Lukas LH2 User manual

179101085 EN
(Translation of the original instruction manual)
replaces 02.2013
Edition 07.2017
Instruction manual for rescue equipment
Hand pump LH2
Foot pump LF2
and accessories

2

3
Contents Page
1. Danger classes 4
2. Product safety 4
3. Intended use 7
4. Main components of the hand pump 8
5. Functional description 8
5.1 Base pump 8
5.2 Overview foot pump 9
5.3 Adapter blocks 10
6. Connection options for rescue equipment 10
6.1 Fittings 10
6.2 Quick-disconnect-couplings 11
6.3 Monocouplings 12
7. Commissioning 13
7.1 Unlocking the pump 13
7.2 Retracting the handle 13
7.3 Bleeding the pump 13
8. Operation 14
8.1 Operation 14
8.2 Shutdown / storage 15
9. Transport 15
10. Maintenance and repair 15
10.1 Basic requirements 15
10.2 Maintenance 16
 10.3 Hydraulicuidchangeoraddinghydraulicuid 17
10.4 Care 17
10.5 Repair 18
11. Troubleshooting 21
12. Technical data 24
12.1 Data of the hand and foot pumps 24
 12.2 Hydraulicuidrecommendation 25
12.3 Hose lines 26
12.4 Operating and storage temperature ranges 26
13. Notes 27

4
Wear helmet with face guard
Wear protective gloves
Wear safety shoes
We distinguish between various categories of safety instructions. The table shown below
shows you the overview, via the assignment of symbols (pictograms) and signal words, of
the concrete danger and the possible consequences.
1. Danger classes
Pictogram Damage /
injury to Key word Denition Consequences
human
DANGER! Immediate danger Death or major
injury
WARNING!
Potentially
dangerous
situation
Potential death or
major injury
CAUTION! Less dangerous
situation
Minor or slight
injury
device
CAUTION!
Danger of damage
to device /
environment
Damage to the
equipment,
damage to the
environment,
damage to
surrounding
materials
- NOTE
Advice for
application and
other important /
useful information
and advice
No injury /
damage to
persons /
environment /
equipment
2. Product safety
LUKAS products are developed and produced in order to ensure the best performance and
quality with proper use.
The safety of the operator is the most important consideration in the product design.
In addition, the operating instructions are to help in using the 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 heeded and
disseminated.
The device must only be operated by educated persons who are trained in safety technology,
since otherwise there is a risk of injury.
We advise all users before using the device to carefully read through the operating instructions
and to follow the instructions contained therein without exception.
Proper recycling
Protect the environment
Read and follow operating
instructions

5
We also recommend that you get instructed by a qualied trainer in the use of 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 instruction, you should read the following safety instructions
again.
Make sure that no body parts
or clothing get between the
openly visible moving parts of
the device.
Immediately report changes
that occur (including changes
in operating behaviour) to
the appropriate persons/
departments! If necessary,
immediately shut down and
secure the device!
Wear protective clothing,
protective helm with visor,
safety shoes and protective
gloves.
Check the device for visible
defects or damage before and
after use.
Working under loads is
prohibited if they are raised
exclusively with hydraulic
devices. If this work is
unavoidable, su󰀩cient
mechanical supports are
additionally required.
Check all lines, hoses and
screwed connections for leaks
and externally visible damages
and repair immediately!
Escaping hydraulic uid can
lead to injuries and res.
In the event of malfunctions,
shut down the device
immediately and secure it. You
should have the malfunction
repaired immediately.
Do not make any changes
(add-ons or conversions) on the
device without the approval of
LUKAS.
Heed all safety instructions
and hazard warnings on the
device and in the operating
instructions.
All safety instructions and
hazard warnings on the device
are to be kept intact and in a
legible condition.
Make sure that all safety covers
are present on the device and
in proper working condition.
Any work procedure that
detracts from the safety and/or
stability of the device should be
abandoned!
Safety equipment must never
be disabled!
The maximum permissible
operating pressure must not be
changed.

