1Basic operation and designated use of the machine
1.1 The machine has been built in accordance with state-of-the-art standards and the
recognized safety rules. Nevertheless, its use may constitute a risk to life and limb of the user or
of third parties, or cause damage to the machine and to other material property.
1.2 The machine must only be used in technically perfect condition in accordance with its
designated use and the instructions set out in the operation manual, and only by safety-conscious
persons who are fully aware of the risks involved in operating the machine. Any functional
disorders, especially those affecting the safety of the machine/plant, should therefore be rectified
immediately!
1.3 The machine is exclusively designed for the use described in the operating manual. Using
the machine for purposes other than those mentioned in the manual, such as driving and controlling
other pneumatic systems, is considered contrary to its designated use. The manufacturer/supplier
cannot be held liable for any damage resulting from such use. The risk of such misuse lies entirely
with the user.
Operating the machine within the limits of its designated use also involves observing the
instructions set out in the operating manual and complying with the inspection and maintenance
directives.
2Organizational measures
2.1 The operating manual must always be at hand at the place of use of the machine!
2.2 In addition to the operating instructions, observe and instruct the user in all other generally
applicable legal and other mandatory regulations relevant to accident prevention and environmental
protection.
This also applies for wearing protective clothing, helmet with visor or goggles and protective
gloves.
2.3 In order to avoid innjuries, the machine must only be operated by a specially trained operator
who has undergone a safety training.
2.4 Observe all safety instructions and warnings attached to the machine. Make sure that safety
instructions and warnings attached to the machine are always complete and perfectly legible.
2.5 Never make any modifications, additions or conversions which might affect safety without
the supplier's approval. This also applies to the installation and adjustment of safety devices and
valves.
2.6 Spare parts must comply with the technical requirements specified by the manufacturer.
Spare parts from original equipment manufacturers can be relied to do so. It is only allowed to use
original LUKAS spare parts of LUKAS system components.
2.8 Adhere to prescribed intervals or those specified in the operating manual for routine checks
and inspections.
2.9 Make sure to dispose properly of packing material and dismounted parts!
3General safety instructions
3.1 In the event of malfunctions, stop the machine immediately and lock it. Have any defects rectified
immediately.
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3.2 Before starting up or setting the machine in motion and during operation of the machine make
sure that nobody is at risk.
3.3 Before transporting the machine always check that the accessories have been safely
stowed away.
3.4 Make sure that there is enough lighting during work.
3.5 Avoid any operation that might be a risk to machine stability.
3.6 Check the machine at least after every operation for obvious damage and defects. Report
any changes (incl. changes in the machine’s working behaviour) to the competent organization
/person immediately. If necessary, stop the machine immediately and lock it. All lines, hoses and
screwed connections have to be checked for leaks and obvious damage. Repair damage
immediately. Splashed oil may cause injury and fire.
3.7 All safety equipment has to be checked for completeness and flawless condition:
- instruction markings and warning signs (safety instructions)
- check safety cover (e.g. motor-safety covers, heat protection etc.) if they are available and
if they are in good condition.
3.8 Working under loads is not allowed if they are only lifted by hydraulic cylinders. If the work
is indispensable sufficient mechanical supports are needed additionally.
4Instructions for maintenance and service
4.1 For the execution of maintenance and service work, tools and workshop equipment adapted
to the task on hand are absolutely indispensable.
Work on the hydraulic system must be carried out only by personnel having special knowledge
and experience with hydraulic equipment.
4.2 Before putting into operation clean the machine, especially connections and threaded
unions, of any traces of oil, fuel or preservatives before carrying out maintenance/repair. Never
use aggressive detergents. Use lint-free cleaning rags and pay attention that the components are
meticulously clean during reassembling after repair.
4.3 During dismantling of machines it is necessary to collect the outrunning hydraulic liquids
completely, so that they cannot reach the ground. They have to be disposed properly accord-ing
to the instructions.
4.4 Always tighten any screwed and thread connections that have been loosened during
maintenance and repair. Observe the stipulated torques.
