Operating instructions for rescue equipment
Contents
1. 26 9 3 2 Changing the blades protective cover and handle on the S311E cutter and on the SC350E and SC250E combi tools NOTE The illustrations show the equipment with the blade arms of the cutter Assembly and disassembly are identical for the combi tool Components to be Required work replaced steps Protective cover 1 9 and 10 Pivot bolt 1 5 and 10 Handle 1 3 and 10 Blade 1 7 and 10 Work steps 1 First of all carefully clean the rescue equipment 2 Next close the blade arms so that the tips are almost touching NOTE The blade bolts are only accessible when the blade arms are almost touching Further procedure 3 Remove screws A from handle B x The handle can then be removed 4 Push the hand guard E in the depicted direction until the safety bolts F are easily accessible Zr 5 Remove self locking nut D and push the pivot bolt G out 6 Remove the retaining rings H and push out bolt J 7 Now you can remove blade K and sliding plates L 8 Fold inthe lever elements M 9 Finally pull the hand guard E off the device as shown 28 10 The work steps must be carried out in reverse order to fit the new parts ATTENTION Don t forget to apply LUKAS special grease to all sliding surfaces ATTENTION The nut of the pivot bolt and the pivot bolt itself are matched by a special procedure Therefore they must only be changed as a set by us2. LUKAS Because you never get a second chance Ce eDRAULIC equipment Cutter combi spreader and rescue ram SP 300 E 172080085 GB SC 350 E Edition 03 2013 SC 250 E replaces 01 2012 Translation of the original operating instructions i oS 4 1 4 2 4 3 4 4 Contents Danger classes Product safety Intended Use Functional description Description Structure of the rescue equipment Hydraulic circuit diagram Controlling the operating movements 5 Operation 31 9 2 Battery or power supply for eDRAULIC device Operating the star grip 6 Cutting spreading pulling squeezing and squashing 6 1 6 2 6 3 6 4 6 5 6 6 Safety instructions Cutting cutter and combi tool Spreading spreader and combi tool Pulling spreader combi tools Squeezing spreader combi tools Squashing rescue ram 7 Dismantling the equipment deactivation following operation 8 Maintenance and service 8 1 8 2 Overview of eDRAULIC devices Safety equipment 9 Repairs 9 7 9 2 9 3 General information Preventive maintenance Repairs 10 Troubleshooting Page 10 10 11 13 14 14 14 15 15 15 16 17 18 19 20 21 21 22 23 23 23 24 24 36 11 Technical data 11 1 11 2 11 3 11 4 17 5 17 6 11 7 11 8 eDRAULIC cutter eDRAULIC combi tool eDRAULIC spreader eDRAULIC rescue ram Noise emissions based on the EN ISO 3744 standard Operating and storage temperature ranges
3. Oscillation vibration Tightening torques for pivot bolts cutters and combi tools only 12 EC Declarations of conformity 13 Accessories 13 1 13 2 13 3 13 4 13 5 Batteries Battery charger Power supply Extension for rescue ram Chain sets 14 Instructions regarding disposal 15 Notes 38 38 39 40 41 41 42 42 42 43 45 45 45 46 46 47 47 48 1 Danger classes We distinguish between various categories of safety instructions The table below provides an overview of the symbols pictograms and signal words assigned to the specific danger and also the possible consequences u a Damage injury to Potentially dangerous situation WARNING Danger of ATTENTION damage to objects environment Advice for application and NOTE other important useful information and advice Wear a helmet with a face guard Wear protective gloves Wear safety shoes Proper recycling Observe principles of environmental protection Read and observe operating instructions 4 DANGER Immediate danger Less dangerous is situation Consequences 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 2 Product safety LUKAS products are developed and manufactured to guarantee the best performance an
4. the power supply can be replaced 4 Insert the recharged or new battery into the eDRAULIC device until it reaches the stop The battery or power supply will be automatically locked when correctly operated 14 5 2 Operating the star grip also see chapter on Controlling the operating movements Open the device or extend the piston gt mt 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 lt a 4 Turn the star grip in the direction of the corresponding symbol close retract and hold it in this position Dead man s function Once released the star grip automatically returns to the central position while fully guaranteeing the load will remain supported 6 Cutting spreading pulling squeezing and squashing 6 1 Safety instructions Before rescue work can commence the position of the accident object must be stabilised You must ensure that it is adequately underpinned and or supported World wide safety guidelines pertaining to the specific country must be observed and complied with In the Federal Republic of Germany regular safety inspections according to the legal accident insurance regulations GUV Gesetzliche Unfallversicherung are mandatory LUKAS eDRAULIC devices are not explosion proof When deploying the devices in potentially explosive areas it must be ensured that it Cannot c