6
Before switching on/engaging
the device or while operating
the device, it must be ensured
that no one is endangered by
the operation of the device.
Observe all intervals that
are prescribed or specied
in the operating instructions
for recurring tests and/or
inspections.
When working in the vicinity
of live components and lines,
take appropriate measures for
preventing current transfers or
high voltage ashovers to the
device.
For repairs only original LUKAS
accessories and spare parts are
to be used.
Make sure that you do not
get caught in the hose loops
and trip when working with or
transporting the device.
Prevent electrostatic discharge,
which has the possible
consequence of spark
formation, when handling the
device.
When the hydraulic pumps are
set up, care needs to be taken
that they are not impaired by
extremely strong temperature
changes.
The device is lled with
hydraulic uid. These hydraulic
uids can be detrimental to
health if they are swallowed
or their vapours are inhaled.
Direct contact with the skin
should be avoided for the same
reason. Also, when handling
hydraulic uids, note that they
can negatively a󰀨ect biological
systems.
When operating and/or storing
the device, make sure that the
function and the safety of the
device are not impaired by
strong external temperature
di󰀨erences or that the device is
damaged. Keep in mind that the
device can also heat up when it
is continuously used.
Make sure there is adequate
lighting while working.
Before transporting the device,
always check to see that the
accessories are positioned
securely to prevent the
possibility of an accident.
Always keep these operating
instructions easily accessible
at the site where the device is
used.
Make sure you properly dispose
of all removed parts, leftover
hydraulic uid, leftover oil and
packing materials.
In addition to the safety instructions of these operating instructions, all generally applicable,
statutory and otherwise binding national and international rules for accident prevention need
to be heeded and disseminated!

7
WARNING / CAUTION / ATTENTION!
The device is specied exclusively for the purpose represented in the operating
instructions (see Chapter "Proper use"). Any use that di󰀨ers or goes beyond this is
considered improper. The manufacturer/supplier shall not be held liable for damages
resulting from improper use. The risk shall be borne solely by the user.
Proper use also includes heeding the operating instructions and complying with the inspection
and maintenance requirements.
Never work in a fatigued or intoxicated state!
3. Intended use
Accessories and spare parts for the rescue equipment can be obtained from your authorised
LUKAS dealer!
The LUKAS hand and foot pumps are used for the operation of LUKAS rescue devices.
They can be used as an additional or replacement drive source along with the LUKAS
hydraulic unit (e.g. in areas at risk for explosion).
Use with equipment of other manufacturers is possible, but requires technical testing and
approval of LUKAS on a case-by-case basis.
WARNING / CAUTION / ATTENTION!
Always note the product limitations with respect to operating pressure, load limit
values and operating conditions. The operating pressure should not be higher
than the lowest maximum operating pressure of any system components.
The operating pressure should NEVER be set higher than that which is specied
in the "Technical Data" chapter. A higher setting may cause property damage
and/or injuries.
Make sure that the usable capacity of the hydraulic pump (see chapter "Technical
Data") is su󰀩cient for operating the connected cylinders or devices.
The required hydraulic uid operating quantity can be found in the chapter
"Technical Data" or in the operating instructions of the devices to be operated.

8
4. Main components of the hand pump
1
2
3
4
5
6
7
1 Drain valve
2 Connection plate with
ttings or couplings
3 Vent / ll cap
4 Retractable pump
lever
5 Tank
6 Lock
7 Base plate
5. Functional description
5.1 Base pump
All LUKAS hydraulic pumps of this series are two-speed, i.e. they have two operating speeds:
• A high speed in the low pressure range (LP) for fast extension of the cylinder or device
while unloaded
• A low speed in the high pressure range (HP) for controlled extension of the cylinder or
device while loaded
The switch from low pressure (LP) to high pressure (HP) is automatic at the factory setting
for changeover pressure (see chapter "Technical Data").
A pressure port "P" with a G1/4" thread and a return port "T" with an M10 thread are directly
available as ports on the pump.
To connect rescue equipment, adapter blocks must be installed (see subchapter "Adapter
blocks" for more information). In the case of the pumps are sold by LUKAS, one of these
adapter blocks is always included as standard equipment and is already installed.
Of course, the installed adapter blocks may be replaced with other ones. However, you must
contact an authorised LUKAS dealer or contact LUKAS directly.
The retractable handle of the LUKAS hydraulic pump combines low required pumping force
with compact dimensions for storage and transport.
In addition, the LUKAS hand and foot pumps for rescue equipment are equipped with a base
plate to ensure a higher stability during operation.

