Lukas SP 512 User Manual

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Instruction manual for rescue equipment

Spreaders

(Translation of the original instruction manual)

171010085 EN

Edition 11.2014

replaces 01.2014

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 Unit 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 15

7. Spreading, pulling, peeling and squeezing 16

7.1 Safety notes 16

7.2 Spreading 16

7.3 Pulling 18

7.4 Peeling 18

7.5 Squeezing 19

8. Dismantling the equipment / deactivation following operation 20

8.1 Spreader 20

8.2 Hydraulic unit 20

8.3 Hoses 20

9. Maintenance and service 20

9.1 Spreader, overall 21

9.2 Protective equipment 21

10. Repairs 22

10.1 General information 22

10.2 Preventative service 23

10.3 Repairs 24

11. Troubleshooting 35

12. Technical data 37

12.1 Peeling 42

12.2 Recommended hydraulic ﬂ uid 42

12.3 Operating and storage temperature ranges 42

13. EC Declaration of conformity 43

14. Notes 44

1. Hazard classes

We distinguish between various categories of safety notes. The table below gives you an overview of the assignment of symbols (pictograms) and key words to the speciﬁ c hazard and possible consequences.

Pictogram

Wear helmet with face protection

Damage /

injury to

human

device

- REMARK

Key word Deﬁ nition Consequences

DANGER! Immediate danger

WARNING!

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

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. spreader 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!

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 oil can result in injuries and ﬁ res.

In the event of malfunctions, immediately deactivate the equipment and secure it. The malfunction is to be repaired immediately .

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

Observe all safety and danger notes on the equipment and in the operating instructions.

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.

All safety and danger notes on the equipment are to be kept complete in a legible condition.

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 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 wearing protective gloves, since the torn edges can be very sharp.

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.

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 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.

Ensure the proper disposal of all removed parts, left-over oil, left-over hydraulic ﬂ uid and 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!

3. Proper use

LUKAS spreaders are designed especially for rescue services. They are used to release persons trapped as a result of a road accident e.g. by forcing open the car doors (see below Fig. 1) or by squashing other parts of the vehicle. In other catastrophic situations they are used to lift (by spreading) or to displace objects in order to rescue buried or trapped persons, e.g. by concrete components in collapsed houses (see below Fig. 2), and to squash constructional components, e.g. pipes.

In principle, objects can be pulled, spread, squashed or compressed in length. All objects to be worked on are to be secured using stable supports or substructures. When lifting loads, additional risks to the operator and/or persons not involved may be

posed if the load moves in an uncontrolled manner or if the spreader slips or tips over. When applying the tool and lifting, make sure that there is no danger, if necessary by using additional supports or safety devices.

ﬁ g. 1 ﬁ g. 2

LUKAS spreaders 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 squeezed:

- live cables

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

- 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 spreading or squashing 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 spreader arms are symmetrically opened by mechanical joints, thereby spreading objects. Closing the spreader arms is also carried out hydraulically and mechanically by reverse order of the piston. All spreaders ensure full load-holding function when disconnected from the hydraulic supply (e. g. when being unintentional decoupled; defective hose, and so on). (For reasons of safety, equipment SP 510 and SP 512 are internally safeguarded from 63 MPa = 630bar When the safeguarding valve responds a screeching noise can occur. Even if the screeching noise occurs in unloaded condition, deactivate the equipment immediately and contact your authorized dealer or LUKAS directly!)

4.2 Unit in detail

Quick-disconnect coupling system:

1 Star grip 2 Control valve 3 Spreader body 4 Handle 5 Hand guard 6 Spreading arm 7a Multifunction tip incl. peeling

function with borehole for chain set

7b Diamond-tip with borehole for chain

set 8 Roll pin 9 Pressure hose 10 Return hose 1 1 Handhold 12 Mono-coupling male 13 Quick-disconnect coupling (male) 14 Quick-disconnect coupling (female)

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.

spreading

pulling / squeezing

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.

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)

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 decoupling could need very high expenditure of force.

To protect them from dust, the accompanying dust protection caps must be put back on.