5. LUKAS offers appropriate training courses for this 21 8 1 Overview of eDRAULIC devices Inspections to be carried out Visual inspection Cutter and combi tool e Opening width of the blade arms on the tips see chapter Technical data e General tightness leaks e Ease of movement of star handle e Existence and stability of handle e Labels completely existent and legibly e Covers in perfect condition e Check the tightening torque of the pivot bolt tightening torque M see Technical data e Blade arms free of cracks and cutting surfaces without nicks or deformations e Cutting surfaces go on top of each other without making contact e The sliding plates bolts and retaining rings of the blade arms are in place and in good condition e Illumination of main switch work area and connection slot fully functional Spreader e Opening width of arms at the tips see chapter on Technical Data e General tightness leaks e Ease of movement of star handle e Existence and stability of handle e Labels completely existent and legibly e Covers in perfect condition e Spreader arms not cracked e Bolts and retaining rings of spreader arms in place and in good condition e The corrugations on the tips should be clean and square without cracks e The tips must be in place and locked e Illumination of main switch work area and connection slot fully functional Rescue ram e Piston can be extended to its full
6. 35 10 Troubleshooting Cause Solution Blades spreader Battery fully Battery flat Charge battery arms or cylinder charged Battery defective Replace battery a Air in the hydraulic Repair by authorised operated system dealer staff specially trained by LUKAS or directly by LUKAS Power supply cable Power supply Reinsert power connected not properly supply into the connected to the connection slot eDRAULIC device not automatically locked Power supply Reconnect external cable not properly power supply connected to the external power supply Power supply or Replace power power supply cable supply or power defective supply cable source defective power source Blades spreader Battery fully ae ee pistons do not move Power supply cable Power supply cable Replace power oe Device defective Repair by authorised dealer staff specially trained by LUKAS or directly by LUKAS Device doesn t oe Device defective Repair by authorised perform at its given dealer staff specially power trained by LUKAS or directly by LUKAS 36 Trouble Control Case Solution Following release Casing damaged or Damage to the Repair by authorised the star grip doesn t star grip operation torsion spring for dealer staff specially return to the central does not work reset trained by LUKAS or position smoothly Soiled valve or star directly by LUKAS grip Defective valve Other mechanical damage e g
7. a gap not suitable for spreading 6 4 Pulling spreader combi tools A WARNING CAUTION ATTENTION O The light metal alloy arms must not be damaged LUKAS chain sets must be used for pulling When using the traction chain the pins and hooks must be in the correct position to ensure that the chain cannot slip Only chain sets in perfect condition may be used The traction chains must be checked by an expert at least once a year Also consult the separate operating instructions for the corresponding chain set Attachment hole for chain sets 18 The connection pieces for the LUKAS chain sets are attached to the boreholes Aon the blades using load bolts see figure on the right Chain sets for SC250E KSV 8 50 for SC350E KSV 8 50 for SP300E KSV 11 NOTE Take note also of all the instructions and regulations in the separately supplied operating instructions for the chain sets 6 5 Squeezing spreader combi tools A WARNING CAUTION ATTENTION MD The light metal alloy arms must not be damaged Squeezing may only take place near the tips see figure below Squeezing area Squeezing area 19 6 6 Squashing rescue ram Before you can carry out any work with the rescue ram you must ensure adequate support This also includes any necessary substructure As part of their design the rescue rams are fitted with claws at the cylinder and piston ends to ensure it is
8. as safe as possible to use Where this support is not adequate e g when pushing away the front part of the vehicle or when pushing a vehicle upwards additional supports and ram attachments may be required and it may need to be secured using straps for example You will find suitable support bearings and cylinder attachments in the LUKAS accessories list WARNING CAUTION ATTENTION Never use a rescue ram without a claw or the required accessories The cylinder could slip during the operation resulting in injury to the user In addition the piston rod or the claw support could be damaged WARNING CAUTION ATTENTION When applying the rescue ram without the LUKAS support care must be taken to ensure that all four tips of both claws i e on the piston and the cylinder side are in good contact with the object When applying the rescue ram to a LUKAS support care must be taken to ensure that the surface between the four tips of the claw is in contact with the round bearing rods This prevents force from acting on only one end of the cylinder Objects lifted up must be subsequently secured with firm supports or substructures An extension is also available for the eDRAULIC rescue ram B A Procedure for installing the extension 1 First pull the claw A off the cylinder base Check whether the O ring B is still attached to the cylinder base and is in good condition Where necessary replace the O ring 2 Check the
