Lukas SC 557 User Manual
Instruction manual for rescue equipment
Cutters and Combi Tools
Blade forms:
S x10 S x11 S x30
(Translation of the original instruction manual)
SC
172047085 EN
Edition 11.2014
replaces 04.2014
Content Page
1.Hazard classes 4
2.Product safety 5
3.Proper use 8
4.Description of the functions 9
4.1 Description 9
4.2 Tools in detail 10
4.3 Circuit diagram 11
4.4 Control of the operating movements 11
4.5 Hydraulic supply 11
4.6 Hoses 11
5.Connecting the equipment 12
5.1 General information 12
5.2 Coupling the mono-couplings 12
5.3 Coupling the quick-disconnect couplings 14
6.Operation 15
6.1 Preparatory measures 15
6.2 Operating the star grip (cover: item 1) 15
7.Cutting, spreading, pulling and squeezing 16
7.1 Safety notes 16
7.2 Cutting 16
7.3 Spreading (combi tools only) 17
7.4 Pulling (combi tools only) 18
7.5 Squeezing (combi tools only) 18
8.Dismantling the equipment / deactivation following operation 19
8.1 Cutters / Combi tools 19
8.2 Hydraulic unit 19
8.3 Hoses 19
9.Maintenance and service 19
9.1 Cutters / Combi tools, overall 20
9.2 Protective equipment 20
10.Repairs 21
10.1 General information 21
10.2 Preventative service 22
10.3 Repairs 23
2
11. Troubleshooting 37
12.Technical Data 40
12.1 Cutters 40
12.2 Combi tools 47
12.3 Torque of the pivot bolt 49
12.4 Cutting capacities 50
12.5 Recommended hydraulic fl uid 51
12.6 Operating and storage temperature ranges 51
13.EC Declarations of conformity 52
13.1 Cutters 52
13.2 Combi tools 54
14.Notes 55
3
We distinguish between various categories of safety notes. The table below gives you an
1. Hazard classes
overview of the assignment of symbols (pictograms) and key words to the specifi c hazard
and possible consequences.
Pictogram
Wear helmet with face protection
Damage /
injury to
human
device
- REMARK
Key word Defi nition Consequences
DANGER! Immediate danger
WARNING!
CAUTION!
CAUTION!
Potentially
dangerous
situation
Less dangerous
situation
Danger of damage
to device /
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 safety 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 in order 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 help 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 implemented 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 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 equipment, and that they should
carefully follow such.
We further recommend that a qualifi ed trainer train you 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 accessories and connected equipment used are suitable for
the max. operating pressure!
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
The responsible department
is to be informed immediately
of any changes (including to
the operating behaviour)! If
necessary, the equipment is
to be deactivated immediately
and secured!
In the event of malfunctions,
immediately deactivate the
equipment and secure it. The
malfunction is to be repaired
immediately .
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
Inspect all cables, hoses
and screwed connections
for leaks and externally
visible damage! If necessary,
repair immediately! Squirting
hydraulic fl uid can result in
injuries and fi res.
Do not carry out any changes
(additions or conversions)
to the equipment without
obtaining the prior approval of
LUKAS.
5
Observe all safety and danger
notes on the equipment and in
the operating instructions.
All safety and danger notes on
the equipment are to be kept
complete in a legible condition.
Any mode of operation which
impairs safety and/or stability
of the equipment is forbidden!
Safety devices may never be
deactivated!
Before the equipment is
switched on/started up, and
during its operation, it must
be ensured that nobody is
endangered by the operation of
the equipment.
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
equipment.
The equipment 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.
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 ensure that, when
working with this equipment
or during transportation of
such, you don’t get stuck in the
looped hoses and trip.
Please note that, when
cuttung or spreading, tearing
or breaking can cause falling
material, or sudden removal of
such can cause it to suddenly
catapult off: 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.
When working with or storing
the equipment, ensure that
the function and the safety
of the equipment are not
impaired by the effects of stark
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.
6
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.
Ensure the proper disposal of
all removed parts, left-over oil
and hydraulic fl uid as well as
packaging materials!
WARNING / CAUTION!
The equipment is to be used exclusively for the purpose stated in the operating
instructions (see chapter “Proper Use”). Any other or further use is not considered
proper use. The manufacturer / supplier is not liable for any damages resulting from improper
use. The user bears sole responsibility for such.
Observance of the operating instructions and compliance with the inspection and maintenance
conditions are part of the proper use.
Never work when you are overtired or intoxicated!
7
3. Proper use
LUKAS “SC” combi tools and LUKAS “S” cutters are designed specifi cally for rescuing
victims in traffi c, rail or air accidents and for making rescues from buildings. They serve the
purpose of freeing injured people in accidents e. g. by cutting doors, roof bars and hinges.
By using the LUKAS combi tools, trapped persons can also be freed e. g. by spreading doors
and / or by removing obstacles with the aid of a chainset. Basically, the combi tools can be
used to cut, pull, spread, squeeze and lift.
Basically , LUKAS cutters can only be used to cut objects. All objects which are to be worked
on are to be secured using stable supports or substructures.
Sample applications of the combi tools:
Sample application of the cutters:
8
LUKAS cutters and combi tools can also be used under water at a depth of up to 40m (131 ft).
CAUTION!
In this case, you must strictly observe any leaks in order to avoid threats to the
environment.
CAUTION!
All objects which are to be worked on are to be secured using stable supports or
substructures.
WARNING / CAUTION!
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 cartouches
NEVER operate the rescue equipment at a higher operating pressure than that
stated in the chapter “Technical data”. A higher setting can result in material
damage and/or injuries.
LUKAS rescue equipment may only be used in areas at risk of explosion if an
explosion has been prevented by appropriate measures. You must also take into
account that sparks may be created, for example by cutting an object.
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 limitation!
Spare parts and accessories for the rescue tool can be ordered from your authorisied
LUKAS-dealer!
4. Description of the functions
4.1 Description
The equipment is designed such that, via a hydraulically activated piston, two equal, opposite
blade arms are symmetrically opened / closed by mechanical joints, thereby spreading,
squeezing, pulling or cutting objects.
All cutters and combi tools ensure full load-holding function when disconnected from the
hydraulic supply (e. g. when being unintentional decoupled; defective hose, and so on).
9
4.2 Tools in detail
10
1
2
3
4
5
7
6
6
11
11
10
9
8
3
4
7
1
5
6
10
9
8
1
2
9
8
5
7
6
5
11
9
10
1
3
quick-disconnect coupling
system:
13
12
1 Star grip
2 Control valve
3 Body of rescue tool
4 Handle
5 Hand guard
6 Blade arm
7 Pivot bolt with self-locking nut
8 Handhold
9 Pressure hose
10 Return hose
1 1 Mono-coupling male
12 Quick-disconnect coupling (male)
13 Quick-disconnect coupling (female)
10
4.3 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
A
B
spreading /
opening
4.4 Control of the operating movements
The spreading arms movement is controlled via the star grip of the mounted valve.
(see cover, item 1 and, below, fi gure 3).
fi g. 3
star grip
4.5 Hydraulic supply
A LUKAS motor pump or hand pump only may be used to drive the equipment.
If the pump unit is a different make, you must make sure that it complies with LUKAS
specifi cations, otherwise potential dangers may occur which are not the responsibility of
LUKAS.
Ensure in particular that the authorised operating pressure for LUKAS equipment is not
exceeded.
REMARK:
Before you use pumps from a different manufacturer, you must contact LUKAS
or an authorised dealer.
4.6 Hoses
The pump unit and the rescue tool are connected by hoses.
11
5. Connecting the equipment
5.1 General information
There are two short hoses on the side of the equipment: they are connected to the pump unit
via two hoses. All hose assemblies are marked with a colour and have couplings to enable
unmistakable connection.
REMARK:
The devices can be equipped with different coupling systems.
They differ only by the article number and not by the designation.
Of course the coupling systems can also be reequipped at a later time.
WARNING / CAUTION!
Before connecting the equipment you have to pay attention that all
used components are suitable to the max operation pressure of
the pump unit! In the case of doubt you have to inquire LUKAS
directly!
5.2 Coupling the mono-couplings
The equipment is connected to the hydraulic pump via mono-coupling halves (male and
female).
dust protection caps
mono-coupling
halve (male)
mono-coupling
halve (female)
12
Before coupling, remove dust protection caps, then connect male and female, and turn
the locking sleeve of the female to direction „1“ until the locking sleeve locks into place.
The connection is now in place and secure. Decoupling is by turning the locking sleeve to
direction „0“.
The equipment can also be coupled under pressure provided the connected equipment is
not activated.
