Instruction manual for rescue equipment Cutters and Combi Tools Blade forms: S x10 S x11 S x30 172047085 EN SC Edition 11.2014 replaces 04.
Content Page 1.Hazard classes 4 2.Product safety 5 3.Proper use 8 4.Description of the functions 9 4.1 Description 9 4.2 Tools in detail 10 4.3 Circuit diagram 11 4.4 Control of the operating movements 11 4.5 Hydraulic supply 11 4.6 Hoses 11 5.Connecting the equipment 12 5.1 General information 12 5.2 Coupling the mono-couplings 12 5.3 Coupling the quick-disconnect couplings 14 6.Operation 15 6.1 Preparatory measures 15 6.2 Operating the star grip (cover: item 1) 15 7.
11.Troubleshooting 37 12.Technical Data 40 12.1 Cutters 40 12.2 Combi tools 47 12.3 Torque of the pivot bolt 49 12.4 Cutting capacities 50 12.5 Recommended hydraulic fluid 51 12.6 Operating and storage temperature ranges 51 13.EC Declarations of conformity 52 13.1 Cutters 52 13.2 Combi tools 54 14.
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 specific hazard and possible consequences.
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.
Observe all safety and danger notes on the equipment and in the operating instructions. All safety and danger notes on the equipment are to be kept complete in a legible condition. Any mode of operation which impairs safety and/or stability of the equipment is forbidden! Comply with all specified dates or dates specified in the operating instructions pertaining to regular controls / inspections on the equipment.
Always keep these operating instructions within reach where the equipment is used. 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.
3. Proper use LUKAS “SC” combi tools and LUKAS “S” cutters are designed specifically for rescuing victims in traffic, rail or air accidents and for making rescues from buildings. They serve the purpose of freeing injured people in accidents e. g. by cutting doors, roof bars and hinges. By using the LUKAS combi tools, trapped persons can also be freed e. g. by spreading doors and / or by removing obstacles with the aid of a chainset.
LUKAS cutters and combi tools can also be used under water at a depth of up to 40m (131 ft). CAUTION! In this case, you must strictly observe any leaks in order to avoid threats to the environment. CAUTION! All objects which are to be worked on are to be secured using stable supports or substructures.
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4.3 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 A spreading / opening B 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, figure 3). fig. 3 star grip 4.5 Hydraulic supply A LUKAS motor pump or hand pump only may be used to drive the equipment.
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.
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.
5.3 Coupling the quick-disconnect couplings The equipment is connected to the hydraulic pump via quick-disconnect-coupling halves (male and female). X Y Before coupling unlock the connect socket by turning the sleeve into position X. Retract sleeve and connect plug and socket. Release sleeve and turn it into position Y. Now the connection has been made and locked. Uncoupling is done in the reverse order.
6. Operation 6.1 Preparatory measures 6.1.1 Commissioning Before commissioning and following repairs, the equipment must be deaerated. - Connect the equipment to the hydraulic pump (see chapter “Connecting the equipment”). - Open / close the blade arms of the equipment without any load at least twice (see chapter “Operation of the star grip”). REMARK: We recommend that during the deaeration, the attached aggregate for the hydraulic supply should stand on a higher level than the body of the rescue tool.
7. Cutting, spreading, pulling and squeezing 7.1 Safety notes Before rescue works can commence, the position of the obstacle must be stabilised. You must ensure an adequate substructure and / or adequate support of the object. World-wide, safety guidelines pertaining to the specific country are to be observed and complied with.
During cutting, the gap between the blade tips (in the crosswise direction) may not be exceeded, otherwise the blade is in danger of breaking: Cutter / combi tool max. gap on the blade tips [mm] / [in.] S 120 2 / 0.08 S 311 3 / 0.12 S 330 S 510 5 / 0.20 S 511 3 / 0.12 S 530 5 / 0.20 S 700 3 / 0.12 SC 357 3 / 0.12 SC 557 CAUTION! Avoid cutting particularly high-strength parts of the vehicle’s bodywork (e.g.
7.4 Pulling (combi tools only) You may only use LUKAS chain sets for pulling purposes. Before the pulling process can be performed, ensure that the bolt and hook fit 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 LUKAS chain set in order to correctly attach, affix and use the chain sets.
8. Dismantling the equipment / deactivation following operation 8.1 Cutters / Combi tools Once work has been completed, the blade 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. REMARK: Never store the cutter / combi tool with fully closed blade arms! The complete closure of the blade arms can cause hydraulic and mechanical stress to build up again.
9.1 Cutters / Combi tools, overall Inspections to be carried out: Visual inspection Cutter / combi tool • Opening width of the blade 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, • Control of the torque of the pivot bolt (torque MA see “Technical Data”), • Couplings must be easy to couple, • Dust protection caps must be available.
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”).
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.
10.3 Repairs 10.3.1 Changing the blade and hand guard of cutters S 3xx and S 5xx 1. First of all, carefully clean the rescue equipment. 2. Next, close the blade arms so that the tips are almost touching. REMARK: The blade bolts are only accessible when the blade arms are almost touching Further procedure: 3. Remove screws A and spring washers B of handle C. Then, the handle can be removed in the direction of the connecting hoses of the device. C B 4.
L 7. Now, you can remove blade K and sliding plates L. M K 8. Fold in the lever elements M. M 9. Finally, remove the hand guard E from the equipment as depicted. E 10. In order to assemble the new parts, points 3-9 are to be carried out in reverse order. CAUTION! Don’t forget to apply LUKAS special grease to all sliding surfaces. REMARK: If you only wish to change the blades, only carry out points 1, 2 as well as points 5., 6. and 7.
10.3.2 Changing the blades of cutter S 120 1. First of all, carefully clean the rescue equipment. 2. Next, close the blade arms so that the tips are almost touching REMARK: The blade bolts are only accessible when the blade arms are almost touching Further procedure: A 3. Remove screws A and hand guard B. C B D 4. Remove nut C and Nord-Lock washer D (stuck together). Then push the pivot bolt E out. G E 5. Remove retaining ring F and push blade bolt G out. F 6. Remove fitting screw H. H 7.
Detail I L 8. Assembly of the new blades is carried out in reverse order. REMARK: Tighten the fit bolt H during assembly with a torque of MA = 40 Nm! H Detail II M REMARK: When assembling the pivot bolt, ensure that it is fixed with the roll pins M as shown in detail II, and that it is prevented from twisting. Detail III M REMARK: Should the adhesion between the Nord-Lock washer and the nut become undone, they can still be used.
10.3.3 Replacing blades, protective covers and handles on the cutter S700 Components to be replaced Required work steps Protective cover 1. - 3. and 8. Pivot bolt 1. - 5. and 8. Handle 1. - 6. and 8. Blade 1. - 7. and 8. Work steps: 1. First of all, carefully clean the rescue equipment. 2. Next, close the blade arms so that the tips are almost touching. 3. Remove the fixing screws “A” and remove the protective cover “B” and the cover caps “C”.
4. Move the blade arms on the unit until the pin “E“ and the locking rings “F” can be accessed through the hole “D”. Turn the unit off and disconnect it from the hydraulic supply (uncouple). F E H G 5. First remove the grub screw “G”, then the central bolt nut “H” and then pull out the pivot bolt “J”. L J 6. Release the fixing screws “K” and remove them. The handle “L” can now be pulled out forwards over the blades. N O K M 7. Remove the locking rings “M” and push the pin “N” out.
8. The work steps must be carried out in reverse order to fit 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.
10.3.4 Changing the blade and hand guard of combi tool 1. First of all, carefully clean the rescue equipment. 2. Next, close the blade arms so that the tips are almost touching. REMARK: The blade bolts are only accessible when the blade arms are almost touching Further procedure: 3. Remove screws A and spring washers B of handle C. The handle can then be removed in the direction of the connecting hoses of the device. B D A 4. C E Remove nut D and washer E from the pivot bolt. 5.
K K 8. Push bolts K out. M L 9. L You can now remove blades L and sliding plates M. N 10. Fold in the lever elements N. G N 11. Finally, remove the hand guard G from the equipment as depicted. 12. In order to assemble the new parts, points 3-11 are to be carried out in reverse order. CAUTION! Don’t forget to apply LUKAS special grease to all sliding surfaces. REMARK: If you only wish to change the blades, only carry out points 1, 2, 4, 5 as well as points 7, 8 and 9.