4.7 Aggressive material (acid, lye, solvent, vapour) can damage the machine. It is necessary
to clean the whole machine if it must be exceptionally operated under such conditions or gets into
touch with these materials. Additionally, the machine must be checked as described under 3.6.
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5Safety Instructions for Hydraulic Hoses
A T T E N T I O N !
- by no means the hose must be exposed to brake fluid as this fluid will destroy outer
layer of hose
- do not expose the hose to any of the following aggressive fluids:
• acid, lye or solvent
• alcohol and fuel
• battery and automatic transmission fluid
• phosphate ester
Clean hose immediately with water and detergent when it was exposed to such fluids.
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2
3
5
5.1Handling of hoses
- never exceed the permissible working pressure as stated on hose and/or literature
- avoid any tension (see figure 1) and do not hang any load onto the hose
- never exceed the minimum bend radius as resulting kink will cause failure of hose (see figure 2)
- do not allow hose to contact sharp edges or rough objects (see figure 3)
- avoid any twisting of hose (see figure 4)
- do not run over hose with any vehicle or equipment ! Hoses which are put on the surface of
sidewalk or street have to be suitably protected (see figure 5)
- do not allow hose to contact areas of high temperature such as mufflers, exhaust manifold,
heaters or burners. Protect the hose as shown in figure 6 or install it in sufficient distance from
the source of heat.
- it is not allowed to attach weights to the hoses
- make sure that no objects fall on the hoses.
5.2 Protection of the working area in case of breakdown of hoses
Hoses have to be installed or protected in such a way that dangers are prevented, if possible,
in case of breakdown of the hoses.
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4
6
Danger can be caused by:
- Uncontrolled hose movement after a hose rupture caused e.g. by external influence.
- Emerging of the pressure medium under pressure.
- Inflammation of pressure medium near igniting sources
Dangers can be prevented by e.g. protective coverings or shieldings
5.2.1 Do not go near leaks!
- High pressure oil easily punctures skin causing serious injury,
gangrene or death!
- If injured, seek emergency medical help! Immediate surgery is
required to remove oil!
- Do not use finger or skin to check for leaks!
- Lower load or relieve hydraulic pressure befor loosening finttings!
5.3 Storage of hoses
- Hoses are subject to a natural aging even if they are stored correctly. Therefore, their storage
and service time is limited.
When storing the hoses please observe the following:
- Store them cool, dry and dustless (eventually wrapped with plastics sheeting); prevent direct
solar radiation and UV rays; shield heat sources which are near the hoses.
- Do not use any ozone producing lamps (e.g. fluorescent light sources, mercury-vapor lamp)
or electrical devices next to the hoses.
- Hoses have to be stored freely of tension and in a horizontal position. If they are stored in
rings the smallest bending radius determined by the manufacturer must not fall below.
5.4 Marking of hoses
- The hose is marked with the manufacturer's name and quarter/year of production.
- The max. allowable pressure and month/year of production is indicated on the hose end fitting.
5.5 Inspection and replacement intervals of hoses
- After each operation the hoses have to be checked for external damages, cracks,
kinks and bubbles!
- The operator has to replace the hoses in appropriate period of times, even if there are no
visible security defects on the hoses.
- The hoses have to be replaced 10 years as from date of manufacture at the latest
(see marking on the hose)!
Hoses are subject to a natural aging even if they are stored correctly. Therefore, their storage
and service time is limited.
- Hoses have to be checked by a skilled person before the first putting into operation
of the technical device and afterwards at least once a year for their safe working
condition.
A skilled person is somebody having sufficient knowledge concerning hydraulic hoses due to his
special training and knowledge. He/she must be acquainted with the local safety working
conditions, accident prevention regulations, technical regulations and approved standards (e.g.
DIN-Standards), so that he/she is capable to estimate the safety working conditions of the
hydraulic hoses.
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5.6 Examples for possible defects of hoses
- Damages of the surface and the interior (e.g. chafe marks, cuts or fissures).
- Embrittlement of the surface (fissuration of the hose material).
- Deformations, which are not in accordance with the natural shape of the hoses, in pressureless
condition or under pressure or in case of bendings, e.g. separation of material layers, blister
formation, squeezing or break spots.