Using 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 into the “C” grooves. Fasten the screw up to the limit stop to ﬁ x the dust protection caps on the coupling pins.

WARNING/CAUTION!

The mono-couplings may not be screwed off the hose assemblies and / or the hose assemblies be confused!

5.3 Coupling the quick-disconnect-couplings

The equipment is connected to the hydraulic pump via quick-disconnect-coupling halves (male and female).

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!

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 spreader 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 spreader arms facing upwards.

2.) open and close fully with the spreader arms facing downwards.

3.) open and close fully with the spreader arms facing upwards.

4.) open and close fully with the spreader 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

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.

7. Spreading, pulling, peeling 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 the event of a potentially explosive situation, it is not permitted to use motor pumps (danger of the formation of sparks). In such cases, hand pumps are to be used.

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 spreader 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 Spreading

Use the front area of the tips for increasing the gap only. Full spreading capacity can be achieved when approximately half of the grooved area of the tips is used. The greatest force is created in the rear area of the spreading range of the tip (refer to images to follow).

WARNING / CAUTION!

The arms – made from a light metal alloy – may not be damaged.

spreading

Increasing

a gap

Increasing

a gap

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

arms.

7.3 Pulling

- LUKAS chain sets are to be used for pulling purposes.

- Before the pulling process can be performed, ensure that the bolt and hook ﬁ t correctly to prevent the chain from slipping.

- Only chain sets in perfect condition may be used.

- The pull chains are to be inspected at least once per year by an expert.

- See separate operating instructions for the relevant chain set!

Mounting bore for chain set

SP 310 / SP 510 SP 512

Mounting bore for chain set

SP 300

7.4 Peeling

With the integrated peeling zone (see ﬁ gure below) in the tool tips of spreaders SP 310, SP 510 and SP 512, sheet steels can be peeled open (for maximum sheet steel thickness t, see chapter “Technical data”).

Peeling zone

WARNING / CAUTION!

Splinters can ﬂ y uncontrollably from particularly hard materials. Keep a safe distance!

7.5 Squeezing

Basically, squeezing may only be carried in the area of the tips, unless an additional squeezing device is used – see ﬁ gures 6 and 7 below. (This additional squeezing device is only available as an accessory for the spreader SP 310).

ﬁ g. 6

Use of this squeezing device enables squeezing closer to the spreader arm pivot point, resulting in a higher squeezing force.

Spreader arm

Assembly:

Squeezing plates A

ﬁ g. 7

ﬁ g. 8

ﬁ g. 9

1. Push the squeezing plate A over the spreader arm until boreholes B1 and B2 lie ﬂ ush above each other.

2. Position the spacer washer C between the two boreholes..

3. Put the screw B from the opposite side of the spreader arm through borehole B1 and spacer washer C (see ﬁ gure 9).

4. Screw the screw B tightly into borehole B2.

8. Dismantling the equipment / deactivation following operation

8.1 Spreader

Once work has been completed, the spreader arms are to be closed so that there is a tip distance of just a few mm. This relieves the hydraulic and mechanical strain on the equipment.

8.2 Hydraulic unit

Upon completion of work, the unit must be deactivated.

8.3 Hoses

First of all, decouple the pressure hose then the return hose as described in chapter “Connecting the equipment”. Ensure that you put the dust protection caps back on to the couplings.

9. Maintenance and service

The equipment is subject to very high mechanical stresses. A visual inspection is to be carried out after every use: however, at least one visual inspection is to be carried out annually. These inspections enable the early detection of wear and tear, which means that punctual replacement of this wearing parts prevents breakages from occurring. A function test is also to be carried out every three years or should there be any doubt regarding the safety or reliability of the equipment. (Please also observe the relevant valid national and international regulations pertaining to service intervals of rescue equipment). In the Federal Republic of Germany, regular safety inspections according to the regulations of the Gesetzlichen Unfallversicherung (GUV; connoted ‘Legal accident insurance’) are mandatory.

CAUTION!

Clean off any dirt before controlling the equipment!

WARNING / CAUTION!

