Lukas SP 512 User Manual

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.

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