Operating instructions for rescue equipment
Electrically insulated
Cutters and Combi Tools
LKS 35 FI:
4
6
LS 330 FI:
4
5
1 Star grip
2 Tool body
3 Handle
4 Protection hose
5 Blade arm
6 Combi blade arm
7 Handhold
3
3
(Translation of the original operating instructions)
8
1
2
2
7
1
7 8 9
8 Pressure hose line
9 Return hose line
10 Mono-coupling nipple
11 Plug coupling nipple
12 Plug coupling sleeve
13 Protection box for plug coupling
14 Protection box for mono-coupling
13
9
14
Mono-coupling
system:
10
Quick-disconnect
coupling system:
12
LS 311 FI:
5
11
172075085 GB
Edition 10.2010
2
Contents Page
1. Hazard classes 4
2. Product safety 5
3. Proper use 8
4. Description of the functions 9
4.1 Description 9
4.2 Circuit diagram 9
4.3 Control of working movements 9
4.4 Hydraulic supply 10
4.5 Hose lines 10
5. Connecting the equipment 10
5.1 General points 10
5.2 Coupling the mono-couplings 11
5.3 Coupling the plug couplings 12
6. Operation 13
6.1 Preparatory actions 13
6.2 Operating the star grip (Item 1 on cover sheet) 13
7. Cutting, spreading, pulling and squeezing 14
7.1 Safety instructions 14
7.2 Cutting 14
7.3 Spreading (combi tools only) 15
7.4 Pulling (combi tools only) 16
7.5 Squeezing (combi tools only) 16
8. Dismantling the equipment / deactivation following operation 17
8.1 Cutting or combi tool 17
8.2 Hydraulic unit 17
8.3 Hose lines 17
9. Maintenance and service 17
9.1 Cutting / combi tool, complete 18
9.2 Safety guards 18
10. Repairs 19
10.1 General points 19
10.2 Preventative service 20
10.3 Repairs 21
11. Troubleshooting 21
3
12. Technical Data 24
12.1 Cutting tools 24
12.2 Combi tools 26
12.3 Tightening torques for pivot bolt 26
12.4 Cutting performance 27
12.5 Hydraulicuidrecommendations 27
12.6 Operating and storage temperature ranges 27
13. EC Declarations of conformity 28
13.1 Cutting tools 28
13.2 Combi tools 30
14. Notes 31
4
Hazard classes1.
We distinguish between various categories of safety notes. The table below gives you an
overview of the assignment of symbols (pictograms) and key words to the specic hazard
and possible consequences.
Pictogram Damage / injury to Key word Denition Consequences
DANGER!
WARNING!
human
CAUTION!
CAUTION!
device
- REMARK
Wear helmet with face protection
Immediate
danger
Potentially
dangerous
situation
Less dangerous
situation
Danger of
damage
to device /
environment
Advice for
application
and other
important / useful
information and
advice
Death or major
injury
Potential death or
major injury
Minor or slight
injury
Damage to the
equipment,
damage to the
environment,
damage to
surrounding
materials
No injury /
damage to
persons /
environment /
equipment
Wear safety gloves
Wear safety shoes
Proper recycling
Observe principles of environmental protection
Read and observe operating instructions
5
Product safety2.
LUKAS products are developed and manufactured in order to guarantee the best performance
and quality when used properly.
Operator safety is the most important aspect of the product design. Moreover, the operating
instructions are intended to help the safe use of LUKAS products.
The generally applicable, legal and other binding regulations pertaining to the prevention of
accidents and protection of the environment apply and are to be implemented in addition to
the operating instructions.
The equipment may only be operated by persons with appropriate training in the safety
aspects of such equipment – otherwise, there is a danger of injury occurring.
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
carefully follow such.
We further recommend that a qualied trainer train you in the use of the product.
WARNING / CAUTION!
The operating instructions for the hoses, the accessories and the connected
hydraulic equipment must also be observed!
Even if you have already received instructions on how to use the equipment, you should still
read the following safety notes through again.
WARNING / CAUTION!
Ensure that the accessories and connected equipment used are suitable for
the max. operating pressure!
Please ensure that no body
parts or clothing get stuck
between the visibly moving
parts (e.g. blade arms).
Wear protective clothing,
safety helmet with visor,
protective gloves
The responsible department
is to be informed immediately
of any changes (including to
the operating behaviour)! If
necessary, the equipment is
to be deactivated immediately
and secured!