9. good fit of the O ring B grease the contact surfaces using LUKAS special grease and insert the extension C onto the cylinder base until it reaches the stop B C 3 When the extension is no longer required after the operation remove it by following the instructions in the reverse order and store it in a suitable place 20 7 Dismantling the equipment deactivation following operation Once work has been completed the arms should be closed until the tips are only a few millimetres apart or the cylinder piston should be almost fully retracted This relieves the hydraulic and mechanical strain on the device as a whole NOTE Never store the eDRAULIC devices with fully closed arms or a fully retracted piston By fully closing the arms or retracting the cylinder piston hydraulic and mechanical tension may develop in the device Clean the rescue device after each operation and grease both the metallic and the mechanically movable parts The locking mechanism for the spreader plug in tips should also be oiled now and again Greasing provides protection against excessive wear and tear or corrosion Avoid storing the rescue equipment in a damp environment 8 Maintenance and service The devices are subject to very high mechanical stresses A visual inspection must therefore be carried out after every use and at least one visual inspection must be carried out every six months These inspections enable the early detection
10. of the delivery scope You will find suitable batteries and power supplies in the LUKAS accessories list eDRAULIC devices are equipped with lighting as standard so that work can be carried out in conditions where visibility is poor The light emitting diodes attached on the operating side light up the work area The main switch has also been provided with a light so that you can see at a glance whether the de vice is switched on When exchanging the battery or power supply the connection slot will be lit up for approximately 30 seconds 10 4 2 Structure of the rescue equipment 4 2 1 Cutter 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 casing 10 Device body 11 Protective cover 12 Illumination 4 2 2 Combi tool 1 4 2 3 Spreader 1 NO 4 2 3 O1 7 10 11 12 Star grip Main switch Quick exchange battery or power supply Release button for Battery and power supply Handle Ventilation slots Blade arms Pivot bolt with secured nut Plastic casing Device body Protective cover Illumination 3 Star grip Main switch Quick exchange battery Or power supply Release button for Battery and power supply Handle Ventilation slots Spreader arms with plug on tips Plastic casing Device body Protective cover Illumination 4 2 4 Rescu
11. of the devices and locked The other side has a mains plug Both are connected by a cable The mains plug is a Schuko plug with Protection Classification IP68 The integrated filter is appropriate for the conversion of AC voltage to DC voltage NOTE Pay strict attention to the separate operating instructions for the power supply 13 4 Extension for rescue ram A special extension is available for the eDRAULIC rescue ram which may be used to enlarge the effectively possible opening width of an object The installation instructions for the extension may be taken from the chapter on Squeezing rescue ram Type 174081000 Dimensions including claw mm 360 x 55 x 55 Ixwxh in 14 17x 2 17 X 2 17 Maximum extension mm possible fin 11 81 00 K 4 2 Weight ko Ibs 9 3 46 13 5 Chain sets Chain sets are required in order to be able to perform pulling operations with the eDRAULIC spreader and the eDRAULIC combi tool see chapter Pulling Suitable chain sets for SC250E KSV 8 50 for SC350E KSV 8 50 for SP300E KSV 11 NOTE The safety information assembly use and technical data for the chain sets can be found in the separately supplied operating instructions for the particular chain set 14 Instructions regarding disposal Please properly dispose of all packing materials and removed parts Electrical equipment accessories and packaging should always be disposed of in an environmentally com
12. the situation Any trapped or enclosed persons must be protected 6 2 Cutting cutter and combi tool The blades should be positioned at a 90 angle to the object to be cut if possible 15 15 7 Ya ZZ RZ WRONG F 16 Higher cutting capacities can be achieved by cutting as close as possible to the blade s pivot point WRONG RIGHT During cutting the gap between the blade tips in the transverse direction must not be exceeded otherwise the blade is in danger of breaking mm in Po SIE won D ATTENTION Avoid cutting through the hardest parts of the vehicle body e g lateral collision protection as this may result in damage to the cutters or to more wear and tear 6 3 Spreading spreader and combi tool Use the front area of the tips for increasing the gap only To increase grip and to avoid having the tips slip or break out of the part to be processed the grip should be reapplied at an early stage In any case the highest force is developed in the rear area of the plug on tip or in the rear spreading area of the combi blades A WARNING CAUTION ATTENTION MD The light metal alloy spreader arms must not be damaged Enlarging a gap Spreading e E approx 25 mm approx 1 in gt 17 IN ANN Working surface is too small Tips get a safe grip Work with the tips only tips slip off Do not damage the Only for increasing the size spreader arms of
13. Paz full load operation measuring distance 5m Ran en 41 11 5 2 R411E dB A j BA measuring distance 1m Operating temperature C F 20 85 4 rar Battery type used for device Lithium ion No load operation No load operation measuring distance 5m dB A 72 20 55 4 Ambient temperature a i i device in operation C F 25 45 13 113 30 60 22 wnt measuring distance 1m full load operation measuring distance 5m dB A rn Storage temperature z full load operation 11 6 Operating and storage temperature ranges 11 7 Oscillation vibration The total oscillation value vibration value to which the upper limbs are exposed is usually below 2 5 m s Higher values may be measured for short periods as a result of interaction with the materials to be processed The oscillations vibrations were determined in accordance with DIN EN ISO 20643 11 8 Tightening torques for pivot bolts cutters and combi tools only i mm 36 46 36 36 wrench size in 142 1 81 1 42 1 42 i Nm 120 10 140 10 110 10 120 10 orque q lbf in 1 062 89 1 239 89 890 89 1 062 89 42 12 EC Declarations of conformity Im Sine der EG Maschinemicnine 206 421 Anhang I In accordance with the EC Machinery Directive 200642 EC Appendix N A Herma erkl ren wir dass die nachfolgend bezeichneten eORAULIC G EA ERTEREEN Ber cksich