9
The LUKAS foot pump and LUKAS hand pump are basically identical in their design and
function. Merely the hand lever and the drain valve were replaced by a foot pump lever.
The foot pump lever can not be retracted, however is equipped with a return spring that
will move the foot pump lever automatically into its upper position after the lock (6)
has been opened (refer to image above).
Therefore it has not to be pulled upward during the pumping procedure as with the hand
lever.
To avoid possible injuries secure the foot pump lever with
your hand before unlocking it. Holding the pump lever down
will prevent it from jumping up after the locking bolt was
shifted into release position.
Installation, connection of devices and maintenance will be carried out
according to the description in this operating instructions.
Unlike with the hand pump, merely the pumping procedure is foot-operated.
1 Drain valve
2 Connection plate with
ttings or couplings
3 Vent / ll cap
4 Foot pump lever
5 Tank
6 Lock
7 Base plate
5.2 Overview foot pump
12
3
4
5
6
7

10
5.3 Adapter blocks
Adapter block Function/use
Connection plate
with ttings
Possibility of connecting hose
lines directly to the hydraulic
pump
Connection
plate with quick-
disconnect-couplings
Possibility of connecting hose
lines directly to the hydraulic
pump via quick-disconnect-
couplings
Connection plate
with monocouplings
Possibility of connecting hose
lines directly to the hydraulic
pump via monocoupling
6. Connection options for rescue equipment
ATTENTION!
Make sure to store all plugs, screw plugs and/or dust caps in a way that
prevents them from getting dirty or lost.
After completion of the work, seal o󰀨 all lines using screw plugs and/or dust
caps to prevent contamination of the hydraulic pump.
When connecting lines to the hydraulic pump, we recommend positioning it
vertically so that the ports point upward. This reduces the danger of hydraulic
uid escaping.
6.1 Fittings
The hose lines are connected via ttings to the hydraulic pump.
1.
2.
1. First remove the closure caps from
the ttings.
2. Then, you can connect the hose lines
to the ttings and tighten them with a
tightening torque of MA= 40 Nm.
ATTENTION!
The return hose must always be connected at the "T" port of the
connection block.
The supply hose line must instead be connected at the "P" port.

11
The hose lines are connected via quick-disconnect coupling halves (female and male) to the
hydraulic pump in such a way that they cannot be reversed.
Before connecting the couplings, remove the dust cap, then pull back and hold the locking
sleeve of the female coupling (Position X). Push the male and female couplings together and
release the locking sleeve. Finally, turn the locking sleeve into Position Y. The connection is
then made and secured. Decoupling is done in the reverse sequence.
WARNING / CAUTION / ATTENTION!
The quick-disconnect-couplings have special functions, in part, and therefore
must not be unscrewed and/or reversed!
X
Y
For dust protection, the supplied dust caps must be reattached.
NOTE:
Coupling the equipment is only possible if the hoses are depressurised.
6.2 Quick-disconnect-couplings
ATTENTION!
Always connect the return line rst and then the supply line!

12
6.3 Monocouplings
Male coupling Female coupling
Dust caps
Before coupling, remove dust caps, then connect male and female couplings and turn locking
sleeve of the female coupling in direction "1" until the locking sleeve latches. The connection
is then made and secured. The decoupling is accomplished by turning the locking sleeve in
direction "0".
The coupling of the devices under pressure is also possible, assuming the connected
equipment is not turned on.
NOTE:
We recommend, when ambient temperatures are low and extension hoses /
hose winders are used, connecting the coupling halves in a depressurised state
because decoupling may otherwise require a very large exertion of force.
For dust protection, the supplied dust caps must be reattached.
WARNING / CAUTION / ATTENTION!
The monocouplings must not be unscrewed and/or the hose lines reversed!
The hose lines are connected via quick-disconnect coupling halves (female and male) to the
hydraulic pump in such a way that they cannot be reversed.

