Operating instructions for rescue equipment
Unitool SC 250 M
2
10
4
5
7
6
1 Rotary knob (control valve)
2 Hand lever
3 Equipment body
4 Handle
5 Protective hose
6 Blade arm
8
(Translation of the original operating instructions)
3
1
7 Pivot bolt with self-locking
nut
8 Rotatable tool head
9 Grab handle
10 Carrying strap
9
173055085 EN
Edition 11.2011
2
Content Page
1. Hazard classes 4
2. Product safety 5
3. Intended use 8
4. Description of function 9
4.1 Description 9
4.2 Operational control 9
5. Operation 10
5.1 Controlling the working direction 10
5.2 Blade arm movement 10
6. Cutting, spreading, pulling and squeezing 11
6.1 Safety information 11
6.2 Cutting 12
6.3 Spreading 13
6.4 Pulling 13
6.5 Squeezing 14
7. Dismantling the equipment / deactivation after use 14
8. Care and maintenance 14
9. Repairs 16
9.1 General 16
9.2 Preventative maintenance 16
9.3 Repairs 17
10. Troubleshooting 19
11. Technical data 20
11.1 Combi tools 20
11.2 Pivot bolt tightening torques 21
11.3 Cutting performance 21
11.4 Temperature ranges for operating and storage 21
12. EC declarations of conformity 22
13. Notes 23
3
1. Hazard classes
We distinguish between various categories of safety instructions. The table below gives you
an overview of the assignment of symbols (pictograms) and key words to the specifi c hazard
and possible consequences.
Pictogram
Wearing helmets with face protection
Damage /
injury to
human
device
- NOTE
Key word Defi nition Consequences
DANGER! Immediate danger Death or major injury
WARNING!
CAUTION!
CAUTION!
Potentially
dangerous
Less dangerous
Danger of damage
to device /
environment
application and
other important /
useful information
and advice
situation
situation
Advice for
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
Wearing safety gloves
Wearing protective footwear
Respecting recycling requirements
Observing environmental protection regulations
Reading and following operating instructions
4
2. Product safety
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. Furthermore, the
operating instructions are intended to help in using LUKAS products safely.
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 device 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 device, and that they should
carefully follow such.
We also recommend that you get instructed by a qualifi ed trainer 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 Technical Data of any accessories used comply with the
maximum power rating of the equipment!
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
Immediately report any
changes that occur (including
changes in operating
behaviour) to the appropriate
persons/departments! If
necessary, the device 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
Check all screwed fi ttings
for leaks and externally
detectable damage and
rectify immediately! Squirting
hydraulic fl uid can result in
injuries and fi res.
5
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 device and in the
operating instructions.
Do not carry out any changes
(additions or conversions) to
the device without obtaining
the prior approval of LUKAS
All safety and danger notes
on the device are to be
kept complete in a legible
condition.
Any mode of operation which
impairs safety and/or stability
of the device is forbidden!
Safety devices may never be
deactivated!
Before the device is switched
on/started up, and during its
operation, it must be ensured
that nobody is endangered by
the operation of the device.
When working close to live
components and cables,
suitable measures must
be taken to avoid current
transfers or high-voltage
transfers to the equipment.
The build-up of static
charge with the potential
consequence of spark
formation is to be avoided
when handling the device.
Comply with all specifi ed
dates or dates specifi ed 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 note, when cutting or
spreading: cutting, tearing
or breaking can cause
material falling down or being
catapulted away because of
sudden removal. Necessary
precautions need to be taken!
Only touch any broken-off
parts or the cut-off parts
wearing protective gloves,
since the torn / cut edges can
be very sharp.
6
The device is fi lled with
a hydraulic fl uid. These
hydraulic fl 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.
Ensure adequate lighting
when you are working.
Always keep these operating
instructions within reach
where the device is used.
In addition to the safety information accompanying these operating instructions, all generally
applicable, legal and other mandatory national and international regulations pertaining to the
prevention of accidents and protection of the environment apply and must be complied with!
When working with or storing
the device, ensure that the
function and the safety of the
device are not impaired by
the effects of stark external
temperatures or that the
device is damaged in any
way. Please note that the
device can also heat up over
a long period of use.
Before transporting the
device, 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 fl uid as well as
packaging materials!
WARNING / CAUTION!
Sparking can occur when the equipment is used on metallic materials or when
metallic parts come into contact with hard or uneven surfaces!
Assess the nature of the working environment before operating the equipment!
WARNING / ATTENTION / CAUTION!
