Lukas S 3 Series User manual

Cutters and combination tools
(Translation of the original operating instructions)
172047085 EN
Edition 03/2023
replaces 06/2021
Operating instructions for rescue equipment
Blade forms:
SC
S 3xx
S 7xx

2
Content Page
1. Dangerclassications 4
2. Productsafety 5
3. Properuse 8
4. Functionaldescription 9
4.1 Description 9
4.2 Equipment in detail 10
4.3 Wiring diagram 12
4.4 Operating movement controls 12
4.5 Hydraulic supply 12
4.6 Hose lines 12
5. Connectingthedevice 13
5.1 General 13
5.2 Coupling the mono-couplings 13
5.3 Coupling the plug couplings 15
6. Operation 15
6.1 Preparatory measures 15
6.2 Operating the star grip 16
7. Cutting,spreading,pullingandsqueezing 16
7.1 Safety instructions 16
7.2 Cutting 17
7.3 Spreading (combination tools only) 20
7.4 Pulling (combination tools only) 21
7.5 Squeezing (combination tools only) 22
8. Dismantlingthedevice/deactivationfollowingoperation 23
9. Maintenanceandservice 23
8.1 Cutter or combination tool 23
8.2 Hydraulic unit 23
8.3 Hose lines 23
9.1 Cutter/combination tool, overall 24
9.2 Protective equipment 24

3
10. Repairs 25
10.1 General 25
10.2 Preventative service 26
10.3 Repairs 27
11. Troubleshooting 39
12. Technicaldata 42
12.1 Cutters 42
12.2 Combination tools 50
12.3 Torque of the pivot bolt 53
12.4 Cutting capacities 54
12.5 Datasheets for product performance 55
 12.6 Recommendedhydraulicuid 66
12.7 Operating and storage temperature ranges 66
13. EC/UKCAdeclarationsofconformity 67
13.1 Cutters 67
13.2 Combination tools 72
14. Notes 75
Content Page

4
 Wearahelmetwithfaceprotection
 Wearprotectivegloves
 Wearprotectivefootwear
 Properrecycling
 Protecttheenvironment
 Readandfollowtheinstructionmanual
Wedi󰀨erentiatebetweenvariousdi󰀨erentcategoriesofsafetyinstructions.Thetableshown
belowprovidesanoverviewoftheassignmentofsymbols(pictograms)andsignalwordsto
thespecicdangerandthepossibleconsequences.
1. Danger classications
Pictogram Damage/
injury to Keyword Denition Consequences
Persons
DANGER! Immediatedanger Deathor
severeinjury
WARNING!
Potentially
dangerous
situation
Potentialdeath
orseriousinjury
CAUTION! Lessdangerous
situation
Minororslight
injury
Property
ATTENTION!
Riskofdamage
toproperty/
environment
Damageto
thedevice,
damagetothe
environment,
damageto
surroundings
NOTE
Handlingtipsand
otherimportant/
usefulinformation
andadvice
Noinjury/
damageto
persons/
environment/
device

5
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instructionmanualisintendedtohelpyouuseLUKASproductssafely.
Inadditiontothesafetyinformationintheseoperatinginstructions,allgenerallyapplicable,
statutoryandotherbindingnationalandinternationalaccidentpreventionregulationsmust
beobservedandoperatorsmustbeinstructedaccordingly.
Thedevicemayonlybeoperatedbypersonswithappropriatetraininginthesafetyaspects
ofsuchequipment,otherwise,thereisariskofinjury.Allrescueteamsworkingattheplaceof
operationmustwearprotectiveclothing.Personsandpatientswithintherescueequipment’s
operationalrangemustbeprotectedbyplacingashatterguardorsuitablealternativedevice
betweentheworkingareaandtheperson.
Wewouldliketopointouttoallusers,theyshouldcarefullyread,understandandfollowall
operatinginstructionsbeforeusingtheproduct.
Wefurtherrecommendthatyouhaveaqualiedtrainershowyouhowtousetheproduct.
WARNING / CAUTION!
Theoperatinginstructionsforthehoses,accessoriesandconnecteddevices
mustalsobeobserved!
Evenifyouhavealreadyreceivedinstructionsonhowtousethedeviceyoushouldstillread
throughthefollowingsafetyinstructionsagain.
WARNING / CAUTION!
Makesurethattheaccessoriesusedandtheconnecteddevicesaresuitable
forthemax.operatingpressure!
Makesurethatnobody
partsorclothinggetscaught
betweentheopen,visibly
movingdeviceparts
(e.g.pistonclawandcylinder).
Workingundersuspended
loadsisnotpermittedwhere
suchloadsarebeinglifted
onlybymeansofhydraulicde-
vices.Ifthisworkisunavoid-
able,suitablemechanicalsup-
portsarealsorequired.
Wearprotectiveclothing,
asafetyhelmetwithvisor,
protectivefootwearand
gloves.
Inspectthedevicebeforeand
afteruseforvisibledefectsor
damage.
Immediatelyreportany
changesthatoccur
(includingchangesin
operatingbehavior)to
theappropriatepersons/
departments!Ifnecessary,
thedeviceistobeshutdown
immediatelyandsecured!
Alllines,hosesandscrew
connectionsmustbechecked
forleaksandexternally
visibledamage.Thesemust
berepairedimmediately!
Escapinghydraulicuidcan
causeinjuriesandres.