14. Servicing During assembly make especially sure that all components are clean since dirt can damage the rescue tool WARNING CAUTION ATTENTION Protective clothes must be worn when repairs are being carried out since the devices may also be pressurised when not in operation NOTE Always register your tool on the LUKAS Hydraulik GmbH internet site Only then are you entitled to the extended guarantee ATTENTION Because LUKAS rescue tools are designed to deliver outstanding performance components must only be replaced with those that are listed in the spare parts lists for the corresponding device Other components in the device may only be replaced if you have participated in an appropriate LUKAS service training course you have the express permission of LUKAS Customer Service valid LUKAS certificate necessary 23 ATTENTION When cleaning the equipment take care not to use any cleaning agent with a pH value outside the range 5 8 9 2 Preventive maintenance 9 2 1 Care instructions From time to time the outside of the device should be cleaned with a damp cloth not the electrical contacts in the connection slot the battery or on the power supply and oil should be applied to the metallic surfaces not the electrical contacts in the connection slot on the battery or on the power supply to prevent corrosion In case of doubt contact your authorised LUKAS dealer or LUKAS directly 9 2 2 Fun
15. This movement can then be used to spread open squeeze or pull open objects The rescue rams are double acting hydraulic cylinders Extension and retraction takes place hydraulically On all devices the movement is activated by means of a valve in the form of a star grip All devices guarantee the dead man s switch and the full load supporting function when the Star grip is released LUKAS eDRAULIC devices do not need to be connected to an external hydraulic source e g a motor pump The hydraulic pressure required is generated within the body of the device Either a battery or an external power supply must be connected as an energy source You can choose which energy source you wish to use Both the battery and the power unit can be plugged into the opening provided in the body of the tool Both will lock in place au tomatically When using batteries as an energy source you have almost unlimited freedom of movement when working i e there are no cables or hoses to hinder you You can extend the operating time of your eDRAULIC device by using several batteries The batteries can be recharged after use using a suitable external charger If you use an external power supply the operating time is essentially unlimited this is only restricted by the external power source and the thermal switch in the power unit To allow you to select the best possible energy supply for your eDRAULIC device neither the battery nor the power supply form part
16. able 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 extreme external temperatures or that the equipment is damaged in any way Please note that the equipment can also heat up over a long period of use Before transporting the equipment always ensure that the accessories are positioned such that they cannot cause an accident Ensure the proper disposal of all removed parts left over oil and hydraulic fluid 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 ATTENTION The device is intended exclusively for the purpose stated in the operating instructions see chapter Intended Use Any other use is not in accordance with its designated use The manufacturer supplier cannot be held liable for any damage resulting from such use The risk of such misuse lies entirely with the user Intended Use includes observance of the operating instructions and compliance with the inspection and maintenance conditions Never work when you are overtired or intoxicated 3 Intended Use LUKAS eDRAULIC devices have been specially designed to rescue or retrieve the bodies of victims of road rai
17. ause an explosion working with the device will not cause an explosion for example formation of sparks when cutting an object N WARNING CAUTION ATTENTION The responsibility for explosion prevention or for ruling out work with an eDRAULIC device rests with the operator of the device or with the person responsible at the place of use When working in areas at risk of explosion all applicable legal national and international regulations standards and safety rules for preventing explosions must be observed without exception 15 Wear the following when working with the rescue tool protective clothing safety helmet with visor or protective goggles protective gloves and if necessary ear protection Before operating the rescue tool you should ensure that its movements or flying fragments will not put participants or bystanders at risk Further avoid unnecessary damage to property belonging to others objects not involved by the rescue equipment flying fragments It is strictly prohibited to reach into the path of the rescue A device e g between the blades or spreader arms or IN between the rescue ram and the material to be processed WARNING CAUTION The particular effect of the force of the rescue equipment during operation could cause pieces of the vehicle to break off or fly off posing a danger to persons Those not involved in the rescue operation should therefore keep at a distance appropriate to