- Leakage points.
- Instructions for installation were not observed.
- Emerging of the hose from the end fittings.
- Damages or deformations of the end fittings which deteriorate the function and stability of the
end fittings or the connection between hose and end fitting.
- Corrosion of the end fittings or the metal inlets, which deteriorates the function and stability.
- Storage and operation periods were exceeded.
6Intended use
6.1 General
This spreader has been specially designed for rescue purposes. Its main purpose is to free injured
people after traffic accidents by spreading open the car doors or pulling up the steering pillar using
a chain set.
In general, objects can be pulled, spreaded or moved. In any case the objects to be manipulated
must be secured with massive prop-ups and supports.
The spreader is suitable for submerged operation in water up to a depth of 40 m.
7Function and performance
7.1 Description
The devices are designed in such a way that a hydraulically actuated piston via mechanical joints
symmetrically closes two identical spreader arms positioned opposite each other.
Opening of the arms is also effected by hydraulic-mechanical means.
7.2 Hydraulic diagram
For your better understanding the hydraulic diagram is
showing in simplified manner the spreader`s hydraulic
cylinder (A) with control valve (B).
7.3 Control of movements in operation
The arm movement is controlled by the firmly mounted star grip control valve (see cover page
item 1).
7.4 Hydraulic oil supply
LUKAS motor/engine pump or hand pump is used for operating the devices.
If the power pack comes from a manufacturer other than LUKAS, it must be ensured that it fulfils
the LUKAS specifications, as otherwise dangers may occur for which LUKAS cannot be held
liable. Especially it has to be made sure that the permissible working pressure of 63 MPa (630
bar) is not exceeded.
7.5 Hoses
The connection between motor pump and spreader unit is normally effected with hoses. If pipes
are to be used, please contact LUKAS.
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8Connection of the tool
8.1 Hydraulic
Two short hoses (each 0.5 m long) are fitted to the tool; they are connected with the motor pump
via a hose pair (5 m / 10 m / 20 m, as is necessary). All hoses are colour marked and have quickconnect couplings so that they can be connected without the risk of mix-up:
HP = High pressureR = reflux
8.2 Connection of the plug-in coupling counterparts for HP and R hoses
The device is connected to the hydraulic pump with the plug-in coupling counterparts (plug and
socket), there being no risk of mix-up.
Before coupling, remove the dust protection covers and unlock the connect socket with adjusting
ring by turning it. Withdraw the sleeve and connect plug and socket while holding the sleeve in
this position. Release the sleeve and set the showglass to „red“ with the adjusting ring. Now the
parts are connected and locked. Decoupling is done in the reverse order.
Note regarding the modified release mechanism as of June 2004
When connecting the hoses, be aware of the following basic functions of the quick couplers:
X
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.
Now the connection has been made and locked. Uncoupling is done in the reverse order.
Connection of the hoses is possible only, when they are depressurized.
In order to prevent contamination of the tool lines protect the couplings with delivered dust caps.
Attention!
Quick couplers partly have special functions. Therefore it is not allowed screwing them off
from the hoses or to exchange them.
Y
9Operation
9.1 Preparatory measures
9.1.1 Initial start-up
Before initial start-up and after repairs, the device must be vented:
- Connect the device to the hydraulic pump (see item 8).
- Fully open and close the device at least twice without load (see item 9.2).
9.1.2 Inspection of the pump power pack
——> See separate Operating Instructions of the power pack (or manual pump) in question.
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Note:
Before working on the motor pump or for coupling/decoupling the hoses, make sure that the motor
pump is switched off (electric connection) or disconnected from the mains and that the lines are
unpressurized.
9.2 Operating of the star grip 1
Opening of the arms:
Rotate star shape ring 1 to the right hand side and hold it in this position.
Closing of the arms:
Rotate star shape ring 1 to the left hand side and hold it in this position.
Load sustain function:
If released, the star shape ring 1 returns automatically to center position, maintaining fully the load
sustain function.
10Spreading and Pulling
10.1 Safety advise
Before the rescue operation begins, the object to be worked upon must be stabilized.