6
Intheeventofmalfunction,
immediatelydeactivatethe
deviceandsecureit.
Repairthefaultimmediately
(orhaveitrepaired).
Donotcarryoutanychanges
(additionsorconversions)to
thedevicewithoutobtaining
thepriorapprovalofLUKAS.
Observeallsafetyanddanger
informationonthedeviceand
intheinstructionmanual.
Allsafetyanddanger
instructionsonthedevice
mustalwaysbecompleteand
inalegiblecondition.
Anymodeofoperationwhich
compromisesthesafetyand/
orstabilityofthedeviceis
forbidden!
Observeallintervalsfor
recurringtestsand/or
inspectionsthatareprescribed
orstatedintheinstruction
manual.
Safetydevicesmustneverbe
disabled!
Themaximumpermissible
operatingpressuremarked
onthedevicemustnotbe
exceeded.
Beforeswitchingon/starting
upthedeviceandduringits
operation,makesurethatthis
willnotposeanydangerto
personnel.
OnlygenuineLUKAS
accessoriesandspareparts
aretobeusedforrepairs.
Pleaseensurethatyoudonot
becomeentangledinhose
loopsandtripwhenworking
withortransportingthedevice.
Whenworkingclosetolive
componentsandcables,
suitablemeasuresmust
betakentoavoidcurrent
transfersorhigh-voltage
transferstothedevice.
Pleasenotethat,when
spreadingandcutting,
tearingorbreakingcancause
materialtofall,orsudden
removalofsuchcancauseit
tosuddenlycatapulto󰀨,
andnecessaryprecautions
mustbetaken.
Thebuild-upofstaticcharges
andpossiblesparkingmust
beavoidedwhenhandlingthe
device.
Onlytouchbroken-o󰀨or
cut-o󰀨partswhilewearing
protectivegloves,asthetorn/
cutedgescanbeverysharp.

7
Inadditiontothesafetyinstructionsintheseoperatinginstructions,allgenerallyapplicable,
statutoryandotherbindingnationalandinternationalaccidentpreventionregulationsmust
beobserved,andoperatorsmustbeinstructedaccordingly.
WARNING / CAUTION / ATTENTION!
Thisdeviceisintendedexclusivelyforthepurpose described in the instruction manual
(see chapter “Proper use”).Any otheruse isnot in accordance with its proper use.
The manufacturer/supplier is not liable for any damage resulting from improper use.
Theuserbearssoleresponsibilityforsuchuse.
Properuseincludesobservanceoftheinstructionmanualandcompliancewiththeinspection
andmaintenanceconditions.
Never work in a fatigued or intoxicated state!
Thedeviceislledwith
hydraulicuid.Thishydraulic
uidcanbedetrimentalto
healthifitisswallowedorits
vaporisinhaled.Directcontact
withtheskinmustbeavoided
forthesamereason.Also,
whenhandlinghydraulicuid,
notethatitcannegatively
a󰀨ectbiologicalsystems.
Whenworkingwithorstoring
thedevice,ensurethatthe
functionandthesafetyofthe
devicearenotimpairedby
thee󰀨ectsofsevereexternal
temperaturesandthatthe
deviceisnotdamagedinany
way.Pleasenotethatthe
devicecanalsoheatupover
alongperiodofuse.
Whenworking,ensure
su󰀩cientlightingsothat
thecuttingprocessandthe
behaviorofthecuttingdevice
andcuttingmaterialisclearly
visible.
Beforetransportingthe
device,alwaysensurethatthe
accessoriesarepositionedin
suchawaythattheycannot
causeanaccident.
Alwayskeepthisinstruction
manualeasilyaccessibleat
theplaceofoperation.
Makesureallpartsremoved,
oilandliquidresidues,and
packagingmaterialsare
disposedofproperly!