18. bgt wurden instrese DIN EN 150 12100 2010 Ausgabe 2011 03 Sicherheit von Maschinen Allgemeine Gestaltungstedsal Risikoheurteih ing ung Resienminnen ung Ta a Sy REND Be BE Bey Dae SEE pape an OAD and the national statutory that implement them The following standards nave particularly been taken into consideration DIN EN ISO 12100 2010 publication date 2011 03 Safety of machinery General principles for design Risk assessment and risk reduction Seite Page 1 vonfof 1 43 44 13 Accessories 13 1 Batteries Only LUKAS lithium ion rechargeable batteries may be used to operate eDRAULIC tools These guarantee optimum performance and maximise the operating time of eDRAULIC tools Charging state indicator Query button 13 2 Battery charger Only the eDRAULIC Power Pack Charger may be used for the lithium ion batteries NOTE Pay strict attention to the separate operating instructions for the battery charger 45 13 3 Power supply The eDRAULIC devices have a unique power supply with integrated electronics allowing the devices to be operated for an almost unlimited time by connecting them to an external power source The power supply converts the voltage of the external power source in such a way that it may be used instead of a battery Cable Adapter Schuko plug Structure There is an adapter on one side of the power supply which can be simply inserted into the connection slot
19. ctional and stress test If there is any doubt regarding the safety or reliability of the equipment a function and stress test must also be performed LUKAS offers appropriate testing equipment for this 9 3 Repairs 9 3 1 Blades protective cover and handle replacement for the S700E cutter Components to be Required work replaced steps Protective cover 1 2 and 7 Pivot bolt 1 4 and 7 Handle 1 5 and 7 Blade 1 6 and 7 24 Work steps 1 First of all carefully clean the rescue equipment 2 Remove the fixing screws A and remove the protective cover B and the cover caps C 3 Move the blade arms on the unit until the pin E and the retaining rings F can be accessed through the hole D Now switch off the device and remove the battery or unplug the power supply from the device 29 4 First remove the grub screw G then the central bolt nut H and then pull out the central pin J 5 Release the fixing screws K and remove them The handle L can now be pulled out forwards over the blades 6 Remove the retaining rings M and push the pin N out You can then pull out the blades O and the slide plates P 7 The work steps must be carried out in reverse order to fit the new parts O ATTENTION Don t forget to apply LUKAS special grease to all sliding surfaces NOTE The torque required can be taken from the spare parts list of your particular unit
20. d quality when used properly Operator safety is the most important aspect of the product design Moreover the operating instructions are intended to aid the safe use of LUKAS products The generally applicable legal and other binding regulations pertaining to the prevention of accidents and protection of the environment apply and are to be complied with in addition to the operating instructions The device may only be operated by persons with appropriate training in the safety aspects of such equipment otherwise there is a danger of injury occurring We would like to point out to all users that they should read the operating instructions carefully before using the equipment and fully comply with the instructions therein We further recommend you have a qualified trainer show you how to use the product WARNING CAUTION The operating instructions for accessories must also be taken into account Even if you have already received instruction you should read the following safety instructions again WARNING CAUTION Please ensure that the accessories you use are appropriate for the maximum operating pressure and the performance of the rescue device Please ensure that no body Working under suspended parts or clothing are caught loads is not permitted if between the visible moving these are supported only parts e g blade arms using hydraulic or electro hydraulic devices If this work is unavoidable suitable mechanical suppo
21. e ram 10 Star grip 2 Main switch 3 Quick exchange battery or power supply 4 Release button for Battery and power supply 5 Ventilation slots 6 Cylinder piston 7 Plastic casing 8 Device body 9 Top claw 0 Bottom claw 1 Illumination 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 4 3 Hydraulic circuit diagram To enable comprehension of the function a simplified hydraulic cylinder of the rescue equipment A hand valve B are depicted here cut close pulling squeezing or extend piston spreading opening or retract piston 13 4 4 Controlling the operating movements The piston movement is controlled by the star grip on the attached valve see illustration below Star grip 5 Operation 5 1 Battery or power supply for eDRAULIC device 5 1 1 Initial start up Before initial operation the battery where used of the rescue device must be fully loaded using the external charger Procedure 1 Unplug the power supply where used from the mains 2 Fully press down the two unlocking buttons and carefully pull the battery or power supply out of the device Do not use force Connection slot 3 The battery can now be recharged in the charger please take note of the separate operating instructions for the charger and the batteries to be used alternatively