In each country, the country-specific safety regulations must be regarded.
When working in an environment which involves a risk of explosions, do not use motor/engine
powered pumps. Instead, use hand pumps.
When operating rescue devices, wear
- protective clothing
- helmet with visor or goggles
- protective gloves.
During operation of the spreader, parts of the object worked on may break away and endanger
people standing nearby. Onlookers must be kept at a safety clearance of at least 5 m.
10.2 Spreading
Use the tips only for widening the gap. When approximately half of the grooved area is used, the
full spreading power may be applied. Maximum force is exerted in the rear section of the tip. Its
special shape protects the spreader arms.
The light metal alloy arms must not be damaged.
Grip area too small. Tips may
break away.
10.2.1 Warnings
Before any operation of the spreader make sure that the movement of the arms does not constitue
a risk to persons (involved or uninvolved) or that the arms or cut-off parts jerking away cannot
damage property.
Safe grip.
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Use tips only, do not damage
the arms!
Do not reach between the spreader arms!
10.3 Pulling
- The chains may only be used for pulling with the rescue device.
- When pulling using a chain, make sure that bolt and hook are properly accommodated, so that
the chain does not slip off..
- Use only flawless chain sets.
- Have an expert check the chains at least once a year.
Refer to the separate operating manuals
10.4 Peeling
The integrated peeling attachment at the tips LSP 40 EN, LSP 60 EN,
LSP 60 F, LSP 80 EN and LSP 100 may be used to peel open steel
sheets up to a gauge of t (see 15.1) If unusually tough material is
processed, the tips may jerk away uncontrollably.
Watch your safety clearance!
10.5 Squeezing
In general, it is only allowed to squeeze in the area of the tips. For the spreader LSP 40B, LSP 40EN
a squeezing device is offered as an accessory (Ref. no. 84150/9150).
The squeezing process is executed between the spreader arms with this device (see instructions
84150/9150-82).
11Dismantling of the device / Stop after operation
11.1 Spreader unit
After operation, close the spreader arms to a tip distance of a few mm. This relaxes the unit
hydraulically and mechanically.
11.2 Hydraulic power pack
Stop the hydraulic power pack after operation.
11.3 Hoses
Uncouple the pressure hose first and the blue return hose second as described under 8.2. Put dust
caps over the couplings.
12Maintenance
12.1 Spreader unit
After each operation a visual check has to be accomplished, at least once per annum. Every 3
years or if there are doubts about security or reliability, an additional funtional test has to be
accomplished. (clean them first if necessary)
Visual inspection
Spreader arms
• Spreader arms and tips without fissures
• bolt and securing rings of the spreader arms are in the right position and orderly
• Corrugation of the tips clean and edged without fissures
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Spreader
• Distance between the arms on the tips (see item 15)
• No leakages
• Easy operation of the star grip
• Handle existing and fast
• Identification plate and position plates legible
• Protection boot undamaged
• Quick connect couplings can be connected easily
• Dust covers in the right position
Hoses
• check according safety instructions for hoses (see item 5)
• Check for oil leakage
Function testing
• Perfect opening and closing with star grip standard version resp. pump-mounted control
valves
12.2 Covers
• Inspection of safety devices at / around spreader unit.
13Repairs
13.1 General
Servicing must be carried out only by the device manufacturer or by personnel trained by the
manufacturer or the authorised LUKAS dealers.
For replacement on all components, use only genuine LUKAS spare parts as specified in the spare
parts list, as here possibly required special tools, mounting information, safety aspects, testing
must absolutely be taken into account. See Section 4.
Protection of the device against hydraulic overload
(only for DIN version with yellow quick coupler on the blue return hose)
If the short hoses of the tool are not connected with the power pack, pressure can be built up
unintentionally in the cylinder due to temperature increase. Therefore, the return hose (0,5 m / blue)
of the tool is equipped with a safety coupling (quick connect plug, colour yellow). Unin-tentional
overpressure (approx. 1.5 MPa) is released through this plug: oil comes out.
