(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 wordDefi nitionConsequences
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
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
Higher cutting capacities can be achieved by cutting as close as possible to the blade’s pivot point.
WRONG
RIGHT
During cutting, the gap between the blade tips (in the transverse direction) must not be
exceeded, otherwise the blade is in danger of breaking:
eDraulic toolmax. gap on the blade tips
/ [in.]
[mm]
S 311 E3 / 0.12
S 700 E3 / 0.12
SC 250 E3 / 0.12
SC 350 E3 / 0.12
ATTENTION!
Avoid cutting through the hardest parts of the vehicle body (e.g. lateral collision
protection), as this may result in damage to the cutters or to more wear and tear!
6.3 Spreading (spreader and combi tool)
Use the front area of the tips for increasing the gap only . To increase grip and to avoid having
the tips slip or break out of the part to be processed, the grip should be reapplied at an early
stage. In any case, the highest force is developed in the rear area of the plug-on tip or in the
rear spreading area of the combi blades.
WARNING / CAUTION / ATTENTION!
The light metal alloy spreader arms must not be damaged.
Spreading
17
Enlarging a gap
approx. 25 mm
approx. 1 in.
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
spreader arms!
6.4 Pulling (spreader, combi tools)
WARNING / CAUTION / ATTENTION!
The light metal alloy arms must not be damaged.
- LUKAS chain sets must be used for pulling.
- When using the traction chain, the pins and hooks must be in the correct position
to ensure that the chain cannot slip.
- Only chain sets in perfect condition may be used.
- The traction chains must be checked by an expert at least once a year.
- Also consult the separate operating instructions for the corresponding chain set!
Attachment hole
for chain sets
18
chain sets are attached to the boreholes
A on the blades using load bolts.
(see fi gure on the right).
Chain sets:
for SC250E: KSV 8/50
for SC350E: KSV 8/50
for SP300E: KSV 11
NOTE:
Take note also of all the instructions and regulations in the separately supplied
operating instructions for the chain sets.
6.5 Squeezing (spreader, combi tools)
WARNING / CAUTION / ATTENTION!
The light metal alloy arms must not be damaged.
Squeezing may only take place near the tips (see fi gure below).
AThe connection pieces for the LUKAS
Squeezing area
Squeezing area
19
6.6 Squashing (rescue ram)
Before you can carry out any work with the rescue ram, you must ensure adequate support.
This also includes any necessary substructure. As part of their design, the rescue rams are
fi tted with claws at the cylinder and piston ends to ensure it is as safe as possible to use.
Where this support is not adequate, e.g. when pushing away the front part of the vehicle or
when pushing a vehicle upwards, additional supports and ram attachments may be required,
and it may need to be secured, using straps for example. You will fi nd suitable support
bearings and cylinder attachments in the LUKAS accessories list.
WARNING / CAUTION / ATTENTION!
Never use a rescue ram without a claw or the required accessories! The cylinder
could slip during the operation, resulting in injury to the user. In addition, the
piston rod or the claw support could be damaged.
WARNING / CAUTION / ATTENTION!
When applying the rescue ram (without the LUKAS support), care must be taken
to ensure that all four tips of both claws, i.e. on the piston and the cylinder side,
are in good contact with the object.
When applying the rescue ram (to a LUKAS support), care must be taken to
ensure that the surface between the four tips of the claw is in contact with the
round bearing rods.
This prevents force from acting on only one end of the cylinder. Objects lifted up
must be subsequently secured with fi rm supports or substructures!
An extension is also available for the eDRAULIC rescue ram.
Procedure for installing the extension:
1. First pull the claw "A" off the cylinder base.
Check whether the O-ring "B" is still attached
to the cylinder base and is in good condition.
Where necessary, replace the O-ring.
2. Check the good fi t of the O-ring "B", grease the contact surfaces using LUKAS special
grease and insert the extension "C" onto the cylinder base until it reaches the stop.
BC
3. When the extension is no longer required after the operation, remove it by following the
instructions in the reverse order and store it in a suitable place.
20
BA
7. Dismantling the equipment / deactivation
following operation
Once work has been completed, the arms should be closed until the tips are only a few
millimetres apart or the cylinder piston should be almost fully retracted. This relieves the
hydraulic and mechanical strain on the device as a whole.
NOTE:
Never store the eDRAULIC devices with fully closed arms or a fully retracted
piston! By fully closing the arms or retracting the cylinder piston, hydraulic and
mechanical tension may develop in the device.
Clean the rescue device after each operation and grease both the metallic and the
mechanically movable parts. The locking mechanism for the spreader plug-in tips should
also be oiled now and again.