The equipment is to be used exclusively for the purpose stated in the operating
instructions (see Chapter entitled ‘Intended Use’) . Use of the equipment for any
purpose other than that stated or for any duty beyond its rated capacity shall be regarded as
imintended use. The manufacturer / supplier is not liable for any damages resulting from
imintended use. The risk shall be borne solely by the user.
Observance of the operating instructions and compliance with the inspection and maintenance
conditions are part of the intended use.
Never work in a fatigued or intoxicated state!
7
3. Intended use
LUKAS handheld combi tools are specially designed for the rescue of casualties in road
accidents, rail accidents and in air travel, and for rescue from buildings. They serve the
purpose of freeing injured people in accidents e. g. by cutting doors, roof bars and hinges.
Trapped persons can also be freed using them e. g. by forcing open doors and/or by removing
obstacles with the aid of a chain set. LUKAS handheld combi tools can basically be used to
cut, pull, open, squeeze and lift objects.
LUKAS handheld combi tools are also suitable for use underwater to depths of 40 m (131
ft) .
CAUTION!
In this case, you must strictly observe any leaks in order to avoid threats to the
environment.
WARNING / CAUTION!
All objects which are to be worked on are to be secured using stable supports or
substructures.
WARNING / ATTENTION / CAUTION!
The following may not be cut / squeezed:
- live electric cables
- pre-tensioned or hardened components, such as springs, spring steels,
steering columns and rollers
- pressurised piping containing gases or liquids,
- composite materials (steel/concrete)
- explosive objects, such as airbag cartridges
NEVER operate the rescue equipment at a higher operating pressure than that
stated in the chapter entitled ‘Technical Data’. A higher setting can result in
material damage and/or injuries.
You can obtain accessories and spare parts for the rescue device from your authorised
LUKAS dealer!
8
4. Description of function
4.1 Description
The LUKAS handheld combi tools are a combi tool and handpump rolled into one unit.
Hydraulic power packs and energy supply or accumulators are therefore not required to
generate the required hydraulic pressure.
This is generated by moving the attached handle, in exactly the same manner as a hand
pump.
The working section of the tool is confi gured so that two equal opposing blade arms with
mechanical joints open or close symmetrically in order to open, squeeze, pull or cut objects.
In addition, LUKAS handheld combi tools are fi tted with a tool head that can rotate through
360° to allow optimum application of the blade arms at all times and ensure optimum
pumping.
4.2 Operational control
The working direction is adjusted before actuating the hand lever by turning the rotary knob
to the desired switching end point (see Cover Sheet Item 1).
The hand lever is actuated to move the two blade arms in the specifi ed working direction.
9
5. Operation
5.1 Controlling the working direction
The working direction is adjusted before actuating the hand lever by turning the rotary knob
to the desired switching end point.
Counterclockwise= closing blade arms - Cutting
Clockwise = opening blade arms - Spreading
5.2 Blade arm movement
Actuate the hand lever (up and down movement) to move the two blade arms in the set
working direction.
NOTE:
We recommend using full strokes when pumping. This means moving the hand
lever the full distance from one end stop to the other.
WARNING / CAUTION!
The hand lever can spring back when operating. This can be caused by excess
hydraulic pressure within the equipment or by external loading.
When operating the equipment, therefore, position yourself in such a way that you
will not be injured if the lever springs back.
10
6. Cutting, spreading, pulling and squeezing
6.1 Safety information
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 specifi c country are to be observed and
complied with. In the Federal Republic of Germany , safety testing is carried out on a regular
basis, in accordance with GUV (German Legal Accident Insurance) regulations.
The following are to be worn when working with the rescue equipment:
- protective clothing,
- helmet with visor or goggles,
- safety gloves
- and ear defenders
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
fl ying fragments. Further avoid unnecessary damage to property belonging to others, objects
not involved by the rescue equipment / fl 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 fl y off, posing a danger to persons.
Ensure that any persons not participating in the rescue are kept at an appropriate
distance from the equipment.
11
6.2 Cutting
The blades must be positioned at a 90° angle to the object to be cut.
15°
15°
12
90°
9
RIGHT
6
Higher cutting capacities can be achieved by cutting as close as possible to the blade’s pivot
point.
RIGHT
During cutting, the gap between the blade tips (in the transverse direction) must not be
exceed of 3 mm (0.12 in.), otherwise the blade is in danger of breaking.
CAUTION!
Avoid cutting particularly high-strength parts of the vehicle’s bodywork (e.g.
side-impact protection): this almost always damages the combi tool!
3
WRONG
WRONG
12
6.3 Spreading
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.