Should the tool have been equipped with couplers of different brand which do not have this safety
function, overpressure would be released through another safety valve (adjusted to approx. 30
MPa) included with the control valve block. In this case oil spill would be observed in the star grip
area. As soon as sufficient pressure is released the valve becomes tight again. Should further
constant leakage ocur, please have the tool inspected by LUKAS personnel.
On repair, protective clothing is mandatory (see Section 1), as the spreaders can be pressurized
also in unoperated state.
13.2 Preventive maintenance
13.2.1 Maintenance advice
To protect the device against external corrosion clean its surface from time to time and slightly
grease it with oil.
13.2.2 Function and load test
If there is any doubt as to the safety and reliability of the equpiment, carry out an additional function
and load test. For this purpose, LUKAS offers a test kit as appropriate equipment.
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13.2.3 Change of hydraulic oil
- after 200 uses, latest after 2 years, the hydraulic oil has to be changed.
- in any case if the oil of the pump (motor / hand pump) which belongs to the unit is changed. By
changing the used oil, it should be avoided that the new oil is polluted by the used oil of the rescue
tool.
Procedure:
The rescue tool is in closed (retracted) position • Change of oil has to be effected at the pump.
Screw off the return hose at the pump:
- in case of hose connection: screw off the connecting piece of the blue return hose.
- in case of quick connect couplings: screw off totally the coupling nut of the quick
connect coupling of the blue return hose.
Extend pump with tool slowly • Collect the used oil at the piston rod side in a separate tank and
dispose of the used oil (as the used oil of the pump) • Do not operate the pump any longer.
Connect the return hose again to the pump:
- Tighten the coupling nut of the quick connect coupling according to 13.3.6
- Screw the hose nipple into the valve bloc with MA = 45 Nm
- Ventilate the tool according to 9.1.1.
13.3 Repairs
13.3.1 Tip Replacement
Procedure:
- use a mandrel to drive out the tightening sleeve
- replace tip
- drive in new tightening sleeve - Attention ! Observe mounting position!
The tightening sleeve comes with the tip.
Attention: prior to mounting all sliding surfaces have to be carefully cleaned and greased with
LUKAS special grease.
13.3.2 Oil spill out of the control valve handle (see cover page item 13)
Pressure or return hose are not tightened properly.
Procedure:
Loosen the 2 allen screws (SW5) inside the handle sleeve and remove them together with the short
plastic isolation sleeves. Pull handle sleeve backwards until the hose connection points become
visible and retighten the retaining nut. Change hose connection sealing rings if necessary. Place
handle sleeve again and tighten it with the 2 allen screws. Make sure that the plastic isolation
sleeves are placed properly on the allen screws before mounting.
13.3.3 Change protection boot (see cover page item 5)
The protection boot shall protect the operator against injuries caused by the moving levers. If the
protection boot is damaged it has to be replaced.
Procedure:
Remove the carrying handle • Change protection boot(s) • Mount and tighten carrying handle.
13.3.4 Carrying handle (see cover page item 4)
Damaged carrying handles have to be replaced immediately.
Procedure:
Remove the handle (held by 2 screws) and change it against a new one • Change screws and
disks if necessary.
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13.3.5 Labels
All damaged or illegible indentification stickers (Safety instructions, type label a.s.o) have to be
replaced.
Procedure:
Remove damaged stickers and clean surface with acetone • Put on new stickers.
13.3.6 Quick couplers
Quick couplers on the 0,5m hoses have to be replaced when
- external damage can be observed
- the locking sleeve doesn´work any more
- oil spill occurs even when the coupling is properly connected
Remark: Faulty couplers have to be changed completely against genuine LUKAS spares, i.e. it
is not permissible to make any repair work.
The retaining nut on the hoses has to be tightened with a torque of MA = 45 Nm
13.3.7 Hood of the valve block
If the hood is damaged so seriously that the star grip doesn´t return any more to zero position
automatically the valve has to be replaced completely or the hood has to be replaced by a authorized
LUKAS dealer or the LUKAS service department.
