Instruction manual for rescue equipment eDRAULIC rescue equipment (cutter, combi tool, spreader and rescue ram) SP 300 E2 SP 310 E2 S 700 E2 S 311 E2 R 411 E SC 357 E2 SC 250 E2 172085085 EN Edition 03.
Content Page 1. Danger classifications 4 2. Product safety 5 3. Proper use 8 4. Functional description 10 4.1 Description 10 4.2 Structure of rescue devices 11 4.3 Hydraulic circuit diagram 13 4.4 Operating movement controls 14 5. Operation 14 5.1 Battery or power supply for eDRAULIC device 5.2 Operating the star grip 14 15 6. Cutting, spreading, pulling, squeezing 15 6.1 Safety notes 15 6.2 Cutting (cutter and combination device) 16 6.
Content Page 11. Technical data 37 11.1 eDRAULIC cutter 37 11.2 eDRAULIC combination device 38 11.3 eDRAULIC spreader 39 11.4 eDRAULIC rescue ram 40 11.5 Noise emission (based on standard EN ISO 3744) 40 11.6 Operating and storage temperature ranges 41 11.7 Oscillation / vibration 41 11.8 Torques for central bolts (only for cutter and combination devices) 41 12. EC Declaration of Conformity 42 13. Accessories 43 13.1 Batteries 43 13.2 Battery charger 43 13.3 Power supply 44 13.
1. Danger classifications We differentiate between various different categories of safety instructions. The table shown below provides an overview of the assignment of symbols (pictograms) and signal words to the specific danger and the possible consequences.
2. Product safety LUKAS products are developed and manufactured to ensure the best performance and quality when used as intended. The safety of the operator is the most important consideration in product design. Furthermore, the operating instructions are intended to help you use LUKAS products safely.
All bolted connections must be checked for leaks and externally visible damage, which must be repaired immediately! Escaping hydraulic fluid can cause injuries and fires. Immediately report any changes that occur (including changes in operating behavior) to the appropriate persons/departments! If necessary, the equipment is to be shut down immediately and secured! In the event of malfunction, immediately deactivate the device and secure it. Repair the fault immediately.
Please ensure that you do not become entangled in cables and trip when working with or transporting the device. Please ensure that the battery contacts are not shortcircuited. The build-up of static charges and therefore possible sparking must be avoided when handling the device. Only touch broken-off or cut-off parts while wearing protective gloves, as the torn / cut edges can be very sharp.
The generally applicable, legal and other binding national and international regulations pertaining to the prevention of accidents and protection of the environment apply and are to be implemented in addition to the operating instructions. WARNING / CAUTION / PLEASE NOTE! The device is intended exclusively for the purpose stated in the operating instructions (see chapter "Proper Use"). Any other use is not in accordance with its designated purpose.
WARNING / CAUTION / PLEASE NOTE! The following may not be cut / squeezed: - live cables - prestressed and hardened parts such as springs, spring steels, steering columns and rollers - pipes under gas or liquid pressure, - compound materials (steel/concrete) - explosive bodies such as airbag cartridges The operating pressure placed on the rescue device may only be directly changed after consultation with LUKAS. A change in settings may result in damage to property and/or injuries.
4. Functional description 4.1 Description The cutting and combination devices have been designed in such a way that a hydraulically operated piston activates mechanical joints symmetrically to open or close a set of two opposite blade arms, thus enabling objects to be cut. The spreaders operate according to a similar principle. These, too, have been designed in such a way that a hydraulically operated piston activates mechanical joints symmetrically to open or close a set of two opposite spreader arms.
4.2 Structure of rescue devices 4.2.
4.2.2 Combination device 1 2 3 12 5 4 10 6 8 7 9 11 4.2.
4.2.4 Rescue ram 11 3 1 10 2 8 11 4 9 5 7 6 1 Star grip 2 Main switch 3 Quick exchange battery or power supply 4 Release button for battery and power supply 5 Ventilation slots 6 Ram piston 7 Plastic housing 8 Tool body 9 Top claw 10 Bottom claw 11 Light 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.
4.4 Operating movement controls The piston movement is controlled by the star grip on the attached valve (see illustration below). Star grip 5. Operation 5.1 Battery or power supply for eDRAULIC device 5.1.1 Commissioning Before initial operation, the battery (where used) of the rescue device must be fully loaded, using the external charger. Procedure: 1. Unplug the power supply (where used) from the mains. 2.
5.2 Operating the star grip (also see chapter on "Operating movement control") Open the device or extend the piston ( / ): Turn the star grip in the direction of the corresponding symbol (open / extend) and hold it in this position. Close the device or retract the piston ( / ): Turn the star grip in the direction of the corresponding symbol (close / retract)and hold it in this position.
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 operating the rescue device, you should ensure that no participants or bystanders are at risk from the movements of the rescue device or from flying fragments! Avoid unnecessary damage to property belonging to others or to objects not involved in the rescue or damage caused by flying fragments.