10.3.5 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 MA = 40 Nm!) 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.
10.3.6 Changing the handle (except S 120) C B B A 33 Remove screws A and spring washers B of handle C. The handle can then be removed in the direction of the connecting hoses of the device.
10.3.7Sharpening the blades Only remove and smoothen any burrs! Chips or deep grooves cannot be ground away. The blades must be replaced in these cases. CAUTION! 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. Use jaw protection on clamping device (e.g. vice) in order not to damage the blades 2. Grinder (e.g.
10.3.8 Mono-couplings The mono-couplings must be replaced in the event of: - external visible damage, - the locking device not working, - hydraulic fluid 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 MA = 40 Nm. Procedure: 1. Remove the cover from the couplings. 2.
10.3.9 Quick-disconnect-couplings The quick-disconnect-couplings must be replaced in the event of: - external visible damage, - the locking device not working, - hydraulic fluid 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 MA = 35 Nm. Procedure: 1. Loosen the connection nut of the hose assembly and remove the coupling. 2.
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Trouble Control Cause Hydraulic fluid leaks on the piston rod Solution Defective rod seal Repair by an authorised dealer, by Damage to the personnel specially piston trained by HURST, or by HURST 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. Does the pressure Pressure release Following the in the Rescue tool.
Trouble Control with quickdisconnect-couplingsystem: Leak in the couplings Is the coupling damaged? Cause Solution coupling damaged Coupling must be replaced immediately Is the leak only Safety valve on the coupling reacted male (in uncoupled status)? After pressure release there is no more leakage.
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. 12.1 Cutters type S 120 ref.no. dimensions l x w x h (w/o connection hoses) max. cutting opening max. cutting force (rear end of the cutting surface) weight incl.
type S 311 ref.no. dimensions l x w x h (w/o connection hoses) max. cutting opening max. cutting force (rear end of the cutting surface) weight incl. hydraulic fluid max. operating pressure min. needed volume of hydraulic fluid [mm] 705 x 211 x 160 [in.] 27.2 x 8.3 x 6.3 [mm] 150 [in.] 5.91 [kN] 642 [lbf.] 144327 [kg] 13.9 [lbs.] 30.7 [Mpa] * 70 [psi.] 10000 [l] ** 0,1 [gal.-US] coupling system 0.026 quick-disconnectcoupling classification acc.
type S 330 ref.no. dimensions l x w x h (w/o connection hoses) max. cutting opening max. cutting force (rear end of the cutting surface) weight incl. hydraulic fluid max. operating pressure min. needed volume of hydraulic fluid [mm] 726 x 211 x 163 [in.] 28.6 x 8.3 x 6.4 [mm] 228 [in.] 9.0 [kN] 616 [lbf.] 138482 [kg] 14,8 [lbs.] 32.7 [Mpa] * 70 [psi.] 10000 [l] ** 0,1 [gal.-US] coupling system 0.026 quick-disconnectcoupling classification acc.
type S 510 ref.no. dimensions l x w x h (w/o connection hoses) max. cutting opening max. cutting force (rear end of the cutting surface) weight incl. hydraulic fluid max. operating pressure min. needed volume of hydraulic fluid [mm] 776 x 240 x 170 [in.] 30.6 x 9.45 x 6.69 [mm] 202 [in.] 7.9 [kN] 962 [lbf.] 216266 [kg] 18,9 [lbs.] 41.7 [Mpa] * 70 [psi.] 10000 [l] ** 0,15 [gal.-US] coupling system 0.04 quick-disconnectcoupling classification acc.
type S 511 ref.no. dimensions l x w x h (w/o connection hoses) max. cutting opening max. cutting force (rear end of the cutting surface) weight incl. hydraulic fluid max. operating pressure min. needed volume of hydraulic fluid [mm] 746 x 245 x 170 [in.] 29.4 x 9.65 x 6.69 [mm] 162 [in.] 6.4 [kN] 1194 [lbf.] 268422 [kg] 18,7 [lbs.] 41.3 [Mpa] * 70 [psi.] 10000 [l] ** 0,15 [gal.-US] coupling system 0.04 quick-disconnectcoupling classification acc.