6.4 Pulling
You may only use LUKAS chain sets for pulling purposes.
Before the pulling process can be performed, ensure that the bolt and hook fi 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, affi x and use the chain sets.
A
Use load bolts to fasten the LUKAS
chainset connecting pieces to the blades
(drilled holes ‘A’). (see diagram right)
recommended chainset: KSV 8/50
13
6.5 Squeezing
Basically, squeezing may only be carried out in the area of the tips (see fi gure below).
Squeezing area
7. Dismantling the equipment / deactivation after use
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 device.
NOTE:
Never store the combi tool with the blade arms fully closed! 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.
8. Care and maintenance
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. (For tightening torques M
Fracture testing of the blades must be carried out after 3 years. Therefore a special crack
testing kit 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, safety testing is carried out on a regular basis, in accordance with
GUV (German Legal Accident Insurance) regulations.
14
see ‘Technical Data’)
A
CAUTION!
Clean off any dirt before checking the device!
When cleaning the equipment, ensure that no cleaning agents are used with pH
values outside the range 5 - 8!
WARNING / ATTENTION / CAUTION!
In order to carry out maintenance and repair works, tools appropriate for the job
and personal protecting equipment are essential.
Inspections to be carried out:
Visual inspection
• Opening width of the blade arms at the tips (see chapter ‘Technical Data’),
• General tightness (leaks),
• Ease of movement of the hand lever,
• Ease of movement of the rotary knob,
• Handle present and secure,
• Ease of rotational movement of tool head through 360°,
• Labelling complete and legible,
• Covers in undamaged condition,
• Check the pivot bolt tightening torque (tightening torque M
• Blade arms free of cracks and nicks or deformations on the cutting surfaces,
• Shearing surfaces pass over each other without making contact,
• Pins and circlips on the blade arms are present and in a proper condition,
• Grooving at the blade tips to be clean and square-edged with no evidence of cracking
(applies to combi tools)
see ‘Technical Data’),
A
Function test
• problem-free opening and closing when operating the hand lever and adjusting the rotary
knob,
• no suspicious noises.
• blade arms stop moving when the movement of the pump is interrupted during the process
(dead man’s handle)
15
9. Repairs
9.1 General
Servicing may only be carried out by the manufacturer or personnel trained by the
manufacturer and by authorised LUKAS dealers.
When replacing components, only original LUKAS spare parts must be used (as detailed
in the Spare Parts List) and instructions relating to the use of special tools, assembly
procedures, safety aspects and testing must be complied with (see also the chapter entitled
‘Maintenance and Servicing’).
During assembly, ensure the complete cleanliness of all components, because dirt
can damage the rescue equipment!
WARNING / ATTENTION / CAUTION!
Protective clothes must be worn when repairs are being carried out, because
the equipment can also be pressurised in an idle state.
NOTE:
Register your equipment on the LUKAS Hydraulik GmbH Internet website. The
extended warranty will only be provided for equipment which has already been
registered.
CAUTION!
Because LUKAS rescue equipment is designed for the highest level of
performance, components may only be replaced with those specifi ed in the
spare parts list for the appropriate equipment.
Other components may be replaced only when:
- you have attended the relevant LUKAS training course.
- you have received explicit permission from the LUKAS Customer Service
Department. (After inquiry, examination for the distribution of permission.
Examination in each individual case necessary!)
CAUTION!
When cleaning the equipment, ensure that no cleaning agents are used with pH
values outside the range 5 - 8!
9.2 Preventative maintenance
9.2.1 Care of the equipment
The equipment casing should be kept clean and oil should be regularly applied to the external
metal services to protect them from corrosion.
9.2.2 Function and load testing
Function and load testing should be carried out in the event of there being any doubt as to
the safety or reliability of the equipment.
LUKAS offers appropriate test equipment to this end.
16
9.3 Repairs
9.3.1 Replacing the blades, protection hose and handle
1. Start by carefully cleaning the rescue equipment.
2. Next, close the blade arms so that the tips are almost touching.
NOTE:
The blade bolts are only accessible when the blade arms are almost touching
3. Remove the self-locking nut ‘A’ and push the
pivot bolt ‘B’ out.
CD
4. Slide the protection hose slightly away until
the locking bolts ‘C’ are easily accessible.
5. Remove the retaining rings ‘D’ and push out
bolt ‘C’.
C D
6. Now, you can remove the blade ‘E’ and the
sliding plates ‘F’.