It is prohibited to work under
load if this load is lifted
exclusively by hydraulic
equipment. If this work
is absolutely imperative,
additional mechanical
supports must be used.
Inspect the equipment before
and after use for visible
defects or damage
Inspect all cables, hoses
and screwed connections
for leaks and externally
visible damage! If necessary,
repair immediately! Squirting
hydraulic uid can result in
injuries and res.
6
In the event of malfunctions,
immediately deactivate the
equipment and secure it. The
malfunction is to be repaired
immediately.
Observe all safety and danger
notes on the equipment and
in the operating instructions.
Do not carry out any changes
(additions or conversions)
to the equipment without
obtaining the prior approval of
LUKAS.
All safety and danger notes
on the equipment are to be
kept complete in a legible
condition.
Any mode of operation which
impairs safety and/or stability
of the equipment is forbidden!
Safety devices may never be
deactivated!
Before the equipment is
switched on/started up, and
during its operation, it must
be ensured that nobody is
endangered by the operation
of the equipment.
Only touch any broken-off
parts or the cut-off parts
wearing protective gloves,
since the torn / cut edges can
be very sharp.
The equipment is lled
with a hydraulic uid.
These hydraulic uids can
be dangerous to health if
swallowed or their vapours
inhaled. Direct contact with
the skin is to be avoided for
the same reason. Please also
note that hydraulic liquids can
also have a negative effect on
biological systems.
Comply with all specied
dates or dates specied in
the operating instructions
pertaining to regular controls /
inspections on the equipment.
The maximum permitted
operating pressure noted on
the equipment must not be
exceeded.
Only original LUKAS
accessories and spare parts
may be used for repairs.
Please ensure that, when
working with this equipment
or during transportation of
such, you don’t get stuck in
the looped hoses and trip.
Please note that, when
cutting or spreading, tearing
or breaking can cause
falling material, or sudden
removal of such can cause
it to suddenly catapult off:
necessary precautions need
to be taken.
When working with or storing
the equipment, ensure that
the function and the safety
of the equipment are not
impaired by the effects of
stark 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.
7
Ensure adequate lighting
when you are working.
Always keep these operating
instructions within reach
where the equipment is used.
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.
Before transporting the
equipment, always ensure
that the accessories are
positioned such that they
cannot cause an accident.
Ensure the proper disposal of
all removed parts, left-over oil
and hydraulic uid as well as
packaging materials!
WARNING / CAUTION!
The equipment is to be used exclusively for the purpose stated in the operating
instructions (see chapter “Proper Use”). Any other or further use is not considered
proper use. The manufacturer / supplier is not liable for any damages resulting from improper
use. The user bears sole responsibility for such.
Observance of the operating instructions and compliance with the inspection and maintenance
conditions are part of the proper use.
Never work when you are overtired or intoxicated!
8
Proper use3.
The electrically insulated LUKAS "LKS" combi tools and electrically insulated LUKAS "LS"
cutters are designed specically for rescuing victims of trafc, rail or air accidents and for
making rescues from buildings. They serve the purpose of freeing injured people in accidents
e. g. by cutting doors, roof bars and hinges. By using the LUKAS combi tools, trapped
persons can also be freed e. g. by spreading doors and / or by removing obstacles with the
aid of a chainset. Basically, the combi tools can be used to cut, pull, spread, squeeze and lift.
Basically, LUKAS cutters can only be used to cut objects.
All objects which are to be worked on are to be secured using stable supports or
substructures.
The electrically insulated LUKAS tools are protected against power arcing (between the
object being worked on and the operator) of up to 1,000 V (AC) or 1,500 V (DC). This means
that objects under live voltage can be cut, squashed or spread providing this maximum
electrical voltage is not exceeded.
When working on such objects you must ensure that you do not come directly into contact
with metallic components of the rescue tool (e.g. the cutter) as these may be live.
A protection box is provided specially for the couplings of the electrically insulated tools to
protect the operator from power surges at these points.
LUKAS cutting and combi tools can, in principle, be used underwater at depths of up to 40m
(131 ft), but live parts must not be cut or crushed underwater.
CAUTION!
When working underwater you must however be extremely careful not to cause
leaks as this can damage the environment.
WARNING / CAUTION!
All objects which are to be worked on are to be secured using stable supports or
substructures.
WARNING / CAUTION!
The following may not be cut / squeezed:
- current carrying cables whose electrical voltage is higher than the
dielectrical strength of the electrically insulated tools.