In order to carry out maintenance and repair works, tools appropriate for the job and personal protecting equipment are essential.

9.1 Spreader, overall

Inspections to be carried out:

Visual inspection

Spreader

• Opening width of the spreader arms on the tips (see chapter “Technical data”),

• General tightness (leaks),

• Operability of the star grip,

• Existence and stability of handle,

• Labels completely existent and legibly,

• Covers in perfect condition,

• Couplings must be easy to couple,

• Dust protection caps must be available.

Spreader arms

• Spreader arms free of tears and without any chipped spots or deformations on the surfaces,

• Bolts and retaining rings of the spreader arms must be present and in correct working order,

• Grooving of the tips must be clean and squared, and not have any tears

• Tips existent and locked

Hoses (see also operating instructions for hydraulic hoses)

• Visual control for visible damage,

• Control for leaks.

Function test

• Opening and closing function ﬂ awlessly upon activation of the star grip,

• no suspicious noises.

• no further movement of the spreader arms upon interruption of the valve activation during the process (“dead-man’s” function)

9.2 Protective equipment

• Control of the protective equipment on / around the rescue equipment, especially the hand guard of the moveable parts (they must be free of tears!).

10. Repairs

10.1 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, assembly advice, safety aspects, inspections might have to complied with (see also chapter “Maintenance and Service”).

During assembly, ensure the complete cleanliness of all components, since dirt can damage the rescue equipment!

WARNING / CAUTION!

Protective clothes must be worn when repairs are being carried out, since parts of the units can also be pressurised in an idle state.

REMARK:

Before you use couplings from a different company , you must contact LUKAS or an authorised dealer.

REMARK when using the quick-disconnect-coupling system:

Overpressure protection of the rescue equipment (model with yellow coupling nipple on the return hose)

If the equipment’s short hoses are not connected to a unit, temperature increases can inadvertently cause pressure to build up in the equipment. Hence, the return hose of the equipment is equipped with a safety coupling (quickdisconnect coupling male, yellow). Unwanted overpressure (approx. 1.5 Mpa) is automatically released via this nipple: hydraulic ﬂ uid leaks. Should an hydraulic ﬂ uid leak on the coupling male be more frequent, please contact your dealer or LUKAS itself.

If couplings from a different company are used which do not have this function, the overpressure protection can react in the valve of the rescue equipment. Hydraulic ﬂ uid leaks in the area of the star grip. Following the reduction in pressure, the valve is once again tight. Should the valve leak permanently, please immediately contact your dealer or LUKAS itself.

CAUTION!

Because LUKAS rescue equipments are appropriate for highest achievements, only components may be exchanged, which are speciﬁ ed in the spare parts list of the appropriate equipment. Further components of the equipment may only be exchanged, when:

- you have participated on a appropriate LUKAS service training.

- you have the explicit permission of the LUKAS Service department (After inquiry , an examination for the distribution of permission is being carried out. An examination in each individual case is necessary!)

10.2 Preventative service

10.2.1 Care regulations

The exterior of the equipment is to be cleaned from time to time in order to protect it from external corrosion. Oil is to be applied to the metallic surfaces.

10.2.2 Function and load test

If there is any doubt regarding the safety or reliability of the equipment, a function and load test must also be performed. LUKAS offers appropriate test equipment to this end.

10.2.3 Changing the hydraulic ﬂ uid

- The hydraulic ﬂ uid must be changed after the equipment has been used approx. 200 times / after three years at the latest.

- It must always be changed whenever the hydraulic ﬂ uid for the accompanying pump (motor / hand pump) is changed. This is to prevent the fresh hydraulic ﬂ uid from becoming contaminated by the used ﬂ uid from the rescue equipment.

Procedure:

1. Close spreader arms (until the tips are almost touching).

2. Change the hydraulic ﬂ uid of the pump. Please observe the separate operating instructions for the pump being used!

3. Screw off the return hose on the pump:

- when the hose connection is directly into the pump:

completely unscrew the connection nut of the connection piece of the blue return

hose.