22. ing a new set Owing to the special method used any loosening of the nut while working will be minimised thus preventing the blade from breaking The nuts can be unscrewed and tightened up to 10 times without affecting the service life 9 3 3 Sharpening the blades Only remove and smoothen any burrs Chips or deep grooves cannot be ground away The blades must be replaced in these cases ATTENTION Only grind in the grinding area see illustration The sliding faces in particular must not be reground Grinding area Direction of movement Blade arm Pivot point Lan Blade m f Slide surtace A plane Q Tools required 1 Use jaw protection on clamping device e g vice in order not to damage the blades 2 Grinder e g angle grinder or belt grinder with abrasive having a grain size of 80 29 Procedure 1 Clamp the blade securely into the clamping device so that it cannot move but with the grinding area exposed 2 Carefully grind the burr away evenly until you reach the sliding surface level see illustration Slide surface plane In addition when grinding you must make sure that the inclination of the cutting surface in the direction of the blade arm movement is not changed Check the incline and smoothness of the ground surface using a suitable measuring tool ATTENTION If you have not maintained the smoothness or incline the proper operation of the blade is no longer guaranteed and the b
23. l or aircraft accidents or to be used during rescue operations from buildings LUKAS eDRAULIC cutters and combi tools are used to free injured persons at accident scenes by cutting through doors roof beams and hinges LUKAS eDRAULIC spreaders and combi tools can also be used to free trapped persons by forcing open doors or to move obstacles aside with the aid of a chain set LUKAS eDRAULIC rescue rams are used to free persons who have become trapped during a car accident when the spreader does not open wide enough for example by spreading or lifting parts of vehicles During other catastrophic events rescue rams and spreaders can also be used to move objects to rescue persons who have been buried or trapped Care must be taken that the object to be worked on has been secured using stable supports or by underpinning it LUKAS eDRAULIC devices are NOT suitable for underwater use WARNING CAUTION Care must be taken that the object to be worked on has been secured using stable supports or by underpinning it WARNING CAUTION ATTENTION The following may not be cut squeezed live cables hardened parts such as springs spring steels steering columns and rollers tubes hoses under gas or liquid pressure compound materials steel concrete explosive bodies such as airbag cartridges The operating pressure set on the rescue device may only be directly changed after consultation with LUKAS A change in settings may result in damage to proper
24. lades must be replaced 9 3 4 Spreader arm spreader tips protective cover and handle exchange for the spreader Components to be Required work replaced steps Handle 1 2 and 8 Plug on tips 1 5 and 8 Protective cover 1 4 and 8 Lever links 1 4 6 and 8 Spreader arms 1 6 and 8 30 Work steps 1 First of all carefully clean the rescue equipment Now switch off the device and remove the battery or unplug the power supply from the device 2 Remove the fixing screws A and remove the handle B 3 Remove the screws C and D 31 5 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 In order to remove the plug on tips G you must simultaneously press the buttons J on each side of a spreader arm H fully together and then pull the plug on tip forwards off the spreader arm 32 6 You need to remove the retaining rings K and the lever links L to replace the Spreader arms H 7 Also remove the retaining rings M and remove the pins N You can then remove the Spreader arms H 8 The work steps must be carried out in reverse order to fit the new parts ATTENTION Don t forget to apply LUKAS special grease to all sliding surfaces NOTE The torque required can be taken from the spare parts list of your particular unit 9 3 5 Rescue ram Work s
25. length see chapter on Technical Data e Cylinder and piston rod undamaged and not deformed e Claws correctly and securely fitted e Claws can be turned and are undamaged no break outs e General tightness leaks e Ease of movement of star handle e Labels completely existent and legibly e Illumination of main switch work area and connection slot fully functional 22 Battery and power supply e Casing undamaged e Electrical contact surfaces clean and undamaged e Cable undamaged e Battery ies fully charged when used e Charging state display of lithium ion battery ies fully functional Functional check e Easy opening and closing or extension retraction of star grip controls e no suspicious noises e no further movement of cutter and spreader arms or cylinder piston when interrupting the valve function during the process dead man s switch 8 2 Safety equipment e Check of the protective equipment on around the rescue equipment especially the hand guard for the moveable parts this must be free of cracks 9 Repairs 9 1 General information Servicing may only be carried out by the manufacturer or personnel trained by the manufacturer and by authorised LUKAS dealers Only LUKAS spare parts may be used to replace all components see spare parts list since special tools and compliance with assembly instructions safety aspects and inspections must be taken into account see also chapter Maintenance and