type S 530 ref.no. dimensions l x w x h (w/o connection hoses) max. cutting opening max. cutting force (rear end of the cutting surface) weight incl. hydraulic fluid max. operating pressure min. needed volume of hydraulic fluid [mm] 780 x 245 x 170 [in.] 30.7 x 9.65 x 6.69 [mm] 297 [in.] 11.7 [kN] 1015 [lbf.] 228172 [kg] 18,1 [lbs.] 40 [Mpa] * 70 [psi.] 10000 [l] ** 0,15 [gal.-US] coupling system 0.04 quick-disconnectcoupling classification acc.
type S 700 ref.no. dimensions l x w x h (w/o connection hoses) max. cutting opening 81-20-70 (172081000) 112081000 [mm] 790 x 300 x 258 [in.] 31.1 x 11.8 x 10.2 [mm] 185 [in.] 7.28 [kg] 21,3 [lbs.] 47.0 weight incl. hydraulic fluid max. operating pressure min. needed volume of hydraulic fluid [Mpa] * 70 [psi.] 10000 [l] ** 0,33 [gal.-US] coupling system 0.09 quick-disconnect coupling classification acc. to DIN EN 13204 BC 180 H-21 classification acc.
12.2 Combi tools type SC 357 ref.no. dimensions l x w x h (w/o connection hoses) 81-30-20 (173037000) 113037000 [mm] 777 x 220 x 170 [in.] 30.6 x 8.67 x 6.7 [mm] 272 [in.] 10.7 [kN] 387 [lbf.] 87001 max. spreading distance (on the blade tips) [mm] 365 [in.] 14.4 max. spreading force (25mm from the tips) [kN] 38 [lbf.] 8500 spreading force HSF (according to NFPA) [kN] 42 [lbf.] 9440 [kN] 32 [lbf.] 7190 pulling force HPF (according to NFPA) [kN] 57 [lbf.
type SC 557 ref.no. dimensions l x w x h (w/o connection hoses) 81-30-30 (173047000) 113047000 [mm] 840 x 280 x 190 [in.] 33.1 x 11.0 x 7.48 [mm] 355 [in.] 14 [kN] 810 [lbf.] 182095 max. spreading distance (on the blade tips) [mm] 430 [in.] 16.9 min. spreading force (25 mm from the tips) [kN] 41,5 [lbf.] 9300 spreading force HSF (according to NFPA) [kN] 47 [lbf.] 10600 [kN] 39 [lbf.] 8770 pulling force HPF (according to NFPA) [kN] 67 [lbf.
12.3 Torque of the pivot bolt type pivot bolt wrench size torque [mm] [Nm] [in.] [lbf.in.] S 120 M22 x 1,5 34 1.34 80 + 10 708 + 89 S 311 S 330 S 510 S 511 S 530 M 24 x 1,5 36 1.42 120 +10 1,062 + 89 M 27 x 1,5 41 1.61 130 +10 1,151 + 89 S 700 M 32 x 1,5 46 1.81 150 + 10 1,328 + 89 M 24 x 1,5 36 1.42 120 +10 1,062 + 89 M 27 x 1,5 41 1.
12.4 Cutting capacities type max. cutting material dimensions Round material steel (Rm = 400 N/mm²) [mm] [in.] S 120 S 311 S 330 S 510 S 511 S 530 S 700 22 0.87 33 1.30 33 1.30 39 1.54 43 1.69 39 1.54 38 1.50 SC 357 30 1.18 SC 557 38 1.
12.5 Recommended hydraulic fluid Hydraulic fluid for LUKAS hydraulic equipment: Mineral oil DIN ISO 6743-4 and others Oil temperature range A -20 .... +55°C -4.0 .... +131°F Oil code Viscosity rating HM 10 VG 10 recommended viscosity range: 10...200 mm²/s Supplied with HM 10 DIN ISO 6743-4. Remarks (10…200 cSt.) CAUTION! Before using hydraulic fluids, which do not correspond to the above-mentioned specifications and/or are not purchased from LUKAS, you have to contact LUKAS itself! 12.
13. EC Declarations of conformity 13.
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Please dispose all packaging materials and dismantled parts properly. 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 cutter_combi_manual_172047085_en.