- when the hose connection is via mono-coupling to the pump:

remove the cover from the mono-coupling (male). completely unscrew the connection nut of the blue returnhose on the mono-coupling

(male).

- when the hose connection is via quick-connect-coupling to the pump:

completely unscrew the connection nut on the quick-disconnect-coupling of the blue return hose.

4. Put the return hose into a separate collecting basin for the hydraulic ﬂ uid still in the

equipment.

5. Slowly open the tool (the pump must be working during this time). The old hydraulic ﬂ uid

from the piston space side runs via the return hose into the separate collecting basin, and is to be disposed of in the same manner as the old hydraulic ﬂ uid of the pump.

6. Switch the pump off (motor pump) / no longer activate it (e.g. hand pump).

7. Reconnect the return hose to the pump:

- when the hose connection is directly into the pump:

screw the connection nut of the connection piece of the blue return hose back on. (Please observe the necessary torque of M

- when the hose connection is via mono-coupling to the pump:

screw the connection nut of the blue return hose back onto the mono-coupling (male). (Please observe the necessary torque of M Pull back the cover on the couplings as far as the limit stop.

- when the hose connection is via quick-connect-coupling to the pump:

screw the connection nut back onto the quick-disconnect-coupling of the blue return hose. (Please observe the necessary torque of M

8. Deaerate the rescue tool as described in the chapter “Preparatory measures”.

= 40 Nm!)

= 35 Nm!)

10.3 Repairs

10.3.1 Chaging the tip (SP 510 and SP 512)

Procedure:

1. Use the pulling pin to remove the roll pin “A”,

2. Replace tip,

CAUTION!

Before assembly , apply LUKAS special grease to all sliding surfaces after having thoroughly cleaned them.

3. Hammer in new roll pin.

CAUTION!

Before assembly , apply LUKAS special grease to all sliding surfaces after having thoroughly cleaned them. Also observe the installation position of the adapter sleeve to ensure optimum force distribution!

Installation position of the roll pin of the SP 310 and SP 510:

The opening of the roll pin should face towards the squeezing surfaces (see ﬁ gure, right)

Installation position of the spiral pin of the SP 512:

The external start of the spiral pin should face towards the rear end of the tip (see ﬁ gure, right)

The roll pin / spiral pin comes with the tip. Pressing onto the tips on the spreader arm enables the roll pins to be inserted more easily into the boreholes.

REMARK:

Always replace both tips.

10.3.2 Replacing the plug-on tips (SP 300 / SP 310)

Procedure:

1. In order to remove the plug-on tips “G”, you need to push the buttons “J” on both sides of a spreader arm completely and simultaneously and then remove the plug-on tip from the spreader arm by pulling it forwards.

2. Place the new tips onto the arm until they automatically click in place on the spreader arm.

NOTE:

Always replace both plug-on tips. When inserting the new tips, push both buttons “J” until the tip can be slid over them. After ﬁ tting, make sure that both buttons “J” are locked on each arm (that they are back in their original position).

10.3.3 Changing or tightening hoses

Hoses of the pressure and/or return pipe leaks or hoses are defective. Tighten the hoses on the safety valve. (Please note! Observe torque of M

REMARK when using mono-couplings:

If you want to change the hoses, you have to dismantle the mono-couplings.

CAUTION (by usage of mono-coupling-system)!

Take care that the port ‘T’ of the rescue tool is always connected to the port ‘T’ of the mono-coupling.

CAUTION (by usage of quick-disconnect-coupling-system)!

The return hose, which is screwed onto the port “T” of the rescue tool, must be equipped with a quick-disconnect-coupling (male) always. However the supplying hose line must be equipped with a quick-disconnectcoupling (female).

= 40 Nm!)

Procedure:

1. Loosen the 2 B screws in the handle sleeve with quick-disconnect protective sleeves C (hexagon socket)

2. Remove handle sleeve A and tighten screwed connection. If necessary, renew seals.

3. Dismantle hose D and sealing ring E. (There is no need to carry out this point if the hoses are just being tightened).