26. of 25mm 0 98in on the tips lbf 9900 125 Max possible spreading force her 28100 LSF spreading force KN according to NFPA Ibf 7400 HSF spreading force KN according to NFPA Ibf 9000 m Maximum spreading distance m r Maximum pulling force 000 on attachment hole for chain set fbf Pulling distance mm on attachment hole for chain set fin HPF pulling force kN according to NFPA lbf LPF pulling force KN according to NFPA Ibf kg Weight excl battery Ibs Nominal electrical voltage with power supply Nominal electrical voltage with lithium ion battery Protection category 40 11 4 eDRAULIC rescue ram 90 40 10 174080000 Length mm 545 retracted in 21 46 Length mm 905 extended in 35 63 Dimensions mm 150 x 265 wxh in 5 91 x 10 43 _ mm 60 Maximum piston extension in 14 17 KN 103 Compressive force lbf 23 156 kg 16 9 Weight excl battery Ibs 373 Nominal electrical voltage V 4 with power supply Nominal electrical voltage iV with lithium ion battery Protection category IP44 11 5 Noise emissions based on the EN ISO 3744 standard 11 5 1 S700E S311E SP300E SC250E and SC350E Battery type used for device Lithium ion No load operation dB A 5 7 measuring distance 1m full load operation dB A gt measuring distance 1m No load operation measuring distance 5m
27. of wear and tear which means that punctual replacement of this wearing parts prevents breakages from occurring Regularly check the torque of the pivot bolt on the cutters and combi tools You will find the tightening torques for the pivot bolt in the chapter Technical data An annual inspection of the tool is due once per year This inspection must be performed by a person with the necessary expertise This means that the person must possess adequate specialist knowledge and experience in the fields of electrical engineering and hydraulics so that they can objectively assess the condition of the tool Every three years a crack test of the blades is also essential A special crack testing kit is available for this A functional test must also be performed every three years or if there is any doubt regarding the safety or reliability of the equipment please also observe the applicable national and international regulations pertaining to service intervals of rescue tools In the Federal Republic of Germany regular safety inspections according to the legal accident insurance regulations GUV Gesetzliche Unfallversicherung are mandatory O ATTENTION Clean off any dirt before checking the device WARNING CAUTION ATTENTION In order to carry out maintenance and repair work tools appropriate for the job and personal protection equipment must be used The maintenance and repair staff must have adequate technical and specialised knowledge
28. patible way Only for EU countries Do not dispose of electrical equipment with your household waste According to the European Directive 2002 96 EC governing electrical and electronic waste and their application in national legislation old electrical equipment must be separately collected and recycled in an environmentally compatible manner Please also take into account the notes in the separate operating instructions for the batteries 47 15 Notes 48 49 50 51 LUKAS Hydraulik GmbH A unit of the IDEX Corporation WeinstraBe 39 Erlangen 91058 Germany Tel 49 0 91 31 698 0 Fax 49 0 91 31 698 394 e mail lukas info idexcorp com www lukas com MADE IN GERMANY eDraulic_Gerate BA GB 172080085 0313 indd Copyright 2013 LUKAS Hydraulik GmbH Subject to revision
29. rts are also required Wear protective clothing Inspect the device before and a safety helmet with visor after use for visible defects or protective footwear and damage gloves The department responsible All screwed connections must must be informed immediately be checked for leaks and of any apparent changes visible damage which must including the operating be repaired immediately behaviour If necessary Squirting hydraulic fluid can the equipment is to be result in injuries and fires deactivated immediately and secured In the event of malfunctions shut down the device immediately and make it safe Repair the fault immediately Observe all safety and danger information on the device and in the operating instructions Any mode of operation which compromises the safety and or stability of the device is forbidden Safety equipment must never be disabled Make sure before switching on starting up the device and during its operation that this will put no one in danger When working in the vicinity of live components and cables appropriate measures must be taken to avoid a transfer of current or high voltage arcing to the device Please ensure that you do not become entangled in cables and trip when working with or transporting the device The build up of static charge and therefore possible sparking must be avoided when handling the device Do not carry out any changes additions or con
30. star grip Hydraulic fluid leaks Repair by authorised on the piston rod Damage to the dealer staff specially piston trained by LUKAS or directly by LUKAS The useful operating Battery defective Replace battery time between the individual charging cycles is less than 5 minutes despite charging the batteries according to the instructions If you cannot rectify the malfunctions inform an authorised LUKAS dealer or the LUKAS customer service department immediately The address of the LUKAS Customer Service Department is LUKAS Hydraulik GmbH WeinstraBe 39 91058 Erlangen Germany Tel 49 09131 698 348 Fax 49 09131 698 353 3 11 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 tables The values may also differ because of reading inaccuracies and or tolerances in the measuring equipment used NOTE The following tables contain only the technical data necessary for operation and storage Further information about your device is available directly from LUKAS 11 1 eDRAULIC cutter We SHE S 700 Ref no 90 20 20 172090000 90 20 70 172080000 Dimensions without battery Mm 860 x 225 x 290 925 x 300 x 290 Ixwxh in 33 86 x 8 86 x 11 42 36 42 x 11 81 x 11 42 i i mm 150 185 Max cutting opening fin 5 91 19 4 24 5 Weight excl battery 42 8 54 0 Nominal elec
