Lukas SC 350 E User Manual
Operating instructions for rescue equipment
eDRAULIC equipment
(Cutter, combi, spreader and rescue ram)
SP 300 E
S 700 E
SC 350 E
SC 250 E
S 311 E
R 411 E
172080085 GB
Edition 03.2013
replaces 01.2012
(Translation of the original operating instructions)
Contents Page
1. Danger classes 4
2. Product safety 5
3. Intended Use 8
4. Functional description 10
4.1 Description 10
4.2 Structure of the rescue equipment 11
4.3 Hydraulic circuit diagram 13
4.4 Controlling the operating movements 14
5. Operation 14
5.1 Battery or power supply for eDRAULIC device 14
5.2 Operating the star grip 15
6. Cutting, spreading, pulling, squeezing and squashing 15
6.1 Safety instructions 15
6.2 Cutting (cutter and combi tool) 16
6.3 Spreading (spreader and combi tool) 17
6.4 Pulling (spreader, combi tools) 18
6.5 Squeezing (spreader, combi tools) 19
6.6 Squashing (rescue ram) 20
7. Dismantling the equipment / deactivation following operation 21
8. Maintenance and service 21
8.1 Overview of eDRAULIC devices 22
8.2 Safety equipment 23
9. Repairs 23
9.1 General information 23
9.2 Preventive maintenance 24
9.3 Repairs 24
10. Troubleshooting 36
2
11. Technical data 38
11.1 eDRAULIC cutter 38
11.2 eDRAULIC combi tool 39
11.3 eDRAULIC spreader 40
11.4 eDRAULIC rescue ram 41
11.5 Noise emissions (based on the EN ISO 3744 standard) 41
11.6 Operating and storage temperature ranges 42
11.7 Oscillation / vibration 42
11.8 Tightening torques for pivot bolts (cutters and combi tools only) 42
12. EC Declarations of conformity 43
13. Accessories 45
13.1 Batteries 45
13.2 Battery charger 45
13.3 Power supply 46
13.4 Extension for rescue ram 46
13.5 Chain sets 47
14. Instructions regarding disposal 47
15. Notes 48
3
1. Danger classes
We distinguish between various categories of safety instructions. The table below provides
an overview of the symbols (pictograms) and signal words assigned to the specifi c danger
and also the possible consequences.
Pictogram
Damage /
injury to
People
Objects
- NOTE
Key word Defi nition Consequences
DANGER! Immediate danger
Potentially
WARNING!
CAUTION!
ATTENTION!
dangerous
situation
Less dangerous
situation
Danger of
damage to objects
/ 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 a helmet with a face guard
Wear protective gloves
Wear safety shoes
Proper recycling
Observe principles of environmental protection
Read and observe operating instructions
4
2. Product safety
LUKAS products are developed and manufactured 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 aid 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 complied with 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 the operating instructions
carefully before using the equipment and fully comply with the instructions therein.
We further recommend you have a qualifi ed trainer show you how to use the product.
WARNING / CAUTION!
The operating instructions for accessories must also be taken into account!
Even if you have already received instruction, you should read the following safety instructions
again.
WARNING / CAUTION!
Please ensure that the accessories you use are appropriate for the maximum
operating pressure and the performance of the rescue device!
Please ensure that no body
parts or clothing are caught
between the visible moving
parts (e.g. blade arms).
Wear protective clothing,
a safety helmet with visor,
protective footwear and
gloves.
The department responsible
must be informed immediately
of any apparent changes
(including the operating
behaviour). If necessary,
the equipment is to be
deactivated immediately and
secured!
Working under suspended
loads is not permitted if
these are supported only
using hydraulic or electrohydraulic devices. If this
work is unavoidable, suitable
mechanical supports are also
required.
Inspect the device before and
after use for visible defects or
damage.
All screwed connections must
be checked for leaks and
visible damage, which must
be repaired immediately!
Squirting hydraulic fl uid can
result in injuries and fi res.
5
In the event of malfunctions,
shut down the device
immediately and make it safe.
Repair the fault immediately.
Observe all safety and danger
information on the device and
in the operating instructions.
Any mode of operation which
compromises the safety and/
or stability of the device is
forbidden!
Safety equipment must never
be disabled!
Do not carry out any changes
(additions or conversions)
to the equipment without
obtaining the approval of
LUKAS beforehand.
All safety and danger
information on the device
must always be complete and
in a legible condition.
Repairs to the device may
only be carried out by trained
service technicians with
specifi c knowledge of the
device.
Use only original LUKAS
accessories and spare parts
when carrying out repairs.
Make sure before switching
on/starting up the device and
during its operation, that this
will put no one in danger.
When working in the vicinity
of live components and
cables, appropriate measures
must be taken to avoid a
transfer of current or highvoltage arcing to the device.
Please ensure that you do not
become entangled in cables
and trip when working with or
transporting the device.
The build-up of static charge
and therefore possible
sparking must be avoided
when handling the device.
Observe all intervals
for recurring tests and/
or inspections that are
prescribed or stated in the
operating instructions.