E
A
B
F
7. Fold down then the lever elements ‘G’.
G
17
E
8. Finally, remove the protection hose ‘H’ from
the tool as shown.
H
9. Unfasten the screws ‘J’ and remove them.
10. Take the handle ‘K’ away in direction of the
LK
11. Assembly is carried out in the reverse order.
NOTE:
If only the blade arms need replacing, follow the procedure as far as Step 6 and
then go on to Step 11.
If the protection hose needs changing, follow the procedure as far as Step 8 and
then go on to Step 11.
J
lever elements and also remove the washers
‘L’ underneath.
CAUTION!
Don’t forget to apply LUKAS special grease to all sliding surfaces.
CAUTION!
A special process is used to match the pivot bolt and the self-locking nut. When
replacing, therefore, always exchange both the pivot bolt and the self-locking nut
for a new pair! Because of the special procedure an unscrewing of the nut while
working will be minimized and a resulting blade crack will be prevented.
The nuts can be unscrewed and retightened up to 10 times without affecting
service performance!
18
9.3.2 Labels
All damaged and/or illegible labels (safety notices, type plate, etc.) must be renewed.
Procedure:
1. Remove damaged and/or illegible labels.
2. Clean surfaces with industrial alcohol.
3. Attach new labels.
Ensure that you attach the labels in the right position. If you are no longer sure about this,
then please contact your authorised LUKAS dealer or LUKAS itself.
10. Troubleshooting
Problem Check Cause Solution
The blade arms cannot
be fully opened or closed
Tool does not deliver the
specifi ed power
The blade arms move
under load independent
without operating the
hand pump
Slow movement of
the blade arms when
pumping in the off-load
condition
Rotary knob on the
control valve diffi cult
to turn under load
conditions
The leaking of hydraulic
fl uid from the pump lever
or from the blade arm
piston rod
Material to be cut slides
between the blade arms
during cutting
Tool head cannot be
turned
More than
pump strokes
required to open or
close the device?
Check pivot bolt Pivot bolt not
Insuffi cient
hydraulic fl uid in the
tool
Device defective
Device defective
Device defective
Device defective
Defective piston rod
seal
Damage to the
piston
tightened with the
prescribed torque
Tool under pressure Depressurise the
Repair by an
authorised dealer,
by personnel
specially trained
by LUKAS, or by
LUKAS itself
Tighten the pivot
bolt.
tool
19
If the defects cannot be remedied, inform an authorised LUKAS dealer or contact LUKAS
Customer Service directly!
The address of LUKAS Customer Services is:
LUKAS
Weinstrasse 39, D-91058 Erlangen
Box No. 2560, D-91013 Erlangen
Tel: (+49) 09131 / 698 - 348
Fax: (+49) 09131 / 698 - 353
Hydraulik GmbH
11. Technical data
Since all values are subject to tolerances, minor differences may occur between the data on
your device and the data in the following schedules!
The values can also differ due to reading inaccuracies and/or the tolerances of the measuring
equipment used.
NOTE:
The following tables contain only the technical data required for standard
acceptance.
Additional data concerning your unit can be obtained from LUKAS on request
11.1 Combi tools
Type SC 250 M
Ref. no. 173055000
Dimensions
(l x w x h)
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)
Mass incl. hydraulic fl uid
Cutting classifi cation acc.
to NFPA 1936
[mm] 850 x 190 x 158
[in.] 33.47 x 7.49 x 6.23
[mm] 225
[in.] 8.9
[kN] 261
[lbf.] 58,673
[mm] 308
[in.] 12.1
[kN] 34
[lbf.] 7,643
[kg] 11,9
[lbs.]
A6/B6/C6/D7/E7
20
11.2 Pivot bolt tightening torques
Type SC 250 M
Pivot bolt M24 x 1,5
Wrench size
Torque
[mm] 36
[in.] 1.42
[Nm] 100 +10
[lbf.in.] 885 + 89
11.3 Cutting performance
Cutting material
Cutting material
dimensions
SC 250 M
max.
[mm]
[in.]
Round material steel
(acc. to EN 13204)
26
1.02
11.4 Temperature ranges for operating and storage
Operating temperature [°C] / [°F] -20 … +55 -4 … +131
Ambient temperature
(device in operation)
Storage temperature
(device not in operation)
[°C] /
[°F] -25 … +45 -13 … +113
[°C] /
[°F] -30 … +60 -22 … +140
21
12. EC declarations of conformity
22
13. Notes
23
Please dispose of 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 2014 LUKAS Hydraulik GmbHUnitool_SC250M_manual_173055085_en.indd
subject to revision
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