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: eDraulic cutting device max. gap at the blade tips [mm] / [in.] S 311 E2 S 700 E2 3 / 0.12 3 / 0.12 SC 250 E2 3 / 0.12 SC 357 E2 3 / 0.12 ATTENTION! Where possible, avoid cutting through high-strength parts of the vehicle body (e.g.
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 spreader arms! 6.4 Pulling (spreader, combination devices) WARNING / CAUTION / PLEASE NOTE! The light metal alloy spreader or combination arms may not be damaged. - LUKAS chain sets must be used for pulling. - When using a chain for pulling, make sure that the pins and hooks are positioned correctly so that the chain cannot slip.
The connecting pieces for LUKAS chain sets are fastened to the blades using load bolts in holes "A". (see illustration on the right) A Chain sets: for SC 250 E2: for SC 357 E2: for SP 300 E2: for SP 310 E2: KSV 8/50 KSV 8/50 KSV 11, KSS 20 (for multi-function tip) KSV 11, KSS 20 (for multi-function tip) NOTE: Also take note of all the instructions and regulations in the separately provided operating instructions for the chain sets. 6.
6.6 Squeezing (rescue ram) Before using the rescue ram, ensure that it is adequately supported. This also includes any underpinning that may be required. The rescue rams have been equipped with a claw on the ram and piston sides to ensure their safest possible 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, ram attachments and the use of holding straps may be required.
7. Dismantling the equipment / deactivation following operation Once work has been completed, the device arms should be closed until the tips are only a few millimeters apart and the ram piston should be almost fully retracted. This relieves the hydraulic and mechanical strain on the equipment. NOTE: Never store the eDRAULIC devices with fully closed arms or a fully retracted piston! By fully closing the arms or retracting the ram piston, hydraulic and mechanical tension may develop in the device.
8.1 Overview of eDRAULIC devices Inspections to be carried out: Visual Inspection Cutting and combination tool • Opening width of the blade arms on the tips (see chapter "Technical data"), • General tightness (leaks), • Operability of the star grip - check the automatic return into middle position after release (dead man’s function), • Existence and stability of handle, • Labels complete and legible, • Covers in perfect condition, • Check the torque of the pivot bolt (for torque MA, see "Technical Data").
Battery and power supply • Casing undamaged, • Electrical contact surfaces clean and undamaged • Cable undamaged • Battery(-ies) fully charged (when used) • Charging state display of lithium-ion battery or batteries fully functional Functional test • Easy opening and closing or extension/retraction of star grip controls, • No unusual noises • No further movement of cutter and spreader arms or ram piston when interrupting the 8.
9. Repairs 9.1 General information Service work may only be performed by the device manufacturer or by personnel trained by the device manufacturer and authorized LUKAS dealers. Only LUKAS spare parts may be used to replace all components (see spare parts list), as special tools and compliance with, assembly instructions, safety aspects and inspections are required (see also chapter "Maintenance and Servicing").
9.2 Preventive service 9.2.1 Care instructions The outside of the device should be cleaned with a damp cloth from time to time (not the electrical contacts in the connection slot, on the battery and on the power supply). In addition, the metal surfaces are to coated with a suitable medium to counteract corrosion (not the electrical contacts in the connection slot, on the battery and on the power supply). (In case of doubt, contact your authorized LUKAS dealer or LUKAS directly!) 9.2.
Work steps: 1. First of all, carefully clean the rescue equipment. 2. Remove the two fixing screws "A" and remove the protective cover "B". To do this, first pull the rounded rear edge outwards and then backwards through the hand grip, as the edges of the protective cover adjoining the cylinder body are kept in place by guide grooves. If necessary, loosen the hand grip and move it backwards to obtain sufficient space to pull it out. Then remove the A cover caps "C".
4. First remove the grub screw "G", then the central bolt nut "H" and then pull out the central pin "J". K G M H N L P O M N 5. Release the fixing screws "K" and remove them. The handle "L" can now be pulled out forwards over the blades. J 6. Remove the locking 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.
9.3.2 Replacing the blades, protective cover and hand grip of the S 311 E2 cutter and SC 357 E2 and SC 250 E2 combination devices NOTE: The illustrations show the equipment with the blade arms of the cutter tool. Assembly and disassembly are identical for the combination tool! Components to be replaced Required work 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.
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. D NOTE: The torque required can be taken from the spare parts list of your particular unit. L E M G J M H H 8. Fold in the lever elements M. J 9. Last of all, pull the protective sleeve "E" off the device, as shown above. K 10. The work steps must be carried out in reverse order to fit the new parts.
9.3.3 Sharpening the blades Remove and smoothen any burrs! Chips or deep grooves cannot be ground away. The blades must be replaced in this case. ATTENTION! Only grind in the grinding area (see illustration)! The sliding faces, in particular, must not be reground! Grinding area Pivot point Blade arm Direction of movement Blade arm Slide surface plane Tools required: 1. Jaw protection on clawing device (e.g. vice) in order not to damage the blades. 2. Grinder (e.g.