4. Screw the hose with sealing ring back on. Please ensure that the insulating washer F is on and correctly assembled.

5. Tighten the hose connection on the safety

dismantle

assemble

valve. (Please note! Observe the necessary torque of M

= 40 Nm!)

6. Then replace handle sleeve, protective sleeves and screws, tighten (Torque: 5Nm) and secure it with threadlocking ﬂ uid (e. g. LOCTITE 243).

10.3.4 Spreader arm, spreader tips, protection cover and handle replacement

(SP 510 and SP 512)

Components to be replaced

Handle 1. - 3. and 7. Protective cover 1. - 4. and 7. Plug-on tips 1. - 5. and 7. Lever links 1. - 5. and 7. Spreader arms 1. - 6. and 7.

Procedure:

1. Close the rescue unit until a gap of only a few mm remains between the tips. Disconnect the device from the hydraulic power supply unit and clean thoroughly.

2. Unscrew nuts “A”, remove washers “B” and remove ﬁ xing bolts “C”.

Required work steps

3. Pull the handle “D” backwards over the hose

4. In the same way, pull the protective cover “E” backwards over the hose connections.

connections.

HJJF

5. Drive the pins “F” out with a drift and remove

6. The pins “L” can be removed after removing the locking rings “K”. You can now remove the spreader arms “M” and replace them.

the plug-on tips “G”. Remove the locking rings “H” and remove the handlebars “J”.

KLL

7. The work steps must be carried out in reverse order to ﬁ t the new parts.

CAUTION!

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.

10.3.5 Spreader arm, spreader tips, protective cover and handle replacement on the SP 300 spreader

Components to be replaced

Handle 1., 2. and 8. Protective cover 1., 5. and 8. Plug-on tips 1. - 4. and 8. Lever links 1. - 4., 6. and 8. Spreader arms 1. - 6. and 8.

Work steps:

1. Close the rescue unit until a gap of only a few mm remains between the tips. Disconnect

it from the hydraulic power supply unit and clean thoroughly.

Required work steps

2. Remove the ﬁ xing screws “A” and remove the handle “B”.

3. Remove the screws “C“ and “D”.

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.

5. In order to remove the plug-on tips “G”, you need to push the buttons “J” on both sides of a spreader arm completely and simultaneously and then remove the plug-on tip from the spreader arm to the front.

6. You need to remove the locking rings “K” and the lever links “L” to replace the spreader

arms “H”.

L K

K L

7. Also remove the locking rings “M” and remove the pins “N”. You can then remove the

spreader arms “H”.

H M

8. The work steps must be carried out in reverse order to ﬁ t the new parts.

CAUTION!

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.

10.3.6 Mono-couplings

The mono-couplings must be replaced in the event of:

- external visible damage,

- the locking device not working,

- hydraulic ﬂ uid continually leaking in a coupled/uncoupled state.

WARNING / CAUTION!

Never repair couplings: they are to be replaced by original LUKAS parts!

During assembly , tighten the connection nut of the hose assembly with a torque of M

= 40 Nm.

Procedure:

1. Remove the cover from the couplings.

2. Loosen the connection nuts of the hose assembly and remove the coupling.

3. Position the new coupling and tighten the connection nuts of the hose assemblies with a torque of M

= 40 Nm and push the cover of the couplings back on.

CAUTION!

Take care that the port ‘T’ of the rescue tool is always connected to the port ‘T’ of the mono-coupling.

10.3.7 Quick-disconnect-couplings

The quick-disconnect-couplings must be replaced in the event of:

- external visible damage,

- the locking device not working,

- hydraulic ﬂ uid continually leaking in a coupled/uncoupled state.

WARNING / CAUTION!

Never repair couplings: they are to be replaced by original LUKAS parts!

During assembly , tighten the connection nut of the hose assembly with a torque of M

= 35 Nm.

Procedure:

1. Loosen the connection nut of the hose assembly and remove the coupling.

2. Position the new coupling and tighten the connection nut of the hose assemblies with a torque of M

= 35 Nm.

CAUTION!