13
NOTE:
With the LUKAS hand and foot pump, a little idle stroke may occur when the
unit is rst used in the high pressure range.
However, this idle stroke independently disappears after a device is operated
2-3 times.
7.1 Unlocking the pump Unlock (1.) the shipping lock of the pump by
sliding the locking pin in the direction of the
hand wheel until it comes against the stop.
To lock (2.) the pin, move it until it comes
against the stop in the other direction. To do
this, the lever must be in the home position
(at the tank).
Locking pin
ATTENTION!
The hydraulic pump should be as close to horizontal as possible, because
otherwise the usable amount changes!
The oil ll plug must always be unscrewed one turn before starting the operation
of the hydraulic pump! This enables the aeration and bleeding of the hydraulic
tank.
After the work is completed but before transport, the oil ll plug should be
retightened!
7. Commissioning
7.2 Retracting the handle
You can pull out the handle by applying pressure to both sides of the thrust piece and
simultaneously pulling in the direction of the handle end until the thrust piece re-engages.
1. 2.
1.
2.
7.3 Bleeding the pump
1. Open the discharge valve.
2. Open the oil ll screw plug on the tank container and check the oil ll level. The oil ll
level should come up to approximately 1-2 cm below the top edge of the oil reservoir.
3. In this state, work the pump handle several times.
Hand wheel (or foot
plate lever)

14
NOTE:
To bleed connected equipment, make sure that the highest point of the connected
devices are below the level of the pump.
Before operating the pump, you should also open the oil ll screw plug. Only in this
way can any trapped air escape the hydraulic system when the pump is operated.
You should operate the connected equipment several times without load.
When you do this, also follow the separate operating instructions of the connected
devices.
WARNING / CAUTION!
Under certain circumstances, the pump handle can "kick back". Make sure that
your body remains to the side of the pump.
ATTENTION!
Never attach an extension to the pump handle that does not belong to the
device. These extensions usually cause the pump to become unstable during
operation.
8. Operation
NOTE:
In order to limit the required force in high pressure operation, we recommended
using short strokes with the pump handle. The greatest pumping e󰀨ect is produced
in the last 5 degrees of the stroke.
Should you use a female quick-disconnect-coupling as the port, quick stop may be
triggered if the discharge valve is opened too quickly (turning counter-clockwise),
i.e. the check valve incorporated in the male quick-disconnect coupling blocks
the return ow of oil while the connection between pump and female quick-
disconnect coupling is depressurised. This is provided as a safety function in case
the connection between the female quick-disconnect-coupling and pump starts
to leak and the pressure drops abruptly. In this case, the "quick stop" prevents,
for example, an abrupt drop in the load when an hydraulic cylinder is operated.
In order to release the quick stop again, more pressure must rst be supplied to
the device. Then, the pressure can be decreased again by slowly opening the
discharge valve.
Procedure:
1. Close discharge valve on the hydraulic pump completely (rotate clockwise).
2. Connect the return line of the device at the return port "T" and then the high pressure line
at the pressure port "P".
3. Move the locking pin into the operating position.
4. Supply the device with hydraulic uid or pressurise by operating the pump lever (up and
down movements).
5. To reduce the pressure of the device, slowly open the discharge valve of the hydraulic
pump (turn counter-clockwise). In this way, you can meter the pressure reduction precisely.
8.1 Operation