REMARK:
We recommend coupling the coupling halves in a pressureless state, when
working in areas with low ambient temperature and the usage of extension hose
assemblies / hose reels, otherwise coupling could need very high expenditure of
force.
To protect them from dust, the accompanying dust protection caps must be put back on.
Fitting the dust protection caps:
The “A” dust protection caps have two internal pins “B”. The dust protection caps must be
placed on the coupling pins in such a way that the pins are guided in the “C” grooves. Fasten
the screw to the limit stop to fi x the dust protection caps on the coupling pins.
A
C
B
WARNING/CAUTION!
The mono-couplings may not be screwed off the hose assemblies and / or the
hose assemblies be confused!
13
5.3 Coupling the quick-disconnect couplings
The equipment is connected to the hydraulic pump via quick-disconnect-coupling halves
(male and female).
X
Y
Before coupling unlock the connect socket by turning the sleeve into position X. Retract
sleeve and connect plug and socket. Release sleeve and turn it into position Y.
Now the connection has been made and locked. Uncoupling is done in the reverse order.
CAUTION!
Always connect the return line fi rst and afterwards the supply line!
REMARK:
Coupling of the devices is only possible, when the hoses are depressurized.
To protect them from dust, the accompanying dust protection caps must be put back on.
WARNING/CAUTION!
The quick-disconnect-couplings partly have special functions. Therefore it is not
allowed to screw them off from the hoses or to exchange them!
14
6. Operation
6.1 Preparatory measures
6.1.1 Commissioning
Before commissioning and following repairs, the equipment must be deaerated.
- Connect the equipment to the hydraulic pump (see chapter “Connecting the
equipment”).
- Open / close the blade arms of the equipment without any load at least twice (see
chapter “Operation of the star grip”).
REMARK:
We recommend that during the deaeration, the attached aggregate for the
hydraulic supply should stand on a higher level than the body of the rescue
tool.
Recommended procedure for the deaeration of the rescue tool:
1.) open and close fully with the blade arms facing upwards.
2.) open and close fully with the blade arms facing downwards.
3.) open and close fully with the blade arms facing upwards.
4.) open and close fully with the blade arms facing downwards.
6.1.2 Inspection of the pump unit
See separate operating instructions for the relevant unit (or for the hand pump).
REMARK:
Before each start-up of the hydraulic unit you have to make sure that the actuating
valves are set to depressurized circulation.
REMARK:
Before coupling the quick-disconnect couplings, the actuating valves of the
hydraulic unit are set to depressurized circulation.
If you use mono-couplings, you can also couple when the hoses are pressurized!
6.2 Operating the star grip (cover: item 1)
Opening the device ( ):
Turn the star grip in a clockwise direction (in the direction of the
relevant symbol) and keep in this position.
Closing the device ( ):
Turn the star grip in an counterclockwise direction (in the direction
of the relevant symbol) and keep in this position.
“Dead-man’s” function:
Following release, the star grip automatically returns to the
central position, guaranteeing the full load-holding.
15
7. Cutting, spreading, pulling and squeezing
7.1 Safety notes
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, regular safety inspections according to the regulations
of the Gesetzliche Unfallversicherung (GUV; connoted ‘Legal accident insurance’) are
mandatory .
In areas at risk of explosion, the equipment can only be used if an explosion has been
prevented by appropriate measures.
The following are to be worn when working with the rescue equipment:
- protective clothing,
- safety helmet with visor or protective goggles,
- protective gloves
- and, if necessary, ear protection
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.
Those not involved in the rescue operation should therefore keep at a distance
appropriate to the situation.
7.2 Cutting
The blades must be positioned at a 90° angle to the object to be cut.
90°
FALSE
RIGHT
Higher cutting capacities can be achieved by cutting as close as possible to the blade’s pivot
point.
FALSE
RIGHT
16
During cutting, the gap between the blade tips (in the crosswise direction) may not be
exceeded, otherwise the blade is in danger of breaking:
Cutter / combi tool max. gap on the blade tips
[mm] / [in.]
S 120 2 / 0.08
3 / 0.12S 311
S 330
S 510 5
S 511 3 / 0.12
S 530 5 / 0.20
S 700 3 / 0.12
/ 0.20
SC 357
SC 557
CAUTION!
Avoid cutting particularly high-strength parts of the vehicle’s bodywork (e.g. sideimpact protection): this almost always causes damage to the cutter / combi tool!
3 / 0.12
7.3 Spreading (combi tools only)
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)
17
Tips get a safe grip.
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