Greasing provides protection against excessive wear and tear or corrosion.
Avoid storing the rescue equipment in a damp environment.
8. Maintenance and service
The devices are subject to very high mechanical stresses. A visual inspection must therefore
be carried out after every use and at least one visual inspection must 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. Regularly
check the torque of the pivot bolt on the cutters and combi tools. (You will fi nd the tightening
torques for the pivot bolt in the chapter "Technical data")
An annual inspection of the tool is due once per year. This inspection must be performed by
a person with the necessary expertise. This means that the person must possess adequate
specialist knowledge and experience in the fi elds of electrical engineering and hydraulics, so
that they can objectively assess the condition of the tool.
Every three years a crack test of the blades is also essential. A special crack testing kit is
available for this.
A functional test must also be performed every three years or if there is any doubt regarding
the safety or reliability of the equipment (please also observe the applicable national and
international regulations pertaining to service intervals of rescue tools). In the Federal
Republic of Germany, regular safety inspections according to the legal accident insurance
regulations (GUV - Gesetzliche Unfallversicherung) are mandatory.
ATTENTION!
Clean off any dirt before checking the device!
WARNING / CAUTION / ATTENTION!
In order to carry out maintenance and repair work, tools appropriate for the job
and personal protection equipment must be used.
The maintenance and repair staff must have adequate technical and specialised
knowledge. LUKAS offers appropriate training courses for this.
21
8.1 Overview of eDRAULIC devices
Inspections to be carried out:
Visual inspection
Cutter and combi tool
• Opening width of the blade arms on the tips (see chapter "Technical data"),
• General tightness (leaks),
• Ease of movement of star handle,
• Existence and stability of handle,
• Labels completely existent and legibly,
• Covers in perfect condition,
• Check the tightening torque of the pivot bolt (tightening torque M
• Blade arms free of cracks and cutting surfaces without nicks or deformations,
• Cutting surfaces go on top of each other without making contact,
• The sliding plates, bolts and retaining rings of the blade arms are in place and in good
condition,
• Illumination of main switch, work area and connection slot fully functional.
Spreader
• Opening width of arms at the tips (see chapter on "Technical Data"),
• General tightness (leaks),
• Ease of movement of star handle,
• Existence and stability of handle,
• Labels completely existent and legibly,
• Covers in perfect condition,
• Spreader arms not cracked,
• Bolts and retaining rings of spreader arms in place and in good condition,
• The corrugations on the tips should be clean and square, without cracks
• The tips must be in place and locked
• Illumination of main switch, work area and connection slot fully functional.
see "Technical data").
A
Rescue ram
• Piston can be extended to its full length (see chapter on "Technical Data"),
• Cylinder and piston rod undamaged and not deformed,
• Claws correctly and securely fi tted,
• Claws can be turned and are undamaged (no break-outs),
• General tightness (leaks),
• Ease of movement of star handle,
• Labels completely existent and legibly,
• Illumination of main switch, work area and connection slot fully functional.
22
Battery and power supply
• Casing undamaged,
• Electrical contact surfaces clean and undamaged
• Cable undamaged
• Battery(-ies) fully charged (when used)
• Charging state display of lithium/ion battery(-ies) fully functional
Functional check
• Easy opening and closing or extension/retraction of star grip controls,
• no suspicious noises.
• no further movement of cutter and spreader arms or cylinder piston when interrupting the
valve function during the process (dead man's switch),
8.2 Safety equipment
• Check of the protective equipment on / around the rescue equipment, especially the hand
guard for the moveable parts (this must be free of cracks!).
9. Repairs
9.1 General information
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 and compliance with assembly instructions, safety aspects and inspections
must be taken into account (see also chapter "Maintenance and Servicing").
During assembly, make especially sure that all components are clean, since dirt can
damage the rescue tool!
WARNING / CAUTION / ATTENTION!
Protective clothes must be worn when repairs are being carried out, since the
devices may also be pressurised when not in operation.
NOTE:
Always register your tool on the LUKAS Hydraulik GmbH internet site. Only then
are you entitled to the extended guarantee.
ATTENTION!
Because LUKAS rescue tools are designed to deliver outstanding performance,
components must only be replaced with those that are listed in the spare parts
lists for the corresponding device.
Other components in the device may only be replaced if:
- you have participated in an appropriate LUKAS service training course.
- you have the express permission of LUKAS Customer Service (valid LUKAS
certifi cate necessary!)
23
ATTENTION!
When cleaning the equipment, take care not to use any cleaning agent with a pH
value outside the range 5 - 8!
9.2 Preventive maintenance
9.2.1 Care instructions
From time to time, the outside of the device should be cleaned with a damp cloth (not the
electrical contacts in the connection slot, the battery or on the power supply) and oil should be applied to the metallic surfaces (not the electrical contacts in the connection
slot, on the battery or on the power supply) to prevent corrosion.
(In case of doubt, contact your authorised LUKAS dealer or LUKAS directly!)
9.2.2 Functional and stress test
If there is any doubt regarding the safety or reliability of the equipment, a function and stress
test must also be performed.
LUKAS offers appropriate testing equipment for this.
9.3 Repairs
9.3.1 Blades, protective cover and handle replacement for the S700E cutter
Components to be
replaced
Protective cover1., 2. and 7.
Pivot bolt1. - 4. and 7.
Handle1. - 5. and 7.
Blade1. - 6. and 7.
Required work
steps
24
Work steps:
1. First of all, carefully clean the rescue equipment.
2. Remove the fi xing screws "A" and
remove the protective cover "B" and the
cover caps "C".
B
3. Move the blade arms on the unit
until the pin "E" and the retaining
rings "F" can be accessed through
the hole "D".
Now switch off the device and
remove the battery or unplug the
power supply from the device.
C
D
B
C
A
EF
25
H
G
4. First remove the grub screw "G", then
the central bolt nut "H" and then pull out
the central pin "J".
J
5. Release the fi xing screws "K" and
remove them. The handle "L" can
now be pulled out forwards over the
blades.
N
M
M
N
7. The work steps must be carried out in reverse order to fi t the new parts.
O
6. Remove the retaining rings "M" and push
the pin "N" out. You can then pull out the
blades "O" and the slide plates "P"
P
O
L
K
ATTENTION!
Don’t forget to apply LUKAS special grease to all sliding surfaces.
NOTE:
The torque required can be taken from the spare parts list of your particular unit.
26
9.3.2 Changing the blades, protective cover and handle on the S311E cutter
and on the SC350E and SC250E combi tools
NOTE:
The illustrations show the equipment with the blade arms of the cutter. Assembly
and disassembly are identical for the combi tool!
Components to be
replaced
Protective cover1. - 9. and 10.
Pivot bolt1., 5. and 10.
Handle1. - 3. and 10.
Blade1. - 7. and 10.
Work steps:
1. First of all, carefully clean 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
Further procedure:
Required work
steps
3. Remove screws "A" from handle "B".
The handle can then be removed.
B
4. Push the hand guard E in the
depicted direction until the safety
bolts F are easily accessible.
A
F
27
E
F
D
5. Remove self-locking nut D and push the
pivot bolt G out.
G
6. Remove the retaining rings H and
push out bolt J.
L
K
8. Fold in the lever elements M.
H
7. Now, you can remove blade K and
sliding plates L.
M
J
H
J
M
9. Finally, pull the hand guard "E" off the
device as shown.
E
28
10. The work steps must be carried out in reverse order to fi t the new parts.
ATTENTION!
Don’t forget to apply LUKAS special grease to all sliding surfaces.
ATTENTION!
The nut of the pivot bolt and the pivot bolt itself are matched by a special procedure.
Therefore they must only be changed as a set by using a new set! Owing to the
special method used, any loosening of the nut while working will be minimised thus
preventing the blade from breaking.
The nuts can be unscrewed and tightened up to 10 times without affecting the
service life!
NOTE:
The torque required can be taken from the spare parts list of your particular unit.
9.3.3 Sharpening the blades
Only remove and smoothen any burrs!
Chips or deep grooves cannot be ground away . The blades must be replaced in these cases.
ATTENTION!
Only grind in the grinding area (see illustration)!
The sliding faces, in particular, must not be reground!
Grinding area
Pivot point
Blade arm
Direction of movement
Slide surface
plane
Tools required:1. Use jaw protection on clamping device (e.g. vice) in order not to
damage the blades
2. Grinder (e.g. angle grinder or belt grinder) with abrasive having
a grain size of 80.
29
Blade arm
Procedure:
1. Clamp the blade securely into the clamping device so that it cannot move, but with the
grinding area exposed.
2. Carefully grind the burr away evenly until you reach the sliding surface level.
(see illustration)
Slide surface plane
In addition, when grinding, you must make sure that the inclination of the cutting surface
in the direction of the blade arm movement is not changed. Check the incline and
smoothness of the ground surface, using a suitable measuring tool.
ATTENTION!
If you have not maintained the smoothness or incline, the proper operation of the
blade is no longer guaranteed and the blades must be replaced.
9.3.4 Spreader arm, spreader tips, protective cover and handle exchange for
the spreader
Components to be
replaced
Handle1., 2. and 8.
Plug-on tips1., 5. and 8.
Protective cover1. - 4. and 8.
Lever links1. - 4., 6. and 8.
Spreader arms1. - 6. and 8.
Required work
steps
30
Work steps:
1. First of all, carefully clean the rescue equipment. Now switch off the device and remove
the battery or unplug the power supply from the device.
A
2. Remove the fi xing screws "A" and
remove the handle "B".
B
3. Remove the screws "C" and "D".
31
C
C
C
D
C
E
4. Remove the two two-piece locking
elements "E" on the protective cover "F"
and remove the two-piece protective
cover by pulling it sideways.
F
F
5. In order to remove the plug-on tips
"G", you must simultaneously press
the buttons "J" on each side of a
spreader arm "H" fully together and
then pull the plug-on tip forwards off
the spreader arm.
H
J
G
J
H
G
32
6. You need to remove the retaining rings "K" and the lever links "L" to replace the
spreader arms "H".
K
L
K
L
H
L
K
L
KK
7. Also remove the retaining rings "M" and remove the pins "N". You can then remove the
spreader arms "H".
H
M
N
H
M
33
8. The work steps must be carried out in reverse order to fi t the new parts.
ATTENTION!
Don’t forget to apply LUKAS special grease to all sliding surfaces.
NOTE:
The torque required can be taken from the spare parts list of your particular unit.
9.3.5 Rescue ram
Work steps for exchanging the cylinder piston claw:
1. First of all, carefully clean the rescue equipment. Now switch off the device and remove
the battery or unplug the power supply from the device.
AB
2. Pull the claw "A" off the cylinder piston
and remove the O-ring "B". Where the
O-ring is damaged, it must be replaced.
3. Insert the O-ring "B" into the groove of the new claw "A" provided and check it for a fi rm fi t. Grease the contact surfaces with LUKAS special grease and thenslide the new claw
onto the cylinder piston up to the limit stop.
Work steps for exchanging the cylinder base claw:
1. First of all, carefully clean the rescue equipment. Now switch off the device and remove
the battery or unplug the power supply from the device.
DC
2. Pull the claw "C" off the cylinder base
and check whether the O-ring "D" in the
cylinder base has been damaged; if yes,
replace it.
3. Check the fi rm fi t of the O-ring "D", grease the contact surfaces with LUKAS special
grease and then slide the new claw "C" onto the cylinder base up to the stop.
34
9.3.6 Labels
All damaged and/or illegible labels (safety instructions, type plate, etc.) must be renewed.
Procedure:
1. Remove damaged and/or illegible labels.
2. Clean surfaces with industrial alcohol.
3. Affi x new labels.
Take care to affi x the labels in the correct positions. If you are no longer sure about this, then
please contact your authorised LUKAS dealer or LUKAS itself.
35
10. Troubleshooting
TroubleControlCauseSolution
Blades, spreader
arms or cylinder
pistons move slowly
or jerkily when
operated
Blades, spreader
arms or cylinder
pistons do not move
when operated.
Device doesn’t
perform at its given
power
Battery fully
charged?
Power supply cable
connected?
Battery fully
charged?
Power supply cable
connected?
Battery fl atCharge battery
Battery defectiveReplace battery
Air in the hydraulic
system
Power supply
not properly
connected to the
eDRAULIC device
(not automatically
locked).
Power supply
cable not properly
connected to the
external power
supply.
Repair by authorised
dealer, staff specially
trained by LUKAS or
directly by LUKAS
Reinsert power
supply into the
connection slot.
Reconnect external
power supply.
Replace power
supply or power
supply cable.
Use other external
power source
Replace power
supply cable
dealer, staff specially
trained by LUKAS or
directly by LUKAS
dealer, staff specially
trained by LUKAS or
directly by LUKAS
36
TroubleControlCauseSolution
Following release,
the star grip doesn’t
return to the central
position
Hydraulic fl uid leaks
on the piston rod
The useful operating
time between the
individual charging
cycles is less than
5 minutes, despite
charging the batteries
according to the
instructions.
If you cannot rectify the malfunctions, inform an authorised LUKAS dealer or the LUKAS
customer service department immediately!
The address of the LUKAS Customer Service Department is:
Casing damaged or
star grip operation
does not work
smoothly?
Damage to the
torsion spring for
reset
Soiled valve or star
grip
Defective valve
Other mechanical
damage (e. g. star
grip)
Defective rod sealRepair by authorised
Damage to the
piston
Battery defectiveReplace battery
Repair by authorised
dealer, staff specially
trained by LUKAS or
directly by LUKAS
dealer, staff specially
trained by LUKAS or
directly by LUKAS
Since all values are subject to tolerances, minor differences may occur between the data on
your equipment and the data in the following tables.
The values may also differ because of reading inaccuracies and/or tolerances in the
measuring equipment used.
NOTE:
The following tables contain only the technical data necessary for operation and
storage.
Further information about your device is available directly from LUKAS.
11.1 eDRAULIC cutter
TypeS 311 ES 700 E
Ref.no.90-20-20 (172090000) 90-20-70 (172080000)
11.5 Noise emissions (based on the EN ISO 3744 standard)
11.5.1 S700E, S311E, SP300E, SC250E and SC350E:
Battery type used for deviceLithium / ion
No-load operation
(measuring distance: 1m)
full load operation
(measuring distance: 1m)
No-load operation
(measuring distance: 5m)
full load operation
(measuring distance: 5m)
[dB(A)]75
[dB(A)]77
[dB(A)]67
[dB(A)]69
41
11.5.2 R411E:
Battery type used for deviceLithium / ion
No-load operation
(measuring distance: 1m)
full load operation
(measuring distance: 1m)
No-load operation
(measuring distance: 5m)
full load operation
(measuring distance: 5m)
[dB(A)]78
[dB(A)]79
[dB(A)]71
[dB(A)]72
11.6 Operating and storage temperature ranges
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
11.7 Oscillation / vibration
The total oscillation value / vibration value to which the upper limbs are exposed, is usually
below 2.5 m/s².
Higher values may be measured for short periods as a result of interaction with the materials
to be processed.
(The oscillations / vibrations were determined in accordance with DIN EN ISO 20643.)
11.8 Tightening torques for pivot bolts (cutters and combi tools only)
typeS 311 ES 700 ESC 250 ESC 350 E
pivot boltM 24 x 1,5M32 x 1,5M 24 x 2M 24 x 1,5
wrench size
torque
[mm]36463636
[in.]1.421.811.421.42
[Nm]120 +10140 + 10110 +10120 +10
[lbf.in.] 1,062 + 89 1,239 + 89890 + 891,062 + 89
42
12. EC Declarations of conformity
43
44
13. Accessories
13.1 Batteries
Only LUKAS lithium-ion rechargeable batteries may be used to operate eDRAULIC tools.
These guarantee optimum performance and maximise the operating time of eDRAULIC
tools.
Charging
state
indicator
Query
button
13.2 Battery charger
Only the "eDRAULIC Power Pack Charger" may be used for the lithium/ion batteries.
NOTE:
Pay strict attention to the separate operating instructions for the battery charger.
45
13.3 Power supply
The eDRAULIC devices have a unique power supply with integrated electronics, allowing
the devices to be operated for an almost unlimited time by connecting them to an external
power source. The power supply converts the voltage of the external power source in such
a way that it may be used instead of a battery.
Cable
Filter
Adapter
Cable
Schuko plug
Structure:
There is an adapter on one side of the power supply which can be simply inserted into
the connection slot of the devices and locked. The other side has a mains plug. Both are
connected by a cable. The mains plug is a Schuko plug with Protection Classifi cation IP68.
The integrated fi lter is appropriate for the conversion of AC voltage to DC voltage.
NOTE:
Pay strict attention to the separate operating instructions for the power supply.
13.4 Extension for rescue ram
A special extension is available for the eDRAULIC rescue ram, which may be used to enlarge
the effectively possible opening width of an object.
The installation instructions for the extension may be taken from the chapter on "Squeezing
(rescue ram)".
TypeExtension
Ref.no.174081000
Dimensions including claw
l x w x h
Maximum extension
possible
Weight
[mm]360 x 55 x 55
[in.]14.17 x 2.17 x 2.17
[mm]300
[in.]11.81
[kg]4,2
[lbs.]9.3
46
13.5 Chain sets
Chain sets are required in order to be able to perform pulling operations with the eDRAULIC
spreader and the eDRAULIC combi-tool (see chapter, "Pulling").
Suitable chain sets:
for SC250E: KSV 8/50
for SC350E: KSV 8/50
for SP300E: KSV 11
NOTE:
The safety information, assembly , use and technical data for the chain sets can be
found in the separately supplied operating instructions for the particular chain set.
14. Instructions regarding disposal
Please properly dispose of all packing
materials and removed parts.
Electrical equipment, accessories and packaging should always be disposed of in an
environmentally compatible way.
Only for EU countries:
Do not dispose of electrical equipment with your household waste!
According to the European Directive 2002/96/EC governing electrical and electronic waste
and their application in national legislation, old electrical equipment must be separately
collected and recycled in an environmentally compatible manner.
Please also take into account the notes in the separate operating instructions for the batteries.