31. teps for exchanging the cylinder piston claw 1 First of all carefully clean the rescue equipment Now switch off the device and remove the battery or unplug the power supply from the device A B 2 Pull the claw A off the cylinder piston and remove the O ring B Where the O ring is damaged it must be replaced 3 Insert the O ring B into the groove of the new claw A provided and check it for a firm fit Grease the contact surfaces with LUKAS special grease and thenslide the new claw onto the cylinder piston up to the limit stop Work steps for exchanging the cylinder base claw 1 First of all carefully clean the rescue equipment Now switch off the device and remove the battery or unplug the power supply from the device 2 Pull the claw C off the cylinder base and check whether the O ring D in the cylinder base has been damaged if yes replace it 3 Check the firm fit of the O ring D grease the contact surfaces with LUKAS special grease and then slide the new claw C onto the cylinder base up to the stop 34 9 3 6 Labels All damaged and or illegible labels safety instructions type plate etc must be renewed Procedure 1 Remove damaged and or illegible labels 2 Clean surfaces with industrial alcohol 3 Affix new labels Take care to affix the labels in the correct positions If you are no longer sure about this then please contact your authorised LUKAS dealer or LUKAS itself
32. trical voltage with power supply Nominal electrical voltage Protection category IP44 Classification NFPA 1936 A7 B8 C6 D7 E7 A8 B9 C8 D9 E9 38 11 2 eDRAULIC combi tool SC 250 SC 350 E 90 30 10 173000000 90 30 20 173010000 a 15000 Ixwxh fin 34 3 x 8 5 x 11 6 37 8 x 8 9 x 11 4 mm Max cutting opening in 9 2 10 43 Max cutting force KN 280 360 rearmost cutting point Ibf 62 944 80 928 Maximum spreading force KN 33 40 at a distance of 25mm 0 98in rom the tips lbf 7 418 8 991 LSF spreading force KN 23 24 according to NFPA lbf 5 170 5 396 HSF spreading force KN according to NFPA 6 519 8 318 184 Max possible spreading force m 41363 78 687 Maximum spreading distance ig 12 6 14 17 Maximum pulling force KN on attachment hole for chain set bf 7 643 9 218 Pulling distance mm on attachment hole for chain set jjn 13 0 14 6 HPF pulling force KN according to NFPA Ibf 8 318 11 014 LPF pulling force KN 2 7 30 according to NFPA ibf 6 070 6 744 kg 16 9 19 8 eight excl battery Ibs 37 3 43 7 Nominal electrical voltage iV D4 04 with power supply Nominal electrical voltage Protection category IP44 IP44 Classification NFPA 1936 A6 B6 C6 D7 E7 A6 B7 C7 D7 E7 39 11 3 eDRAULIC spreader Type SPE Refano 90 40 15 171050000 Dimensions excl battery mm 895 x 355 x 290 Ixwxh fin 35 2 x 14 0 x 11 4 Maximum spreading force kN at a distance
33. ty and or injuries LUKAS eDRAULIC devices are not explosion proof When deploying the devices in potentially explosive areas it must be ensured that it cannot cause an explosion working with the device will not cause an explosion for example formation of sparks when cutting an object The responsibility for explosion prevention or for ruling out work with an eDRAULIC device rests with the operator of the device or with the person responsible at the place of use When working in areas at risk of explosion all applicable legal national and international regulations standards and safety rules for preventing explosions must be observed without exception The rescue equipment should not come into contact with acids or alkalis If this is unavoidable clean the equipment immediately afterwards with a suitable cleaning agent You can order spare parts and accessories for the rescue tools from your authorised LUKAS dealer Applications 4 Functional description 4 1 Description The cutters and combi tools have been designed in such a way that a hydraulically operated piston activates mechanical joints symmetrically to open or close a set of two opposite blade arms thus enabling objects to be cut The spreaders operate according to a similar principle They too have been designed in such a way that a hydraulically operated piston activates mechanical joints symmetrically to open or close a set of two opposite spreader arms
34. versions to the equipment without obtaining the approval of LUKAS beforehand All safety and danger information on the device must always be complete and in a legible condition Repairs to the device may only be carried out by trained service technicians with specific knowledge of the device Use only original LUKAS accessories and spare parts when carrying out 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 and squashing operations as a result of shearing tearing or breaking appropriate countermeasures must Please ensure that the battery contacts are not short circuited Only touch any broken off parts or the cut off parts wearing protective gloves since the torn cut edges can be very sharp Protect the eDRAULIC devices against humidity and moisture The equipment is filled with hydraulic fluid These hydraulic fluids 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 eDRAULIC devices are not suit
Download Pdf Manuals
Related Search