9.3.4 Replacing the spreader arm, spreader tips, protective cover and handle of the spreader Components to be replaced Required work steps Handle 1., 2. and 8. Plug-on tips 1., 3. and 8. Protective cover 1. - 7. and 8. Lever links 1. - 6. and 8. Spreader arms 1. - 7. and 8. 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. A 2. Remove the fixing screws "A" and remove the handle "B".
4. Remove screws "C" and disks "D" and push back the protective cover "E" as far as possible to reach the locking rings for the bolts "M". C M D E D 5. You will only be able to pull off the protective cover "E" once you have removed the spreader arms (see Section 7a). 6. You need to remove the locking rings "K" and the lever links "L" by pulling them outwards to replace the spreader arms "H". L K M P N H M 7. Remove one locking ring "M" on each side to enable you to remove the bolts "N".
7a. Once the spreader arms have been removed, you can remove the protective cover "E" by pulling it forwards. E 8. The work steps must be carried out in reverse order to fit the new parts. ATTENTION! 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 steps for exchanging the ram 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 ram 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.
10. Troubleshooting Fault Blades, spreader arms or ram pistons move slowly or jerkily when operated Check Cause Battery fully charged? Charge battery Battery defective Replace battery Air in the hydraulic system Repair by an authorized dealer, by personnel specially trained by LUKAS, or by LUKAS itself Power supply not properly connected to the eDRAULIC device (not automatically locked). Reinsert power supply into the connection shaft.
Fault Following release, the star grip doesn’t return to the central position Check Cause Solution Casing damaged or star grip operation not working smoothly? Damage to the torsion spring for reset Repair by an authorized dealer, by personnel specially trained by LUKAS, or by LUKAS itself Soiled valve or star grip Defective valve Other mechanical damage (e.g.
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.
11.2 eDRAULIC combination device Device type SC 250 E2 SC 357 E2 Item number 90-30-12 90-30-22 Dimensions (excluding battery) [mm] LxWxH [in.] Max. cutting opening Max. cutting force (rearmost cutting point) Minimum spreading force (at a distance of 25 mm / 0.98 inches from the tips) 849 x 215 x 262 929 x 225 x 262 33.4 x 8.46 x 10.3 36.6 x 8.86 x 10.3 231 274 [mm] [in.] 9.1 10.8 [kN] 280 380 [lbf.] 63000 85400 [kN] 32 38 [lbf.
11.3 eDRAULIC spreader Device type SP 300 E2 SP 310 E2 Item number 90-10-12 90-10-22 Dimensions (excluding battery) [mm] LxWxH [in.] 881 x 355 x 262 955 x 345 x 276 34.7 x 14 x 10.3 37.6 x 13.6 x 10.9 Minimum spreading force (at a distance of 25 mm / 0.98 inches from the tips) [kN] 36 50 [lbf.] 8100 11000 Max. possible spreading force [kN] 145 324 [lbf.] 32600 72800 [kN] 33 46 [lbf.] 7420 10300 [kN] 40 58 [lbf.
11.4 eDRAULIC rescue ram Device type R 411 E Item number 90-40-10 (174080000) Length (retracted) Length (extended) [mm] 545 [in.] 21.5 [mm] 905 [in.] Dimensions W x H Maximum piston extension Compressive force Mass (excl. battery) 35.6 [mm] 150 x 265 [in.] 5.9 x 10.4 [mm] 360 [in.] 14.2 [kN] 103 [lbf.] 23200 [kg] 16.9 [lbs.] 37.3 Nominal electrical voltage (with power supply) [V] 24 Nominal electrical voltage (with lithium-ion battery) [V] 25.
11.6 Operating and storage temperature ranges Operating temperature [°C] / [°F] -20 … +55 -4 … +131 Ambient temperature (device in operation) [°C] / [°F] -25 … +45 -13 … +113 Storage temperature (device not in operation) [°C] / [°F] -30 … +60 -22 … +140 11.7 Oscillation / vibration The total oscillation value / vibration value to which the upper limbs are exposed, is usually below 2.5 m/s².
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13. Accessories 13.1 Batteries Only LUKAS lithium-ion rechargeable batteries may be used to operate eDRAULIC devices. These guarantee optimum performance and maximize the operating time of the eDRAULIC devices. Charging state display Query button Technical Data nom. Voltage Capacity Energy Weight Unit V DC Ah Wh kg lbs Battery type 1 25.2 2.6 65 0.92 2.03 Battery type 2 25.2 5.0 126 0.94 2.07 13.
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 can be used instead of a battery.
13.5 Chain sets Chain sets are required in order to be able to perform pulling operations with the eDRAULIC spreader and the eDRAULIC combination tool (see chapter, "Pulling"). Suitable chain sets: for SC 250 E2: for SC 357 E2: for SP 300 E2: for SP 310 E2: KSV 8/50 KSV 8/50 KSV 11, KSS 20 (for multi-function tip) KSV 11, KSS 20 (for multi-function tip) 14. Instructions regarding disposal Please duly dispose of all packaging materials and removed items.
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Please duly dispose of all packaging materials and removed items. LUKAS Hydraulik GmbH A Unit of IDEX Corporation 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 eDRAULIC2_manual_172085085_0314_en.