- pretensioned and hardened parts such as springs, spring steels,
steering columns and rollers
- tubes / hoses under gas or liquid pressure,
- compound materials (steel/concrete)
- explosive bodies such as airbag cartouches
NEVER operate the rescue equipment at a higher operating pressure than that
stated in the chapter “Technical data”. A higher setting can result in material
damage and/or injuries.
You can obtain accessories for the rescue tools from your authorisied LUKAS dealer!
9
Description of the functions4.
4.1 Description
The equipment is designed such that, via a hydraulically activated piston, two equal, opposite
blade arms are symmetrically opened / closed by mechanical joints, thereby spreading,
squeezing, pulling or cutting objects.
All cutters and combi tools ensure full load-holding function when disconnected from the
hydraulic supply (e. g. when being unintentional decoupled; defective hose, and so on).
The tools are protected by special handles, the special protection hose and protection box
for the couplings that protect the operator from power arcing.
4.2 Circuit diagram
To enable comprehension of the function, a simplied hydraulic cylinder of the rescue
equipment (A) + hand valve (B) are depicted here.
cut / close / pulling /
squeezing
A
B
spreading /
opening
4.3 Control of working movements
The movement of the piston is controlled via the star grip for the tted valve (see cover sheet
Item 1 and Figure 3 below).
Fig. 3
star grip
10
4.4 Hydraulic supply
A LUKAS motor pump or hand pump only may be used to drive the equipment.
If the pump unit is a different make, you must make sure that it complies with LUKAS
specications, otherwise potential dangers may occur which are not the responsibility of
LUKAS. Ensure in particular that the authorised operating pressure for LUKAS equipment
is not exceeded.
REMARK:
Before you use pumps from a different manufacturer, you must contact LUKAS
or an authorised dealer.
4.5 Hose lines
The pump unit and rescue tool are connected via special hose lines that also prevent power
arcing.
Connecting the equipment5.
5.1 General points
The tool is equipped with two hose lines; they are connected to the pump unit via two hoses.
All hose assemblies are marked with a colour and have couplings to enable unmistakable
connection.
WARNING / CAUTION!
To protect from electrical power arcing, the coupling parts must be always be
enclosed inside an appropriate LUKAS protection box before starting the rescue
work!!
REMARK:
The devices can be equipped with different coupling systems.
They differ only by the article number and not by the designation.
Of course the coupling systems can also be reequipped at a later time.
11
WARNING / CAUTION!
Before connecting the equipment you have to pay attention that all
used components are suitable to the max operation pressure of
the pump unit! In the case of doubt you have to inquire LUKAS
directly!
5.2 Coupling the mono-couplings
The equipment is connected to the hydraulic pump via mono-coupling halves (male and
female).
dust protection caps
mono-coupling halve
(male)
Before coupling, remove dust protection caps, then connect male and female, and turn the
locking sleeve of the female to direction „1“ until the locking sleeve locks into place. The
connection has now been established and secured. Decoupling is by turning the locking
sleeve to direction „0“.
The equipment can also be coupled under pressure provided the connected equipment is
not activated.
REMARK:
We recommend coupling the coupling halves in a pressureless state, when
working in areas with low ambient temperature and the usage of extension hose
assemblies / hose reels, otherwise coupling could need very high expenditure
of force.
To protect them from dust, the accompanying dust protection caps must be put back on.
WARNING / CAUTION!
The mono-couplings may not be screwed off the hose assemblies and / or the
hose assemblies be confused!
mono-coupling halve
(female)
12
5.3 Coupling the plug couplings
The equipment is connected to the hydraulic pump via quick-disconnect-coupling halves
(male and female).
X
Y
Before coupling unlock the connect socket by turning the sleeve into position X. Retract sleeve
and connect plug and socket. Release sleeve and turn it into position Y. The connection has
now been established and secured. Uncoupling is done in the reverse order.
CAUTION!
Always connect the return line rst and afterwards the supply line!
REMARK:
Coupling of the devices is only possible, when the hoses are depressurized.
To protect them from dust, the accompanying dust protection caps must be put back on.
WARNING / CAUTION!
Some of the plug couplings have special functions and must therefore not be
unscrewed from the hose lines and/or swapped round!
13
Operation6.
6.1 Preparatory actions
6.1.1 Initial commissioning
Before commissioning and following repairs, the equipment must be deaerated.
- Connect the equipment to the hydraulic pump (see chapter “Connecting the equipment”).
- Open / close the blade arms of the equipment without any load at least twice (see
chapter “Operation of the star grip”).
REMARK:
We recommend that during the deaeration, the attached aggregate for the hydraulic
supply should stand on a higher level than the body of the rescue tool.
Recommended procedure for the deaeration of the rescue tool:
1.) Fully open and close the tool once with the blade arms pointing upwards.
2.) Fully open and close the tool once with the blade arms facing downwards.
3.) Fully open and close the tool once with the blade arms pointing upwards.
4.) Fully open and close the tool once with the blade arms facing downwards.
6.1.2 Checking the pump unit
See separate operating instructions for the relevant unit
(or the hand pump).
REMARK:
Before each start-up of the hydraulic unit you have to make sure that the actuating
valves are set to depressurized circulation.
REMARK:
Before coupling the quick-disconnect couplings, the actuating valves of the
hydraulic unit are set to depressurized circulation.
If you use mono-couplings, you can also couple when the hoses are pressurized!
6.2 Operating the star grip (Item 1 on cover sheet)
Opening the tool ( ):
Turn the star grip in a clockwise direction (in the direction of the
relevant symbol) and keep in this position.
Closing the tool ( ):
Turn the star grip in an counterclockwise direction (in the
direction of the relevant symbol) and keep in this position.
“Dead-man’s” function:
Following release, the star grip automatically returns to the
central position, guaranteeing the full load-holding.
14
Cutting, spreading, pulling and squeezing7.
7.1 Safety instructions
Before rescue works can commence, the position of the obstacle must be stabilised.
You must ensure an adequate substructure and / or adequate support of the object.
World-wide, safety guidelines pertaining to the specic country are to be observed and
complied with. In the Federal Republic of Germany, regular safety inspections according
to the GUV legal accident insurance regulations (Gesetzlichen Unfallversicherung) are
mandatory.
In the event of a potentially explosive situation, it is not permitted to use motor pumps (danger
of the formation of sparks). In such cases, hand pumps are to be used.
The following are to be worn when working with the rescue equipment:
- protective clothing,
- safety helmet with visor or protective goggles,
- protective gloves
- and, if necessary, ear protection
Before activating the rescue equipment, always ensure that there is no danger to persons
either involved / uninvolved in the action by the movement of the rescue equipment or by
ying fragments. Further avoid unnecessary damage to property belonging to others, objects
not involved by the rescue equipment / ying fragments.
Reaching between the blade arms is strictly forbidden!
WARNING / CAUTION!
The particular effect of the force of the rescue equipment during operation could
cause pieces of the vehicle to break off or y off, posing a danger to persons.
Those not involved in the rescue operation should therefore keep at a distance
appropriate to the situation.
7.2 Cutting
The blades must be positioned at a 90° angle to the object to be cut.
90°
FALSE
RIGHT
Higher cutting capacities can be achieved by cutting as close as possible to the blade’s pivot
point.
FALSE
RIGHT
15
During cutting, the gap between the blade tips (in the crosswise direction) may not be
exceeded, otherwise the blade is in danger of breaking:
Cutter / combi tool max. gap on the blade tips
[mm] / [in.]
LS 311 FI STREAM 3 / 0.12
LS 330 FI STREAM 3 / 0.12
LKS 35 FI STREAM 3 / 0.12
CAUTION!
Avoid cutting particularly high-strength parts of the vehicle’s bodywork (e.g.
side-impact protection): this almost always causes damage to the cutter /
combi tool!
7.3 Spreading (combi tools only)
Use the front area of the tips for increasing the gap only. Full spreading capacity can be
achieved when approximately half of the grooved area of the tips is used. The greatest force
is created in the rear area of the spreading range of the combi blade.
Working surface is too
small, tips slip off.
Only for increasing
the size of a gap (not
suitable for spreading).
Tips get a safe grip. Work with the tips only.
Do not damage the
arms.
16
7.4 Pulling (combi tools only)
You may only use LUKAS chain sets for pulling purposes.
Before the pulling process can be performed, ensure that the bolt and hook t correctly to
prevent the chain from slipping.
Only chain sets in perfect condition may be used!
The pull chains are to be inspected at least once per year by an expert!
See separate operating instructions for the relevant LUKAS chain set in order to
correctly attach, afx and use the chain sets.
The connection pieces of the LUKAS
chain sets are afxed to the boreholes
A on the blades using load bolts (see
gure, right).