14Troubleshooting
TroubleCheckCauseRemedy
Hoses cannot bePressurizedRelieve pump pressure
coupled
On actuating bladesHoses correctlyAir in the hydraulicThoroughly vent pump
move slowly or byconnected powersystemunit: see 9.1.1
jerkspack operating
No pressure build-upNot enough oil in handRefill oil and vent the
Star grip doesn't returnReturn spring isAsk authorized dealer or
to center position whendamaged or returnLUKAS themselves
releasedmechanism is dirtyfor repair
Oil leakage out ofUntightness, eventuallyReplace hoses
hoses or hose fittingsdamages
Surface of hydraulicContact withChange hoses
hoses is dissolvedagressive fluids
Leakages on theSeal defective pistonReplacement of seals
piston rodrodby authorized dealer or
If the defects cannot be repaired, contact an authorized LUKAS dealer or the LUKAS service
department. The address:
LUKAS Hydraulik GmbH, Weinstraße 39, D-91058 Erlangen, Pf 2560, D-91013 Erlangen, service
phone 09131/698 348; fax 09131/698 353.
resp. motor pump. system (see operating
Vent pumpe afterinstruction 9.1.1)
changing oil
LUKAS themselves
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15Technical data
TypeLSP 40 BLSP 40 ENLSP 60 ENLSP 60 F
Ref. no.84150/089084150/089584150/054784150/0560
Spreading force (kN)
in all operating ranges
Spreading distance min. (mm)620720800800
Pulling force (kN)28 ... 6126 ... 46
Pulling distance (mm)
with chain set KSV 11
with chain set KSV 13------668
with chain set KSS 20520--710710
Dimensions l x w x h (mm)774x299x170790x299x180 880x378x212 880x378x212
Weight incl. oil filling (kg)1819.62525.8
Operating pressure (MPa) max. 63*
Necessary oil quantity (l)
TÜV (DIN)SP29-93-TP18SP42-99-TP18 SP43-99-TP18-French Standard NFS 61571 120.33.93: EH40-40EH 60-60
prEN 13204LHS 40MHS 60--
TypeLSP 80 EN
Ref. no.84150/0570
Spreading force (kN)
in all operating ranges
Spreading distance min. (mm)610
Pulling force max. (kN)99
Pulling distance (mm)
with chain set KSV 13/100
Dimensions l x w x h (mm)770x380x216
Weight incl. oil filling (kg)25.9
Operating pressure (MPa)max. 63*
Necessary oil quantity (l)
TÜV (DIN)
French Standard NFS 61571
EN 13204CS84/610-26
40 ... 12041.5 ... 23062 ... 23062 ... 230
39...58 w. KSV 1145...65 w. KSV 13
487575665--
1
0.130.250.420.34
84 ... 540
437
1
0.34
* 1MPa = 10 bar
1
Necessary oil quantity in the hydraulic power pack for operating the tool
(Difference in quantity piston / rode side)
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15.1 Peeling
TypeLSP 40 B LSP 40 EN LSP 60 EN LSP 60 F LSP 80 EN
Max. thickness of steel plate t (mm)44555
Max. opening (mm x mm)500 x 500 520 x 520 650 x 650 650 x 650 500 x 500
15.2 Oil recommendations
For LUKAS hydraulic devices, use mineral oil in accordance with DIN 51 524 and others
Recommended viscosity range: 10 ... 200 mm²/s,
delivered with HLP 22 to DIN 51 524
15.3 LUKAS Hoses
Bending radiusRmin = 38 mm
Burst resistancesafety factor: burst pressure / max. operating pressure, min. 4 : 1
Temperature resistance - 40°C ... + 100°C
Operating mediumMineral oil according to DIN 51524
15.4 Others
Working temperature-20 ... +55°C
Ambient temperature (power pack in operation)-24 ... +45°C
Storage temperature (power pack not in operation) -30 ... +60°C
LUKAS Hydraulik GmbH
A Unit of IDEX Corporation
Weinstraße 39, D-91058 Erlangen
Postfach 2560, D-91013 Erlangen • Germany
Tel.: +49(0)9131/698-0 • Fax: +49(0)9131/698-394
e-mail: info@lukas.de