15
9. Transport
8.2 Shutdown / storage
To shut down or store the pump, seal all hydraulic connections with the associated screw
plugs or dust caps.
After sealing the hydraulic ports, open the drain screw (not up to the stop!) to depressurise
the pump.
Then carefully clean the external dirt o󰀨 of the hydraulic pump.
In addition, with a longer storage time, the outside of the device should be cleaned and all
visible mechanical moving parts need to be oiled.
ATTENTION!
After completion of the work but before transport, check to make sure the oil ll
screw plug is screwed in tightly!
Make sure the pump is not stored in a damp environment.
The pump lever is used as a carrying handle! Special pumps may be the exception in this
case. These pumps are custom-assembled for each customer; therefore, there may be a
di󰀨erent transport device or none! In these cases, please refer to your authorised dealers
or LUKAS directly. The lever must be locked for transport, as described in the chapter
"Unlocking the pump".
10. Maintenance and repair
Service work may only be performed by the device manufacturer or by personnel trained by
the device manufacturer and authorised LUKAS dealers.
All components must be replaced with original LUKAS spare parts, which are listed in the
spare parts list, because in this context even required special tools, assembly instructions,
safety aspects and/or checks absolutely must be taken into consideration.
During the assembly work, pay particular attention to the cleanliness of all components
because dirt can damage the equipment!
10.1 Basic requirements
WARNING / CAUTION / ATTENTION!
To perform maintenance and repairs, personal safety equipment appropriate for
the work is an absolute requirement. (incl. shields).
Assembly and repair work on the pump may only be performed if the entire
hydraulic system is depressurised!
Couplings should not be repaired; they should be replaced with original LUKAS
parts!
NOTE:
Always send the warranty tab back to LUKAS hydraulics GmbH.
You should always contact LUKAS or an authorised dealer before using outside
couplings.
Do not perform any repairs without the corresponding LUKAS spare parts list,
because necessary tightening torques for screw connections and/or in some
cases also important additional information are listed there.

16
The equipment is subject to very high mechanical stresses. Therefore, a visual inspection
needs to be made after each use, at least once per month (if continually used, once per
week).
In this way, early signs of wear are recognisable so that damage to the device can be
avoided by prompt replacement of these worn parts. Also check regularly to make sure that
all attachment screws are tightened (heed any applicable tightening torque specications).
At least once a year (if continually used once every half year) or if there is a doubt about
the safety or reliability, a functional check should be also performed (for this purpose, also
heed the corresponding applicable national and international specications related to the
maintenance intervals of the devices).
ATTENTION!
Clean the device before checking for dirt!
Do not use any aggressive agents for cleaning; it could cause damage to the
equipment.
Because LUKAS devices are designed for the highest performance, only
components may be replaced that are listed in the spare parts lists of the
corresponding device.
Additional components of the equipment may only be replaced if:
- You have participated in a corresponding LUKAS service training course.
- You have the express permission of LUKAS customer service (by request,
check on the grant of permission. A check is necessary in each individual
case).
10.2 Maintenance
Before performing maintenance work, clean the hydraulic pump thoroughly.
After performing the maintenance work, you should carefully coat all metallic parts with oil
to prevent any corrosion.
Checks (Maintenance measures):
Perform a visual inspection of the hydraulic pump at least once per month; in the case of
continuous use, once a week.
Visual inspection
Hand and foot pump
• are all hydraulic connections still tightened,
• generally sealed, no leaks present (oil "sweat" has no e󰀨ect on the operation),
• is damage to pump housings, valve blocks or attachment parts recognisable, especially
on the moving parts such as the piston rods,
• are all uid levels within the prescribed tolerances,
• are all non-moving parts rmly attached,
• is there no corrosion,
• freedom of movement for the pump lever and the hand wheels or foot plate
(check in the depressurised state),
• the couplings are easy to couple (if attached),
• are dust caps in place,
• are identication plate, all control decals, instruction decals, labels and warnings present
and legible.

17
NOTE:
In this test, an idle time of approximately 2 minutes needs to be observed and
the hydraulic pump needs to be reloaded to operating pressure.
The resulting max. operating pressure must not drop by more than 5% after
10 seconds.
A test pressure gauge is available from the LUKAS line of accessories.
Perform an operational check of the hydraulic pump at least once per year; in the case of
continuous use, once every half year.
Operational check
• no suspicious noises,
• tests at maximum load.
Execution:
Place the hydraulic pump on a solid base to operate. Then, connect a test manometer
to the supply hose line. Release the pump lever lock and close the discharge valve.
Then, the pressurisation to operating pressure corresponding to the specication on the
identication plate occurs.
10.3 Hydraulicuidchangeoraddinghydraulicuid
The hydraulic uid should be changed if dirty at least once a year. When the hydraulic pump
is operated in an especially dusty environment, we recommend changing the uid at least
once every half year.
ATTENTION!
Add hydraulic uid only if the hydraulic pump is disconnected from the lines or
the equipment operated with the pump is hydraulically depressurised. Otherwise,
after lling the entire hydraulic system could contain more hydraulic uid than the
tank can hold.
Procedure:
1. Open the bleed/ll cap on the tank.
2. Add hydraulic uid until the uid level comes up to 1-2 cm below the top edge of the oil
tank.
3. Bleed the hydraulic pump as described in the chapter "bleeding the pump".
4. Check the uid level again and close the tank again at the correct uid level with the
vent/ll cap on the tank. Should the tank no longer be su󰀩ciently full after bleeding, start
the ll procedure again at item 2.
NOTE:
Should the uid level in the tank still not be reached after repeated relling (during
maintenance), we recommend searching for leaks in the hydraulic system.
10.4 Care
If possible, do not store the hand pump in a damp or extremely dusty environment in order
to ensure a long service life. If this is unavoidable, you should perform more frequent
maintenance and/or shield the pump from these e󰀨ects if possible.
Regularly coat all metal parts with oil to prevent any corrosion.

