Operating instructions Rescue Hand pump LH2 and accessories 179101085 GB Publication 12.
Contents Page 1. Danger classes 4 2. Product safety 4 3. Proper use 7 4. Main components of the hand pump 8 5. Functional description 8 5.1 Base pump 8 5.2 Adapter blocks 9 6. Connection options for rescue equipment 9 6.1 Fittings 9 6.2 Quick-disconnect-couplings 10 6.3 Monocouplings 11 7. Commissioning 12 7.1 Unlocking the pump 12 7.2 Retracting the handle 12 7.3 Bleeding the pump 12 8. Operation 13 8.1 Operation 13 8.2 Shutdown / storage 14 9. Transport 14 10.
1. Danger classes 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.
We also recommend that you get instructed by a qualified 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.
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 specified 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 flashovers to the device. For repairs only original LUKAS accessories and spare parts are to be used.
WAR N IN G / C A U TION / AT T E NT I O N! The device is specified exclusively for the purpose represented in the operating instructions (see Chapter "Proper use"). Any use that differs 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.
4. Main components of the hand pump 4 3 6 1 2 3 4 5 6 7 Drain valve Connection plate with fittings or couplings Vent / fill cap Retractable pump lever Tank Lock Base plate 5.1 Base pump 5 7 1 2 5. Functional description All LUKAS hand pumps of this series are two-speed, i.e.
5.2 Adapter blocks Adapter block Function/use Connection plate with fittings Possibility of connecting hose lines directly to the hand pump Connection Possibility of connecting hose plate with quicklines directly to the hand disconnect-couplings pump via quick-disconnectcouplings Connection plate with monocouplings Possibility of connecting hose lines directly to the hand pump via monocoupling 6.
6.2 Quick-disconnect-couplings 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. X Y 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.
6.3 Monocouplings 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. Dust caps Male coupling Female coupling 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".
7. Commissioning NOTE: With the LUKAS hand pump, a little idle stroke may occur when the unit is first used in the high pressure range. However, this idle stroke independently stops after a device is operated 2-3 times. ATTENTION! The hand pump should be as close to horizontal as possible, because otherwise the usable amount changes! The oil fill plug must always be unscrewed one turn before starting operation of the hand pump! This enables the aeration and bleeding of the hydraulic tank.
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 fill 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. 8.
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 off of the hand 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! 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.
Perform an operational check of the hand 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 hand 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 specification on the identification plate occurs.
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.
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. E F G H Tank J K L 10.5.
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 fluid continuously escapes. Procedure: 1. Unscrew and remove coupling. 2.
11. Troubleshooting Problem Connected device does not move, moves only slowly or moves intermittently. Cause Remedy Fluid level in the hydraulic tank too low Add hydraulic fluid up to max. fill level. Discharge valve open Hose line not properly connected or damaged Close discharge valve. Check connection of the hose line and reconnect it if necessary. Load on the device Use a different device. too high Air in the hydraulic system Bleed system as described in the chapter “Bleeding the pump”.
Problem Device does not move back into the starting position, moves incompletely back toward the starting position or moves more slowly into the starting position than normal. Connected device not reaching its limit position Cause Remedy Discharge valve closed Open discharge valve. Fluid level in the hydraulic tank too high Loose hydraulic coupling Reduce hydraulic fluid down to max. fill level. Check all couplings and retighten them.
Problem In the case of a monocoupling system: Hose lines cannot be coupled In the case of a monocoupling system: Hose lines frequently cannot be coupled Cause They are under excessive pressure (e.g.
12. Technical data Because all values are subject to tolerances, there cannot be any differences between the data of your device and the data of the following tables! 12.1 Data of the hand pumps 12.1.1 Pump labelling LH 2 / 1.8 - 50 Tank size Model series max. operating pressure in MPa (1 MPa = 10 bar) NOTE: The automatic pressure switch from low pressure to high pressure occurs at 2 MPa (= 20 bar) 12.1.
Hand pump with quick-disconnect-couplings: Tank size 1,8 3,8 12.1.4 [l] [l] Dimensions Weight min. required lxwxh (incl. max. hydraulic fluid fill level) Fill quantity 724 x 200 x 160 [mm] 7,3 [kg] 2,38 [l] 28.96 x 7.87 x 6.30 [in.] 16.1 [lbs.] 0.63 [gal.-US] 740 x 200 x 160 [mm] 11,6 [kg] 4,61 [l] 29.13 x 7.87 x 6.30 [in.] 25.6 [lbs.] 1.22 [gal.-US] Flow rates NOTE: The flow output per piston stroke of the hand pumps depend exclusively on the model series.
12.3 Hose lines Bending radius Rmin = 38 mm (Rmin = 1.5 in.) Pressure resistance Safety factor: Burst pressure / max. Operating pressure, min. 4:1 Temperature resistance - 40°C ... + 100°C (- 40°F … + 212°F) Operating fluid Mineral oil according to DIN EN ISO 6743-4 12.
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Please properly dispose of all packing materials and removed parts. Weinstraße 39, D-91058 Erlangen Postfach 2560, D-91013 Erlangen Phone: (+49) 0 91 31 / 698 - 0 Fax.: (+49) 0 91 31 / 698 - 394 e-mail: lukas.info@idexcorp.com Made in GERMANY LH2_RG_BA_GB_1790101085_1208.