Please note that material
could fall down or suddenly
break free during spreading,
cutting, squeezing and
squashing operations as a
result of shearing, tearing
or breaking; appropriate
countermeasures must
Please ensure that the
battery contacts are not shortcircuited.
Only touch any broken-off
parts or the cut-off parts
wearing protective gloves,
since the torn / cut edges can
be very sharp.
6
Protect the eDRAULIC
devices against humidity and
moisture
The eDRAULIC devices are
not suitable for underwater
use.
The equipment is fi lled
with 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 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.
When working with or storing
the equipment, ensure
that the function and the
safety of the equipment
are not impaired by the
effects of extreme 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.
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 fl uid as well as
packaging materials!
WARNING / CAUTION / ATTENTION!
The device is intended exclusively for the purpose stated in the operating instructions
(see chapter "Intended Use"). Any other use is not in accordance with 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.
Intended Use includes observance of the operating instructions and compliance with the
inspection and maintenance conditions.
Never work when you are overtired or intoxicated!
7
3. Intended Use
LUKAS eDRAULIC devices have been specially designed to rescue or retrieve the bodies
of victims of road, rail or aircraft accidents or to be used during rescue operations from
buildings. LUKAS eDRAULIC cutters and combi tools are used to free injured persons at
accident scenes by cutting through doors, roof beams and hinges. LUKAS eDRAULIC
spreaders and combi tools can also be used to free trapped persons by forcing open doors
or to move obstacles aside with the aid of a chain set. LUKAS eDRAULIC rescue rams are
used to free persons who have become trapped during a car accident when the spreader
does not open wide enough, for example by spreading or lifting parts of vehicles. During
other catastrophic events, rescue rams and spreaders can also be used to move objects to
rescue persons who have been buried or trapped.
Care must be taken that the object to be worked on has been secured using stable supports
or by underpinning it.
LUKAS eDRAULIC devices are NOT suitable for underwater use.
WARNING / CAUTION!
Care must be taken that the object to be worked on has been secured using
stable supports or by underpinning it.
WARNING / CAUTION / ATTENTION!
The following may not be cut / squeezed:
- live cables
- 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 cartridges
The operating pressure set on the rescue device may only be directly changed
after consultation with LUKAS. A change in settings may result in damage to
property and/or injuries.
LUKAS eDRAULIC devices are not explosion-proof!
When deploying the devices in potentially explosive areas, it must be ensured that:
- it cannot cause an explosion.
- working with the device will not cause an explosion; for example, formation of
sparks when cutting an object.
The responsibility for explosion prevention or for ruling out work with an eDRAULIC
device rests with the operator of the device or with the person responsible at the
place of use.
When working in areas at risk of explosion, all applicable legal,
national and international regulations, standards and safety rules
for preventing explosions must be observed without exception!
The rescue equipment should not come into contact with acids or alkalis. If this is
unavoidable, clean the equipment immediately afterwards with a suitable cleaning
agent.
8
Y ou can order spare parts and accessories for the rescue tools from your authorised LUKAS
dealer!
Applications:
9
4. Functional description
4.1 Description
The cutters and combi tools have been designed in such a way that a hydraulically operated
piston activates mechanical joints symmetrically to open or close a set of two opposite blade
arms, thus enabling objects to be cut.
The spreaders operate according to a similar principle. They, too, have been designed in
such a way that a hydraulically operated piston activates mechanical joints symmetrically
to open or close a set of two opposite spreader arms. This movement can then be used to
spread open, squeeze or pull open objects.
The rescue rams are double-acting hydraulic cylinders. Extension and retraction takes place
hydraulically.
On all devices, the movement is activated by means of a valve in the form of a star grip.
All devices guarantee the dead man's switch and the full load-supporting function when the
star grip is released.
LUKAS eDRAULIC devices do not need to be connected to an external hydraulic source
(e.g. a motor pump). The hydraulic pressure required is generated within the body of the
device.
Either a battery or an external power supply must be connected as an energy source.
You can choose which energy source you wish to use. Both the battery and the power unit
can be plugged into the opening provided in the body of the tool. Both will lock in place automatically.
When using batteries as an energy source, you have almost unlimited freedom of movement
when working, i.e. there are no cables or hoses to hinder you. You can extend the operating
time of your eDRAULIC device by using several batteries. The batteries can be recharged
after use, using a suitable external charger
If you use an external power supply, the operating time is essentially unlimited; this is only
restricted by the external power source and the thermal switch in the power unit.
T o allow you to select the best possible energy supply for your eDRAULIC device, neither the
battery nor the power supply form part of the delivery scope. You will fi nd suitable batteries
and power supplies in the LUKAS accessories list.
eDRAULIC devices are equipped with lighting as standard so that work can be carried out in
conditions where visibility is poor.
The light-emitting diodes attached on the operating side light up the work area. The main
switch has also been provided with a light, so that you can see at a glance whether the device is switched on. When exchanging the battery or power supply, the connection slot will
be lit up for approximately 30 seconds.
