Lukas LS 330 Fi User Manual
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.
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