Chain sets:
for LKS 35 FI: KSV 8
A
7.5 Squeezing (combi tools only)
Basically, squeezing can only be carried out in the area of the tips (see gure below).
Squeezing area
17
Dismantling the equipment / deactivation following operation8.
8.1 Cutting or combi tool
Once work has been completed, the blade arms are to be closed so that there is a tip distance
of just a few mm. This relieves the hydraulic and mechanical strain on the equipment.
REMARK:
Never store the cutter / combi tool with fully closed blade arms! The complete
closure of the blade arms can cause hydraulic and mechanical stress to build
up again.
Free the rescue equipment of any stubborn dirt which may have become attached
during use.
If the equipment is to be stored for a longer period of time, the exterior is to be
cleaned completely and the mechanically mobile parts are to be lubricated.
Avoid storing the rescue equipment in a damp environment.
See also the chapter “Safety regulations for hoses”.
8.2 Hydraulic unit
Upon completion of work, the unit must be deactivated.
8.3 Hose lines
First of all, decouple the pressure hose then the return hose as described in chapter
“Connecting the equipment”.
Ensure that you put the dust protection caps back on to the couplings.
Maintenance and service9.
The equipment are subject to very high mechanical stresses. A visual inspection is to be
carried out after every use: however, at least one visual inspection is to be carried out every
six months. These inspections enable the early detection of wear and tear, which means
that punctual replacement of this wearing parts prevents breakages from occurring. Also
regularly check the torque of the pivot bolt. (Torque M
Every three years also a crack test of the blades are essential. Therefore a special crack
testing kit is is available.
Every three years or if there is any doubt regarding the safety or reliability of the equipment,
a function test must also be performed. (Please also observe the relevant valid national and
international regulations pertaining to service intervals of rescue equipment). In the Federal
Republic of Germany, regular safety inspections according to the GUV legal accident
insurance regulations (Gesetzlichen Unfallversicherung) are mandatory.
see “Technical Data”).
A
CAUTION!
Clean off any dirt before controlling the equipment!
WARNING / CAUTION!
In order to carry out maintenance and repair works, tools appropriate for the job
and personal protecting equipment are essential.
18
9.1 Cutting / combi tool, complete
Inspections to be carried out:
Visual inspection
Cutter / combi tool
• Opening width of the blade arms on the tips (see chapter “Technical data”),
• General tightness (leaks),
• Operability of the star grip,
• Existence and stability of handle,
• Labels completely existent and legibly,
• Covers in perfect condition,
•
Torque control of the pivot bolt (torque MA see "Technical data"),
• Couplings must be easy to couple,
• Dust protection caps must be available.
Blade arms
• Blade arms free of tears and without any chipped spots or deformations on the cutting
surfaces,
• Cutting surfaces go on top of each other without making contact,
• Bolts and retaining rings of the blade arms must be present and in correct working order,
• Grooving of the tips must be clean and squared, and not have any tears (applies to combi
tools).
Hoses (see also “Safety regulations for hydraulic hoses”)
• Visual control for visible damage,
• Control for leaks.
Function test
• Opening and closing function awlessly upon activation of the star grip,
• no suspicious noises,
• no further movement of the blade arms upon interruption of the valve activation during the
process (“dead-man’s” function).
9.2 Safety guards
• Control of the protective equipment on / around the rescue equipment, especially the
hand guard of the moveable parts (they must be free of tears!).
• If there is any doubt concerning the power arcing resistance, or in the event of damage to
the protection hose, an additional insulation test is required. This test must be carried out
taking all applicable laws, standards and regulations into consideration.
WARNING / CAUTION!
Insulation tests must be carried out using appropriate measuring equipment and
in compliance with the applicable laws, standards and regulations, or must be
carried out by LUKAS directly.
19
Repairs10.
10.1 General points
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) since
special tools, assembly advice, safety aspects, inspections might have to complied with (see
also chapter “Maintenance and Service”).
During assembly, ensure the complete cleanliness of all components, since dirt can
damage the rescue equipment!
WARNING / CAUTION!
Protective clothes must be worn when repairs are being carried out, since parts
of the units can also be pressurised in an idle state.
REMARK:
Please always return the guarantee registration card to LUKAS Hydraulik GmbH.
Only then are you entitled to the extended guarantee.
REMARK:
Before you use couplings from a different company, you must contact LUKAS or
an authorised dealer.