10.3.78 Valve cover

If the cover is deformed to such an extent that the star grip no long works correctly , the valve must be replaced in its entirety. Have repairs carried out by an authorised dealer, by personnel specially trained by LUKAS, or by LUKAS customer service only.

10.3.9 Labels

All damaged and/or illegible labels (safety notices, type plate, etc.) must be renewed.

Procedure:

1. Remove damaged and/or illegible labels.

2. Clean the surfaces using industrial alcohol.

3. Attach new labels. Ensure that you attach the labels in the right position. If you are no longer sure about this,

then please contact your authorised LUKAS dealer or LUKAS itself.

11. Troubleshooting

Trouble Control Cause Solution

Spreader arms move slowly or jerkily when activated

Device doesn’t perform at its given power

Following release, the star grip doesn’t return to the central position

with mono-couplingsystem: Hoses

cannot be coupled

with monocoupling-system:

It is frequently not possible to couple hose assemblies

with quickdisconnect-couplingsystem: Hoses

cannot be coupled Hydraulic ﬂ uid leak

on the hoses or the ﬁ xing-ins

Are the hoses connected properly?

Does the pump unit work?

Check the hydraulic ﬂ uid level in the supplying pump

Cover damaged or star grip hard to move?

Control the degree of viscosity and application temperature of the used hydraulic ﬂ uid

Is the pump working?

Are the hoses defective?

Air in the hydraulic system

Insufﬁ cient hydraulic ﬂ uid in the pump

Damage to the torsion spring for reset

Soiled valve or star grip

Defective valve Other mechanical

damage (e. g. star grip)

Pressure too high (e.g. caused by too-high ambient temperature)

Coupling defective Coupling needs to be

Hydraulic ﬂ uid not adapted to the application situation

Coupling defective Coupling needs to be

Pressurized Relieve pump Coupling defective Coupling needs to be

Leak, possible damage

Deaerate pump system

Top up hydraulic ﬂ uid, deaerate

Repair by an authorised dealer, by personnel specially trained by LUKAS, or by LUKAS itself

Set hydraulic pump to pressureless circulation

replaced immediately Hydraulic ﬂ uid

must be replaced (see chapter “Recommended Hydraulic ﬂ uids”)

replaced immediately

replaced immediately Replace hoses

Trouble Control Cause Solution

Damages on the surface of the hydraulic hoses

Hydraulic ﬂ uid leaks on the piston rod

Leak on the handhold Increase load? Load increase

Does the pressure set on the pump comply with the maximum permissible pressure on the rescue equipment?

Hoses in handhold loose?

Check the connections of the mono-coupling (female)

Especially by usage of quick-disconnectcouplings: Leak on

the handhold

Is the return hose connected correctly?

Mechanical damages or contact with aggressive agents

Defective rod seal Repair by an Damage to the

piston

(e.g. something has fallen onto the part to be lifted, thereby suddenly increasing the load)

Pressure release in the Rescue tool.

Hoses in handhold not tightened

Supply and return connection of the mono-coupling (female) inverted

Return hose is not coupled correctly or not connected.

Replace hoses

authorised dealer, by personnel specially trained by LUKAS, or by LUKAS itself

Secure the loads and move them by using other tools

Move the load somewhere else, where the moving load is lighter

Use supporting equipment to move the load.

Following the reduction in pressure, no further leak is present.

Should, however, there be a further leak on the handhold, immediately deactivate the rescue equipment, and contact an authorised dealer or LUKAS itself.

Tighten hoses.

Reconnect the hoses of the monocooupling (female) in the right way

Re-connect the return hose and secure it.

Trouble Control Cause Solution

Especially by usage of mono-couplings:

Leak on the handhold

with mono-couplingsystem: Leak in the

couplings

with quickdisconnect-couplingsystem: Leak in the

couplings

If it isn’t possible to rectify the malfunctions, inform an authorised LUKAS dealer or the LUKAS customer service department immediately! The address for the LUKAS customer service department is:

check the connections of the hoses

Is the coupling damaged?