10
4.2 Structure of the rescue equipment
4.2.1 Cutter
2
1
3
12
10
11
8
1 Star grip
2 Main switch
9
5
7
12
11
1
2
3 Quick exchange battery or
power supply
4 Release button for
Battery and power supply
5 Handle
6 Ventilation slots
7 Blade arms
8 Pivot bolt with
secured nut
9 Plastic casing
10 Device body
1 1 Protective cover
12 Illumination
6
4
3
5
11
8
6
7
11
10
9
4
4.2.2 Combi tool
1
2
12
5
3
4
10
8
7
4.2.3 Spreader
5
9
7
11
6
1 Star grip
2 Main switch
3 Quick exchange battery
or power supply
4 Release button for
9
11
1
2
10
Battery and power supply
5 Handle
6 Ventilation slots
7 Blade arms
8 Pivot bolt with
secured nut
9 Plastic casing
10 Device body
1 1 Protective cover
12 Illumination
6
1 Star grip
2 Main switch
3 Quick exchange battery
or power supply
4 Release button for
Battery and power supply
5 Handle
8
6 Ventilation slots
7 Spreader arms with plug-
on tips
8 Plastic casing
9 Device body
10 Protective cover
1 1 Illumination
3
4
12
4.2.4 Rescue ram
2
11
9
NOTE:
When working with the eDRAULIC rescue ram, it should be applied to the object
to be processed in such a way that the battery or power supply can be replaced
at any time.
1
6
3
4
5
7
11
10
8
1 Star grip
2 Main switch
3 Quick exchange battery
or power supply
4 Release button for
Battery and power supply
5 Ventilation slots
6 Cylinder piston
7 Plastic casing
8 Device body
9 Top claw
10 Bottom claw
11 Illumination
4.3 Hydraulic circuit diagram
To enable comprehension of the function, a simplifi ed hydraulic cylinder of the rescue
equipment (A) + hand valve (B) are depicted here.
cut / close / pulling /
squeezing
or extend piston
spreading /
A
B
13
opening
or retract piston
4.4 Controlling the operating movements
The piston movement is controlled by the star grip on the attached valve (see illustration
below).
Star grip
5. Operation
5.1 Battery or power supply for eDRAULIC device
5.1.1 Initial start-up
Before initial operation, the battery (where used) of the rescue device must be fully loaded,
using the external charger.
Procedure:
1. Unplug the power supply (where used) from the mains.
2. Fully press down the two unlocking buttons and carefully pull the battery or power
supply out of the device.
Do not use force!
Connection slot
3. The battery can now be recharged in the charger (please take note of the separate
operating instructions for the charger and the batteries to be used); alternatively,
the power supply can be replaced.
4. Insert the recharged or new battery into the eDRAULIC device until it reaches the stop.
The battery or power supply will be automatically locked when correctly operated.
14
5.2 Operating the star grip
(also see chapter on "Controlling the operating movements")
Open the device or extend the piston ( / ):
Turn the star grip in the direction of the corresponding symbol
(open / extend)and hold it in this position.
Close the device or retract the piston ( / ):
Turn the star grip in the direction of the corresponding symbol
(close / retract)and hold it in this position.
"Dead-man’s" function:
Once released, the star grip automatically returns to the central
position while fully guaranteeing the load will remain supported.
6. Cutting, spreading, pulling, squeezing and squashing
6.1 Safety instructions
Before rescue work can commence, the position of the accident object must be stabilised.
You must ensure that it is adequately underpinned and/or supported.
World-wide, safety guidelines pertaining to the specifi c country must be observed and
complied with. In the Federal Republic of Germany, regular safety inspections according
to the legal accident insurance regulations (GUV - Gesetzliche Unfallversicherung) are
mandatory.
WARNING / CAUTION / ATTENTION!
LUKAS eDRAULIC devices are not explosion-proof!
When deploying the devices in potentially explosive areas, it must be ensured
that:
- it cannot cause an explosion.
- working with the device will not cause an explosion; for example, formation of
sparks when cutting an object.
The responsibility for explosion prevention or for ruling out work with an eDRAULIC
device rests with the operator of the device or with the person responsible at the
place of use.
When working in areas at risk of explosion, all applicable legal,
national and international regulations, standards and safety rules
for preventing explosions must be observed without exception!
15
Wear the following when working with the rescue tool:
- protective clothing,
- safety helmet with visor or protective goggles,
- protective gloves
- and, if necessary, ear protection
Before operating the rescue tool, you should ensure that its movements or fl ying fragments
will not put participants or bystanders at risk! Further avoid unnecessary damage to property
belonging to others, objects not involved by the rescue equipment / fl ying fragments.
It is strictly prohibited to reach into the path of the rescue
device (e.g. between the blades or spreader arms or
between the rescue ram and the material to be processed)!
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.
Those not involved in the rescue operation should therefore keep at a distance
appropriate to the situation. Any trapped or enclosed persons must be protected.
6.2 Cutting (cutter and combi tool)
The blades should be positioned at a 90° angle to the object to be cut, if possible.
15°
15°
RIGHT
12
90°
9
3
16
WRONG
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