REMARK when using the quick-disconnect-coupling system:
Overpressure protection of the rescue equipment
(model with yellow coupling nipple on the return hose)
If the equipment’s short hoses are not connected to a unit, temperature
increases can inadvertently cause pressure to build up in the equipment. Hence,
the return hose of the equipment is equipped with a safety coupling (quickdisconnect coupling male, yellow). Unwanted overpressure (approx. 1.5 Mpa) is
automatically released via this nipple: hydraulic uid leaks.
Should an hydraulic uid leak on the coupling male be more frequent, please
contact your dealer or LUKAS itself.
If couplings from a different company are used which do not have this function,
the overpressure protection can react in the valve of the rescue equipment.
Hydraulic uid leaks in the area of the star grip. Following the reduction in
pressure, the valve is once again tight.
Should the valve leak permanently, please immediately contact your dealer or
LUKAS itself.
CAUTION!
Because LUKAS rescue equipments are appropriate for highest achievements,
only components may be exchanged, which are specied in the spare parts list
of the appropriate equipment.
Further components of the equipment may only be exchanged, when:
- you have participated on a appropriate LUKAS service training.
- you have the express permission of LUKAS customer service (after inquiry,
assessment prior to granting of permission. All cases must be assessed
individually!)
20
10.2 Preventative service
10.2.1 Note concerning care
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.
10.2.2 Functional and loading test
If there is any doubt regarding the safety or reliability of the equipment, a function and load
test must also be performed.
LUKAS offers appropriate test equipment to this end.
10.2.3 Replacing the hydraulic uid
- The hydraulic uid must be changed after the equipment has been used approx. 200
times / after three years at the latest.
- It must always be changed when the hydraulic uid for the accompanying pump (motor/
hand pump) is changed. This ensures that the fresh uid is not contaminated by used uid
in the rescue tool.
Procedure:
1. Close blade arms (until the tips are almost touching).
2. Change the hydraulic uid of the pump. Please observe the separate operating instructions
for the pump being used!
3. Screw off the return hose on the pump:
- if the hose is connected to the pump directly:
completely unscrew the connection nut of the connection piece of the blue return hose.
- if the hose is connected to the pump via a mono-coupling:
remove the cover from the mono-coupling (male).
completely unscrew the connection nut of the blue returnhose on the mono-coupling
(male).
- if the hose is connected to the pump using a plug coupling:
completely release the union nut of the hose line from the plug coupling nipple
of the blue return line.
4. Put the return hose into a separate collecting basin for the hydraulic uid still in the equipment.
5. Slowly open the tool (the pump must be working during this time). The old hydraulic uid
from the ring space side runs via the return hose into the separate collecting basin, and is
to be disposed of in the same manner as the old hydraulic uid of the pump.
6. Switch the pump off (motor pump) / no longer activate it (e.g. hand pump).
7. Reconnect the return hose to the pump:
- if the hose is connected directly to the pump:
screw the connection nut of the connection piece of the blue return hose
(Please observe the necessary torque of M
- if the hose is connected to the pump via a mono-coupling:
screw the connection nut of the blue return hose
(Please observe the necessary torque of M
Pull back the cover on the couplings as far as the limit stop.
- if the hose is connected to the pump using a plug coupling:
Screw the union nut of the hose line back onto the plug coupling nipple
of the blue return line.
(Please observe the necessary torque of M
8. Deaerate the rescue tool as described in the chapter “Preparatory measures”.
= 40 Nm!)
A
= 40 Nm!)
A
= 35 Nm!)
A
21
10.3 Repairs
Since repairs to the electrically insulated rescue tools must always be concluded by testing
and conrmation of the minimum electrical arcing resistance, repairs may only be carried out
by authorised specialised dealers or by LUKAS directly.
Troubleshooting11.
Trouble Control Cause Solution
Blade arms move
slowly or jerkily when
activated
Device doesn’t
perform at its given
power
Following release,
the star grip doesn’t
return to the central
position
with mono-couplingsystem: Hoses
cannot be coupled
with monocoupling-system:
It is frequently not
possible to couple
hose assemblies
Are the hoses
connected
properly?
Does the pump
unit work?
Check the
hydraulic uid level
in the supplying
pump
Cover damaged
or star grip hard to
move?