Is the leak only on the coupling male?

hose connection to the couplings interchanged

Returnline disabled

coupling damaged Coupling must be

Safety valve reacted

reconnect the hoses to the coupling in the right way

disconnect the returnline from the coupling, clean it and reconnect it.

replaced immediately

replaced immediately After pressure

release there is no more leakage.

LUKAS

Weinstraße 39, D-91058 Erlangen Tel.: (+49) 09131 / 698 - 348

Fax.: (+49) 09131 / 698 - 353

Hydraulik GmbH

12. Technical data

Since all values are subject to tolerances, minor differences may occur between the data on your equipment and the data in the following schedules!

NOTE:

The following tables contain only the technical data required for standard acceptance. Additional data concerning your unit can be obtained from LUKAS on request.

type SP 300

ref. no.

min. spreading force

(25mm / 0.98in. from the tips)

max. spreading force

spreading force HSF

(according to NFPA)

spreading force LSF

(according to NFPA)

max. spreading distance

max. pulling force (on mounting

borehole for chain set) pulling distance (on mounting

borehole for chain set)

pulling force HPF

(according to NFPA)

pulling force LPF

(according to NFPA)

dimensions

l x w x h

weight incl. hydraulic ﬂ uid

max. operating pressure

min. needed volume of hydraulic ﬂ uid

coupling system mono-coupling classiﬁ cation acc. to DIN EN 13204 AS36/605-18

[kN] 36

[lbf.] 8090

[kN] 125

[lbf.] 28100

[kN] 40

[lbf.] 9000

[kN] 33

[lbf.] 7419

[mm] 605

[in.] 23.8

[kN] 31

[lbf.] 7000

[mm]

[in.] 18.7

[kN] 24

[lbf.] 5400

[kN] 20

[lbf.] 4500

[mm] 750 x 355 x 255

[in.] 29.5 x 14.0 x 10.0

[kg] 17,5

[lbs.] 38.6

[Mpa] * 70

[psi.] 10000

[l] ** 0,14

[gal.-US] 0.04

(111051000/171051000)

81-10-15

475

* 1 MPa = 10 bar ** Necessary volume of hydraulic ﬂ uid in the hydraulic unit to operate the unit (differential volume on piston / rod side)

type SP 310 ref. no.

min. spreading force

(25mm / 0.98in. from the tips)

max. spreading force

spreading force HSF

(according to NFPA)

spreading force LSF

(according to NFPA)

max. spreading distance [mm] 720

max. pulling force (on mounting

borehole for chain set) pulling distance (on mounting

borehole for chain set)

pulling force HPF

(according to NFPA)

pulling force LPF

(according to NFPA)

dimensions

l x w x h

weight incl. hydraulic ﬂ uid

max. operating pressure

min. needed volume of hydraulic ﬂ uid

coupling system mono-coupling classiﬁ cation acc. to DIN EN 13204 AS46/720-20

[kN] 46

[lbf.] 10300

[kN] 308

[lbf.] 69200

[kN] 55

[lbf.] 12400

[kN] 44

[lbf.] 9890

[in.] 28.3

[kN] 41

[lbf.] 9200

[mm] 573

[in.] 22.6

[kN] 32

[lbf.] 7200

[kN] 25

[lbf.] 5600

[mm] 783 x 345 x 192

[in.] 30.8 x 13.6 x 7.6

[kg] 19,9

[lbs.] 43.9

[Mpa] * 70

[psi.] 10000

[l] ** 0,24

[gal.-US] 0.07

81-10-25

(1 11010000/171010000)

* 1 MPa = 10 bar ** Necessary volume of hydraulic ﬂ uid in the hydraulic unit to operate the unit (differential volume on piston / rod side)

type SP 510 ref. no. 1 11030000

min. spreading force

(25mm / 0.98in. from the tips)

max. spreading force

(25mm / 0.98in. from the tips)

spreading force HSF

(according to NFPA)

spreading force LSF

(according to NFPA)

max. spreading distance

max. pulling force (on mounting

borehole for chain set) pulling distance (on mounting

borehole for chain set)

pulling force HPF

(according to NFPA)

pulling force LPF

(according to NFPA)

dimensions

l x w x h

weight incl. hydraulic ﬂ uid

max. operating pressure

min. needed volume of hydraulic ﬂ uid

coupling system Steckkupplung Monokupplung classiﬁ cation acc. to DIN EN 13204 BS 62/800-25

