Operating instructions for rescue equipment eDRAULIC equipment (Cutter, combi, spreader and rescue ram) SP 300 E S 700 E S 311 E R 411 E SC 350 E SC 250 E 172080085 GB Edition 03.2013 replaces 01.
Contents Page 1. Danger classes 4 2. Product safety 5 3. Intended Use 8 4. Functional description 10 4.1 Description 10 4.2 Structure of the rescue equipment 11 4.3 Hydraulic circuit diagram 13 4.4 Controlling the operating movements 14 5. Operation 14 5.1 Battery or power supply for eDRAULIC device 14 5.2 Operating the star grip 15 6. Cutting, spreading, pulling, squeezing and squashing 6.1 Safety instructions 15 15 6.2 Cutting (cutter and combi tool) 16 6.
11. Technical data 38 11.1 eDRAULIC cutter 38 11.2 eDRAULIC combi tool 39 11.3 eDRAULIC spreader 40 11.4 eDRAULIC rescue ram 41 11.5 Noise emissions (based on the EN ISO 3744 standard) 41 11.6 Operating and storage temperature ranges 42 11.7 Oscillation / vibration 42 11.8 Tightening torques for pivot bolts (cutters and combi tools only) 42 12. EC Declarations of conformity 43 13. Accessories 45 13.1 Batteries 45 13.2 Battery charger 45 13.3 Power supply 46 13.
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.
2. Product safety LUKAS products are developed and manufactured 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 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.
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. Do not carry out any changes (additions or conversions) 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.
Protect the eDRAULIC devices against humidity and moisture The eDRAULIC devices are not suitable for underwater use. 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.
3. Intended Use LUKAS eDRAULIC devices have been specially designed to rescue or retrieve the bodies of victims of road, rail 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.
You can order spare parts and accessories for the rescue tools from your authorised LUKAS dealer! Applications: 9
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.
4.2 Structure of the rescue equipment 4.2.
1 4.2.2 Combi tool 3 2 12 4 5 6 10 1 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 8 7 9 11 1 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 Cylinder piston 7 Plastic casing 8 Device body 9 Top claw 10 Bottom claw 11 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.
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.
5.2 Operating the star grip (also see chapter on "Controlling the operating movements") 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.
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.
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 tool S 311 E S 700 E SC 250 E SC 350 E max. gap on the blade tips [mm] / [in.] 3 / 0.12 3 / 0.12 3 / 0.12 3 / 0.12 ATTENTION! Avoid cutting through the hardest 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, combi tools) WARNING / CAUTION / ATTENTION! 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.
The connection pieces for the LUKAS chain sets are attached to the boreholes A on the blades using load bolts. (see figure on the right). A 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) WARNING / CAUTION / ATTENTION! The light metal alloy arms must not be damaged.
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 as safe as possible to use. Where this support is not adequate, e.g.
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.
8.1 Overview of eDRAULIC devices Inspections to be carried out: Visual inspection Cutter and combi tool • Opening width of the blade arms on the tips (see chapter "Technical data"), • General tightness (leaks), • Ease of movement of star handle, • Existence and stability of handle, • Labels completely existent and legibly, • Covers in perfect condition, • Check the tightening torque of the pivot bolt (tightening 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(-ies) fully functional Functional check • Easy opening and closing or extension/retraction of star grip controls, • no suspicious noises. • no further movement of cutter and spreader arms or cylinder piston when interrupting the valve function during the process (dead man's switch), 8.
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.
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". C B D A B 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.
H G 4. First remove the grub screw "G", then the central bolt nut "H" and then pull out the central pin "J". L J 5. Release the fixing screws "K" and remove them. The handle "L" can now be pulled out forwards over the blades. N O K M 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" P M N O 7. The work steps must be carried out in reverse order to fit the new parts.
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 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.
D 5. Remove self-locking nut D and push the pivot bolt G out. H J G 6. Remove the retaining rings H and push out bolt J. L H J 7. Now, you can remove blade K and sliding plates L. M K 8. Fold in the lever elements M. M 9. Finally, pull the hand guard "E" off the device as shown.
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 using 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.
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.
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". B 3. C C Remove the screws "C" and "D".
E 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. F F 5. H 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.
6. You need to remove the retaining rings "K" and the lever links "L" to replace the spreader arms "H". K L K L H L K L K K 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 steps 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.
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.
10. Troubleshooting Trouble Blades, spreader arms or cylinder pistons move slowly or jerkily when operated Control Battery fully charged? Cause Battery flat Solution Charge battery Battery defective Replace battery Air in the hydraulic system Repair by authorised dealer, staff specially trained by LUKAS or directly by LUKAS Reinsert power supply into the connection slot. Power supply cable Power supply connected? not properly connected to the eDRAULIC device (not automatically locked).
Trouble Following release, the star grip doesn’t return to the central position Control Casing damaged or star grip operation does not work smoothly? Cause Damage to the torsion spring for reset Soiled valve or star grip Solution Repair by authorised dealer, staff specially trained by LUKAS or directly by LUKAS 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. 11.1 eDRAULIC cutter Type S 311 E Ref.no.
11.2 eDRAULIC combi tool Type SC 250 E SC 350 E 90-30-10 (173000000, 173115000) 90-30-20 (173010000) [mm] 870 x 215 x 295 908 x 225 x 290 [in.] 34.3 x 8.5 x 11.6 37.8 x 8.9 x 11.4 233 265 Ref.no. Dimensions (excl. battery) lxwxh Max. cutting opening [mm] [in.] 9.2 10.43 Max. cutting force (rearmost cutting point) [kN] 280 360 [lbf.] 62,944 80,928 Maximum spreading force (at a distance of 25mm / 0.98in. from the tips) [kN] 33 40 [lbf.
11.3 eDRAULIC spreader Type SP 300 E Ref.no. 90-10-15 (171050000) [mm] Dimensions (excl. battery) lxwxh Maximum spreading force (at a distance of 25mm / 0.98in. from the tips) Max. possible spreading force 895 x 355 x 290 [in.] 35.2 x 14.0 x 11.4 [kN] 44 [lbf.] 9900 [kN] 125 [lbf.] 28100 LSF spreading force (according to NFPA) [kN] 33 [lbf.] 7400 HSF spreading force (according to NFPA) [kN] 40 [lbf.] 9000 [mm] 605 [in.] 23.
11.4 eDRAULIC rescue ram Type R 411 E Ref.no. 90-40-10 (174080000) [mm] Length (retracted) [in.] [mm] Length (extended) [in.] [in.] Maximum piston extension Compressive force Weight (excl. battery) 905 35.63 [mm] Dimensions wxh 545 21.46 150 x 265 5.91 x 10.43 [mm] [in.] 360 14.17 [kN] 103 [lbf.] 23,156 [kg] 16,9 [lbs.] 37.3 Nominal electrical voltage [V] (with power supply) 24 Nominal electrical voltage [V] (with lithium/ion battery) 25,2 Protection category IP44 11.
11.5.2 R411E: Battery type used for device No-load operation (measuring distance: 1m) full load operation (measuring distance: 1m) No-load operation (measuring distance: 5m) full load operation (measuring distance: 5m) Lithium / ion [dB(A)] 78 [dB(A)] 79 [dB(A)] 71 [dB(A)] 72 11.
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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.
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.
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.
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LUKAS Hydraulik GmbH A unit of the 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 eDraulic_Geräte_BA_GB_172080085_0313.