Control the
degree of viscosity
and application
temperature of
the used hydraulic
uid
Air in the hydraulic
system
Insufcient
hydraulic uid in
the pump
Damage to the
torsion spring for
reset
Soiled valve or
star grip
Defective valve
Other mechanical
damage (e. g. star
grip)
Pressure too high
(e.g. caused by
too-high ambient
temperature)
Coupling defective Coupling needs to be
Hydraulic uid
not adapted to
the application
situation
Coupling defective Coupling needs to be
Deaerate pump
system
Top up hydraulic uid,
deaerate
Repair by an
authorised dealer, by
personnel specially
trained by LUKAS, or
by LUKAS itself
Set hydraulic pump
to pressureless
circulation
replaced immediately
Hydraulic uid
must be replaced
(see chapter
“Recommended
Hydraulic uids”)
replaced immediately
with quickdisconnect-couplingsystem: Hoses
cannot be coupled
Hydraulic uid leak
on the hoses or the
xing-ins
Is the pump
working?
Are the hoses
defective?
Pressurized Relieve pump
Coupling defective Coupling needs to be
replaced immediately
Leak, possible
damage
Replace hoses
22
Trouble Control Cause Solution
Damages on the
surface of the
hydraulic hoses
Hydraulic uid leaks
on the piston rod
Leak on the handhold Increase load?
(combi tool when
spreading)
Does the pressure
set on the pump
comply with
the maximum
permissible
pressure on
the rescue
equipment?
Hoses in handhold
loose?
Check the
connections of the
mono-coupling
(female)
Especially by usage
of quick-disconnectcouplings: Leak on
the handhold
Is the return
hose connected
correctly?
Mechanical
damages or
contact with
aggressive agents
Defective rod seal Repair by an
Damage to the
piston
Load increase
(e.g. something
has fallen onto the
part to be lifted,
thereby suddenly
increasing the
load)
Pressure release
in the Rescue tool.
Hoses in handhold
not tightened
Supply and return
connection of the
mono-coupling
(female) inverted
Return hose is not
coupled correctly
or not connected.
Replace hoses
authorised dealer, by
personnel specially
trained by LUKAS, or
by LUKAS itself
Secure the loads and
move them by using
other tools
Move the load
somewhere else,
where the moving
load is lighter
Use supporting
equipment to move
the load.
Following the
reduction in pressure,
no further leak is
present.
Should, however,
there be a further
leak on the handhold,
immediately
deactivate the rescue
equipment, and
contact an authorised
dealer or LUKAS
itself.
Tighten hoses.
Reconnect the
hoses of the monocooupling (female) in
the right way
Re-connect the return
hose and secure it.
23
Trouble Control Cause Solution
Especially by usage
of mono-couplings:
Leak on the handhold
with mono-couplingsystem: Leak in the
couplings
with quickdisconnect-couplingsystem: Leak in the
couplings
If it isn’t possible to rectify the malfunctions, inform an authorised LUKAS dealer or the
LUKAS customer service department immediately!
The address for the LUKAS customer service department is:
check the
connections of the
hoses
Is the coupling
damaged?
Is the coupling
damaged?
Is the leak only
on the coupling
male (in uncoupled
status)?
hose connection
to the couplings
interchanged
Returnline
disabled
coupling damaged Coupling must be
coupling damaged Coupling must be
Safety valve
reacted
reconnect the hoses
to the coupling in the
right way
disconnect the
returnline from the
coupling, clean it and
reconnect it.
replaced immediately
replaced immediately
After pressure
release there is no
more leakage.
LUKAS
Weinstraße 39, D-91058 Erlangen
Postfach 2560, D-91013 Erlangen
Tel.: (+49) 09131 / 698 - 348
Fax.: (+49) 09131 / 698 - 353
Hydraulik GmbH
24
Technical Data12.
Since all values are subject to tolerances, minor differences may occur between the data on
your equipment and the data in the following schedules!
12.1 Cutting tools
type LS 330 FI STREAM LS 330 FI STREAM
ref.no. 112070000 172070000
dimensions l x w x h
(w/o connection hoses)
max. cutting opening
max. cutting force
(rear end of the cutting
surface)
weight incl. hydraulic
uid
max. operating pressure
min. needed volume
of hydraulic uid
coupling system
[mm] 733 x 210 x 195
[in.] 28.85 x 8.27 x 7.68
[mm] 228
[in.] 8.98
[kN] 616
[lbf.] 138,489
[kg] 17,7
[lbs.] 39.0
[Mpa] * 70
[psi.] 10,153
[l] ** 0,098
[gal.-US] 0.026
quick-disconnect-
coupling
mono-coupling
* 1 MPa = 10 bar
** Required volume of hydraulic uid in the hydraulic power pack for operating the
tool (differential volume piston/rod side)
25
type LS 311 FI STREAM LS 311 FI STREAM
ref.no. 112075000 172075000
dimensions l x w x h
(w/o connection hoses)
max. cutting opening
max. cutting force
(rear end of the cutting
surface)
weight incl. hydraulic
uid
max. operating pressure
min. needed volume
of hydraulic uid
coupling system
* 1 MPa = 10 bar
** Required volume of hydraulic uid in the hydraulic power pack for operating the
tool (differential volume piston/rod side)
[mm] 697 x 210 x 195
[in.] 27.44 x 8.27 x 7.68
[mm] 150
[in.] 5.91
[kN] 642
[lbf.] 144,335
[kg] 16,9
[lbs.] 37.26
[Mpa] * 70
[psi.] 10,153
[l] ** 0,098
[gal.-US] 0.026
quick-disconnect-
coupling
mono-coupling
26
12.2 Combi tools
type LKS 35 FI LKS 35 FI
ref.no. 113070000 173070000
dimensions l x w x h
(w/o connection hoses)
max. cutting opening
max. cutting force
(rear end of the cutting surface)
max. spreading distance
(on the blade tips)
max. spreading force
(25mm from the tips)
weight incl. hydraulic uid
max. operating pressure
min. needed volume
of hydraulic uid
coupling system quick-disconnect-coupling mono-coupling
[mm] 762 x 210 x 195
[in.] 30.00 x 8.27 x 7.68
[mm] 265
[in.] 10.43
[kN] 418
[lbf.] 93,975
[mm] 360
[in.] 14.17
[kN] 49,5
[lbf.] 11,129
[kg] 17,0
[lbs.] 37.5
[Mpa] * 70
[psi.] 10,153
[l] ** 0,066
[gal.-US] 0.017
* 1 MPa = 10 bar
** Required volume of hydraulic uid in the hydraulic power pack for operating the
tool (differential volume piston/rod side)
12.3 Tightening torques for pivot bolt
type LS 311 FI LS 330 FI LKS 35 FI
pivot bolt M 24 x 1,5 M 24 x 1,5 M 24 x 1,5
wrench size
torque
[mm] 36 36 36
[in.] 1.42 1.42 1.42
[Nm] 120 +10 120 +10 120 +10
[lbf.in.] 1,062 + 89 1,062 + 89 1,062 + 89
27
12.4 Cutting performance
Cutting material
Cutting material dimensions
LS 311 FI LS 330 FI LKS 35 FI
max. max. max.
[mm] [mm] [mm]
[in.] [in.] [in.]
Round material steel
(acc. to EN 13204)
Round material steel
(acc. to NFPA 1936)
33 33 30
1.30 1.30 1.18
33 33 30
1.30 1.30 1.18
12.5 Hydraulic uid recommendations
Mineral oil DIN ISO 6743-4 for LUKAS hydraulic equipment and others
Oil temperature range Oil code Viscosity rating Remarks
A -20 .... +55°C HM 10 VG 10
Oil temperature range Oil code Viscosity rating Remarks
A -4.0 .... +131°F HM 10 VG 10
recommended viscosity range: 10...200 mm²/s (10…200 cSt.)
Supplied with HM 10 DIN ISO 6743-4.
CAUTION!
Before using hydraulic uids, which do not correspond to the above-mentioned
specications and/or are not purchased from LUKAS, you have to contact
LUKAS itself!
12.6 Operating and storage temperature ranges
Operating temperature [°C] -20 … +55
Ambient temperature (device in operation) [°C] -25 … +45
Storage temperature (device not in operation) [°C] -30 … +60
Operating temperature [°F] -4 … +131
Ambient temperature (device in operation) [°F] -13 … +113
Storage temperature (device not in operation) [°F] -22 … +140
28
13.1 Cutting tools
EC Declarations of conformity13.
29
30
13.2 Combi tools
31
Notes14.
Please dispose all packaging materials and
dismantled parts properly
LUKAS
A Unit of IDEX Corporation
Hydraulik GmbH
Weinstraße 39, D-91058 Erlangen
Tel.: (+49) 0 91 31 / 698 - 0
Fax.: (+49) 0 91 31 / 698 - 394
e-mail: lukas.info@idexcorp.com
www.lukas.com
Made in GERMANY
© Copyright 2010 LUKAS Hydraulik GmbHFI_Geräte_BA_GB_172075085_1010.indd
subject to revision
Loading...