18
10.5 Repair
ATTENTION!
Because LUKAS devices are designed for the highest performance, only
components may be replaced that are listed in the spare parts lists of the
corresponding device and whose replacement is described here.
Additional components of the equipment may only be replaced if:
- You have participated in a corresponding LUKAS service training course.
- You have the express permission of LUKAS customer service (by request,
check on the grant of permission. A check is necessary in each
individual case).
10.5.1 Base plate replacement
The base plate must be replaced if external damage is present that represents a danger for
user and device upon further use. In particular, the base plate must be replaced if the stability
of the hydraulic pump can no longer be ensured.
Procedure:
1. Remove screws A and B.
2. Remove base plate C and replace it with a new one.
3. Reinsert screws A and B and tighten.
A
C
B
10.5.2 Removing tank for cleaning, replacing the tank or the seals
The tank should be cleaned at least once per year in order to remove the accumulated dirt.
The tank must be replaced if there is any external damage that impairs the safety of
the device.
The tank seals must be replaced if there are any leaks at the junction points of the tank.
Procedure:
1. Remove base plate as described in the chapter "Replacing
base plate".
2. Empty tank by removing the screw plug (item D) and emptying
the tank.
D
ATTENTION!
Properly dispose of the removed hydraulic uid and all
damaged components!

19
E F G H Tank J K L
3. Remove the nut (item E) and sealing ring situated under it (item F).
4. Remove base plate (item G) and the sealing ring (item H).
5. Remove tank and the seal (item J) as well as the connection plate (item K) and seal
(item L).
6. The assembly is done in reverse order. Replace all damaged parts with new ones.
The tightening torque of the nuts is 40 Nm.
10.5.3 Lever replacement
The lever must be replaced if external damage is present that represents a danger for user
and device upon further use.
Procedure:
1. Drive out dowel pin (item M).
M
N
2. Remove lever (item N) and replace with a new one.
3. Reinsert dowel pin (item M).
10.5.4 Couplings
WARNING / CAUTION / ATTENTION!
Couplings should not be repaired; they should be replaced with original LUKAS
parts!
10.5.4.1 Monocouplings
The monocouplings must be replaced if:
- exterior damage is present,
- the lock does not function,
- in the coupled and/or decoupled state, hydraulic uid continuously escapes.

20
Procedure for installation in the valve block:
1. Unscrew coupling from connection plate.
2. Screw new coupling into the connection plate with a torque of MA= 40 Nm.
10.5.4.2 Quick-disconnect-couplings
The quick-disconnect-couplings should be replaced if:
- exterior damage is present,
- the lock does not function,
- in the coupled and/or decoupled state, hydraulic uid continuously escapes.
Procedure:
1. Unscrew and remove coupling.
2. Screw in new screw-on male coupling and tighten with a torque of MA= 35 Nm.
ATTENTION!
The return port must always be equipped with a female quick-disconnect-coupling.
The supply port should instead be equipped with a male quick-disconnect-coupling.
10.5.5 Decals
All damaged and/or illegible decals (safety instructions, identication plate, etc.)
must be replaced.
Procedure:
1. Remove damaged and/or illegible decals.
2. Clean surfaces with acetone or industrial alcohol.
3. Adhere new decals.
Make sure to adhere the decals in the correct positions. If this is no longer known, you should
consult your authorised LUKAS dealer or contact LUKAS directly.