[kN] 62

[lbf.] 13900

[kN] 230

[lbf.] 51706

[kN] 79,9

[lbf.] 17962

[kN] 54,6

[lbf.] 12275

[mm] 800

[in.] 31.50

[kN] 55

[lbf.] 12365

[mm] 665

[in.] 26.18

[kN] 44,4

[lbf.] 9982

[kN] 31,1

[lbf.] 6992

[mm] 900 x 380 x 215

[in.] 35.43 x 14.96 x 8.46

[kg] 25

[lbs.] 55.1

[Mpa] * 70

[psi.] 10000

[l] ** 0,43

[gal.US]

81-10-30

(171030000)

0.12

* 1 MPa = 10 bar ** Necessary volume of hydraulic ﬂ uid in the hydraulic unit to operate the unit (differential volume on piston / rod side)

type SP 512 ref. no. 111040000

min. spreading force

(25mm / 0.98in. from the tips)

max. spreading force

(25mm / 0.98in. from the tips)

spreading force HSF

(according to NFPA)

spreading force LSF

(according to NFPA)

max. spreading distance

max. pulling force (on mounting

borehole for chain set) pulling distance (on mounting

borehole for chain set)

pulling force HPF

(according to NFPA)

pulling force LPF

(according to NFPA)

dimensions

l x w x h

weight incl. hydraulic ﬂ uid

max. operating pressure

min. needed volume of hydraulic ﬂ uid

coupling system Steckkupplung Monokupplung classiﬁ cation acc. to DIN EN 13204 CS 84/610-26

[kN] 84

[lbf.] 18900

[kN] 120

[lbf.] 26977

[kN] 108

[lbf.] 24279

[kN] 77

[lbf.] 17310

[mm] 610

[in.] 24.0

[kN] 98

[lbf.] 22031

[mm] 437

[in.] 17.2

[kN] 67

[lbf.] 15062

[kN] 49

[lbf.] 11016

[mm] 784 x 380 x 216

[in.] 31.87 x 14.96 x 8.50

[kg] 26,4

[lbs.] 58.2

[Mpa] * 70

[psi.] 10000

[l] ** 0,34

[gal.US]

0.09

81-10-40

(171040000)

* 1 MPa = 10 bar ** Necessary volume of hydraulic ﬂ uid in the hydraulic unit to operate the unit (differential volume on piston / rod side)

12.1 Peeling

Type SP 310 SP 510 SP 512 max. sheet steel

thickness “t” max. possible

peeling length

[mm] 4 5 5

[in.] 0.16 0.20 0.20

[mm] 520 650 500

[in..] 20.47 25.59 19.69

12.2 Recommended hydraulic ﬂ uid

Hydraulic ﬂ uid for LUKAS hydraulic equipment:

Mineral oil DIN ISO 6743-4 and others

Oil temperature range Oil code Viscosity rating Remarks

recommended viscosity range: 10...200 mm²/s (10…200 cSt.) Supplied with HM 10 DIN ISO 6743-4.

-20 .... +55°C

-4.0 .... +131°F

CAUTION!

Before using hydraulic ﬂ uids, which do not correspond to the above-mentioned speciﬁ cations and/or are not purchased from LUKAS, you have to contact LUKAS itself!

HM 10 VG 10

12.3 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

12.4 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.

13. EC Declaration of conformity

14. Notes

Please dispose all packaging materials and dismantled parts properly

LUKAS

A Unit of IDEX Corporation

Weinstraße 39, D-91058 Erlangen Tel.: (+49) 0 91 31 / 698 - 0 Fax.: (+49) 0 91 31 / 698 - 394 e-mail: lukas.info@idexcorp.com www.lukas.com

Hydraulik GmbH

subject to revision

Lukas SP 512 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual