Lukas SC 357 E2 User Manual

Instruction manual for rescue equipment

eDRAULIC rescue equipment

(cutter, combi tool, spreader and rescue ram)

SP 300 E2 SP 310 E2

S 700 E2

SC 357 E2 SC 250 E2

S 311 E2

R 411 E

172085085 EN Edition 03.2014

(Translation of the original instruction manual)

1. Danger classiﬁ cations 4

2. Product safety 5

3. Proper use 8

4. Functional description 10

4.1 Description 10

4.2 Structure of rescue devices 11

4.3 Hydraulic circuit diagram 13

4.4 Operating movement controls 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 15

6.1 Safety notes 15

6.2 Cutting (cutter and combination device) 16

6.3 Spreading (spreader and combination device) 17

6.4 Pulling (spreader, combination devices) 18

6.5 Squeezing (spreader, combination devices) 19

6.6 Squeezing (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 Protective equipment 23

8.3 Checking the ﬁ lter in the battery shaft 23

9. Repairs 24

9.1 General information 24

9.2 Preventive service 25

9.3 Repairs 25

10. Troubleshooting 35

Content Page

11. Technical data 37

11.1 eDRAULIC cutter 37

11.2 eDRAULIC combination device 38

11.3 eDRAULIC spreader 39

11.4 eDRAULIC rescue ram 40

11.5 Noise emission (based on standard EN ISO 3744) 40

11.6 Operating and storage temperature ranges 41

11.7 Oscillation / vibration 41

11.8 Torques for central bolts (only for cutter and combination devices) 41

12. EC Declaration of Conformity 42

13. Accessories 43

13.1 Batteries 43

13.2 Battery charger 43

13.3 Power supply 44

13.4 Extension for rescue ram 44

13.5 Chain sets 45

14. Instructions regarding disposal 45

15. Notes 46

Content Page

1. Danger classiﬁ cations

We differentiate between various different categories of safety instructions. The table shown below provides an overview of the assignment of symbols (pictograms) and signal words to the speciﬁ c danger and the possible consequences.

Pictogram

Wear a helmet with a face guard.

Damage /

injury to

Persons

Property

- NOTE

Keyword Deﬁ nition Consequences

DANGER! Immediate danger

WARNING!

CAUTION!

ATTENTION!

Potentially dangerous

situation

Less dangerous

situation

Risk of damage

to property/

environment

Handling tips and

other important/

useful information

and advice

Death or severe

injury

Potential death or

serious injury

Minor or slight

injury

Damage to the

equipment,

damage to the

environment,

damage to

surroundings

No injury/damage

to persons/

environment/

device

Wear protective gloves.

Wear safety shoes

Proper recycling

Protect the environment

Read and follow the operating instructions.

2. Product safety

LUKAS products are developed and manufactured to ensure the best performance and quality when used as intended. The safety of the operator is the most important consideration in product design. Furthermore, the operating instructions are intended to help you use 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 complied with in addition to the operating instructions. The equipment may only be operated by persons with appropriate training in the safety aspects of such equipment, otherwise, there is a risk of injury. We would like to point out to all users that they should carefully read the operating instructions and the instructions they contain before they use the equipment and carefully follow them. We further recommend that you have a qualiﬁ ed trainer show you how to use the product.

CAUTION!

The operating instructions for accessories must also be taken into account!

Even if you have already received instructions on how to use the equipment, you should still read through 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 visibly moving parts (e.g. blade arms).

Wear protective clothing, a safety helmet with visor, protective footwear and gloves.

Working under suspended loads is not permitted where such loads are being lifted only by means of hydraulic or electro-hydraulic devices. If this work is unavoidable, suitable mechanical supports are also required.

Inspect the device before and after use for visible defects or damage.

Immediately report any changes that occur (including changes in operating behavior) to the appropriate persons/departments! If necessary, the equipment is to be shut down immediately and secured!

In the event of malfunction, immediately deactivate the device and secure it. 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!

All bolted connections must be checked for leaks and externally visible damage, which must be repaired immediately! Escaping hydraulic ﬂ uid can cause injuries and ﬁ res.

Do not carry out any changes (additions or conversions) to the equipment without obtaining the prior approval of LUKAS.

All safety and danger instructions on the device must always be complete and in a legible condition.

Repairs to the equipment may only be carried out by a trained service technician with speciﬁ c knowledge of the device.

Safety devices may never be disabled!

Before switching on/starting up the device and during its operation, make sure that nobody will be endangered by this.

When working close to live components and cables, suitable measures must be taken to avoid current transfers or high-voltage transfers to the equipment.

Only genuine LUKAS accessories and spare parts are to be used for repairs.

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 operations as a result of shearing, tearing or breaking; appropriate steps must be taken to avoid this.

Please ensure that you do not become entangled in cables and trip when working with or transporting the device.

Please ensure that the battery contacts are not shortcircuited.

The build-up of static charges and therefore possible sparking must be avoided when handling the device.

Protect the eDRAULIC devices against humidity and moisture

The equipment is ﬁ lled with hydraulic ﬂ uid. This hydraulic ﬂ uid can be detrimental to health if it is swallowed or its vapor is inhaled. Direct contact with the skin must be avoided for the same reason. Also, when handling hydraulic ﬂ uid, note that it can negatively affect biological systems.

Make sure that there is adequate lighting while working.

Always keep these operating instructions easily accessible at the place of operation.

Only touch broken-off or cut-off parts while wearing protective gloves, as the torn / cut edges can be very sharp.

The eDRAULIC devices are not suitable for underwater use.

When working with or storing the equipment, ensure that the function and the safety of the equipment are not impaired by the effects of severe external temperatures and that the equipment is not 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 in such a way 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!

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.

WARNING / CAUTION / PLEASE NOTE!

The device is intended exclusively for the purpose stated in the operating instructions (see chapter "Proper Use"). Any other use is not in accordance with its designated purpose.

The manufacturer/supplier is not liable for any damage resulting from improper use. The user bears sole responsibility for such use. Proper use includes observance of the operating instructions and compliance with the inspection and maintenance conditions.

Never work in a fatigued or intoxicated state!

3. Proper 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 cutting and combination devices are used to free injured persons at accident scenes by cutting through doors, roof beams and hinges. LUKAS eDRAULIC spreaders and combination devices can also be used to free persons who have become trapped by pushing open doors or removing obstacles 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.

CAUTION / PLEASE NOTE!

Care must always be taken that the environment of the object to be processed remains stable and secured against unintentional shifting by using strong supports or underpinning.

LUKAS eDRAULIC devices are NOT suitable for underwater use.

WARNING / CAUTION / PLEASE NOTE!

The following may not be cut / squeezed:

- live cables

- prestressed and hardened parts such as springs, spring steels, steering columns and rollers

- pipes under gas or liquid pressure,

- compound materials (steel/concrete)

- explosive bodies such as airbag cartridges

The operating pressure placed 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-protected! When using the devices in potentially explosive environment, the following

must be excluded:

- that the device could trigger an explosion.

- that working with the device could trigger an explosion; e.g. sparks may result from cutting an object.

The responsibility for explosion prevention or for ruling out work with an eDRAULIC device 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 avoiding explosions must be observed without restriction!

The rescue equipment should not come into contact with acids or alkalines. If this is unavoidable, clean the equipment immediately afterwards with a suitable cleaning agent.

You can obtain accessories and replacement parts for the rescue devices from your authorized LUKAS dealer!

4. Functional description

4.1 Description

The cutting and combination devices 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. These, 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 be used to spread open, squeeze or pull open objects.

The rescue rams are double-acting hydraulic cylinders. Extension and retraction takes place hydraulically.

For 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). Generation of the required hydraulic pressure takes place 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 accumulator battery and the mains power unit can be inserted into the opening provided in the body of the tool. They are then automatically locked into position. 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 are making use of an external power supply, the device can be used for an almost unlimited time. This time is only limited by the external energy source and the overheating switch of the power supply. To 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 bat- teries and power supplies in the LUKAS accessories list.

eDRAULIC devices come with standard light ﬁ ttings to facilitate work under poor light conditions. The light-emitting diodes attached on the operating side light up the work area. The main switch has also been equipped with a ring light, so that you can immediately detect whether the device is switched on or not. When exchanging the battery or power supply, the connection slot will light up for approximately 30 seconds.

4.2 Structure of rescue devices

4.2.1 Cutting device

1 Star grip 2 Main switch

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 housing 10 Tool body 11 Protective cover 12 Light

4.2.2 Combination device

4.2.3 Spreader

1 Star grip 2 Main switch 3 Quick exchange battery

or power supply

4 Release button for bat-

tery and power supply 5 Handle 6 Ventilation slots 7 Blade arms 8 Pivot bolt with secured

nut 9 Plastic housing 10 Tool body 11 Protective cover 12 Light

1 Star grip 2 Main switch 3 Quick exchange battery

or power supply 4 Release button for

battery and power supply 5 Handle 6 Ventilation slots 7 Spreader arms with plug-

on tips 8 Plastic housing 9 Tool body 10 Protective cover 11 Light

4.2.4 Rescue ram

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 Star grip 2 Main switch 3 Quick exchange battery

or power supply

4 Release button for

battery and power

supply 5 Ventilation slots 6 Ram piston 7 Plastic housing 8 Tool body 9 Top claw 10 Bottom claw 11 Light

4.3 Hydraulic circuit diagram

To enable comprehension of the function, a simpliﬁ ed hydraulic ram of the rescue equipment (A) + hand valve (B) are depicted here.

cutting / gripping / pulling / squeezing

or extending the piston

spreading /

opening or retracting the piston

4.4 Operating movement controls

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 Commissioning

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.

5.2 Operating the star grip

(also see chapter on "Operating movement control")

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:

Following release, the star grip automatically returns to the central position, fully guaranteeing load retention.

6. Cutting, spreading, pulling, squeezing

6.1 Safety notes

Before rescue work can commence, the object must be stabilized in its current position. Ensure that the objects to be worked on are adequately underpinned and/or supported to ensure that there is no risk of sliding or shifting. Worldwide 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 regulations of the Gesetzlichen Unfallversicherung (GUV; ‘Legal accident insurance’)

are mandatory.

WARNING / CAUTION / PLEASE NOTE!

LUKAS eDRAULIC devices are not explosion-protected! When using the devices in potentially explosive environments, the following

must be excluded:

- that the device could trigger an explosion.

- that working with the device could trigger an explosion; e.g. sparks may result from cutting an object.

The responsibility for explosion prevention or for ruling out work with an eDRAULIC device lies 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 avoiding explosions must be observed without restriction!

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