or containers under gas or liquid pressure
- explosive bodies such as airbag cartridges
The internally set operating pressure may only be directly changed after
consultation with LUKAS. A change in settings may result in damage to property
and/or injuries.
The H1and H2 lifting sets are not explosion protected!
When using the equipment in explosive areas you must rule out any chance of
the equipment causing an explosion.
The responsibility for explosion prevention or for prohibiting work with a lifting set
rests with the operator of the device or with the person responsible at the place
of use.
When working in explosive areas, all applicable legal, national
and international regulations, standards and safety rules for
avoiding explosions must be observed without restriction!
The lifting set should not come into contact with acids or alkalis. If this is
unavoidable, clean the equipment immediately afterwards with a suitable cleaning
agent.
You can obtain other accessories and replacement parts for the lifting sets from your
authorised LUKAS dealer!
WARNING / CAUTION!
Always ensure that the surroundings of the object to be lifted remain stable and
are secured against accidental shifting by sustainable supports or substructures.

10
4. System description and overview
4.1 Design of the system and connection of the components
2
1
A LUKAS lifting set generally includes a hydraulic hand pump which serves as a drive for
one or two single-acting hydraulic cylinders. Operating the hand pump presses hydraulic
fluid into the cylinder or cylinders, causing the cylinder piston to extend and lift an attached
load. The reset spring in the cylinder causes the cylinder to retract in the idle stroke or it is
retracted under loading by the force exerted by the attached load.
The components are joined together by connection hoses and couplings.
The accessories make it possible to optimally use the cylinders in any position desired at
the site.
The cylinders are controlled by the pump movement on the hand pump. The drain valve
must be closed to build up pressure. The hand wheels (distributor stop valves) must be open
when two cylinders are operated with 2-way distributors. A hydraulic load holding function
is provided when the isolating valves (distributors) are closed. You should also secure the
system mechanically when the cylinders are continuously loaded (under load).
4
5
4a
4b
33a3b
5a
Connection of two (2)
cylinders using the distributor
valve
Connection of one (1)
cylinder directly to the pump
1
1
5
5