8
3. Proper use
LUKAS“SC”combinationtoolsandLUKAS“S”cuttersaredesignedspecicallyforrescuing
andretrievingvictimsintra󰀩c,railorairaccidentsandforcarryingoutrescuesfrombuildings.
Theyareusedforfreeingpeopleinjuredinaccidentse.g.bycuttingdoors,roofbarsand
hinges.ByusingtheLUKAScombinationtools,trappedpersonscanalsobefreede.g.by
spreadingoutdoorsand/orbyremovingobstacleswiththeaidofachainset.Ingeneral,
thecombinationtoolcanbeusedtocut,pull,spread,squeezeandliftobjects.Ingeneral,
LUKAScutterscanonlybeusedtocutobjects.
Allobjectstobeworkedonmustbesecuredusingstablesupportsorsubstructures.
Sample applications of the combination tools:
Sample application of the cutters:

9
4. Functional description
You can obtain accessories and replacement parts for the rescue devices from your
authorizedLUKASdealer.
LUKAScuttersandcombinationtoolscanalsobeusedunderwateratadepthofupto40m
(131 ft).
ATTENTION!
Inthiscase,youmustpaystrictattentiontoanyleaksinordertopreventrisks
threateningtheenvironment.
WARNING / CAUTION!
Allobjectstobeworkedonmustbesecuredusingstablesupportsorsubstructures.
WARNING / CAUTION / ATTENTION!
Thefollowingmaynotbecut/squeezed:
- livecables
- preloaded and hardenedpartssuchassprings,springsteels,
  steeringcolumns,bodyworkreinforcements,hingesand
  xingbolts,e.g.forfasteningseatbelts
 - pipesundergasorliquidpressure,
 - compoundmaterials(steel/concrete)
 - explosivebodiessuchasairbagcartridges
NEVERoperatetherescueequipmentatahigheroperatingpressurethanthat
stated in the chapter “Technical data”.A higher setting can cause damage to
propertyand/orleadtoinjuries.
LUKASrescueequipmentmayonlybeusedinanareaatriskofexplosionifan
explosionhasbeenpreventedbyappropriatemeasures.Youmustalsotakeinto
accountthefactthatsparksmaybecreated,forexamplewhencuttinganobject.
When working in potentially explosive atmospheres, all applicable
legal, national and international regulations, standards and
safety rules for avoiding explosions must be observed without
restriction.
4.1 Description
Theequipmentisdesignedsuchthat,viaahydraulicallyactivatedpiston,twoequal,opposite
blade arms are symmetrically opened/closed by mechanical joints, thereby spreading,
squeezing,pullingorcuttingobjects.
Allcuttersandcombinationtoolsensureafullload-holdingfunctionwhendisconnectedfrom
thehydraulicsupply(e.g.whenunintentionallydecoupled,defectivehose,etc.).

10
 1 Stargrip
 2 Controlvalve
 3 Bodyofrescuedevice
 4 Handle
 5 Protectivehose/protectivecover
 6 Bladearm
 7 Pivotboltwithself-lockingnut
 8 Handhold
 9 Pressurehose
10 Returnhose
11 Mono-couplingnipple
12 Quick-disconnectcouplingnipple
13 Quick-disconnectcouplingsleeve
14 Kink-protection
Quick-disconnect coupling
system:
13
12
2
3
6
9
10
1
4
5
67
8
9
10 11
1
5
6
7
8
10
9
11
3
4.2 Equipment in detail
2
3
4
1
5
6
7
1
9
10 11
8
5
14
14
14

11
 1 Stargrip
 2 Controlvalve
 3 Bodyofrescuedevice
 4 Handle
 5 Protectivehose/protectivecover
 6 Bladearm
 7 Pivotboltwithself-lockingnut
 8 Handhold
 9 Pressurehose
10 Returnhose
11 Mono-couplingnipple
12 Quick-disconnectcouplingnipple
13 Quick-disconnectcouplingsleeve
14 Kink-protection
Quick-disconnect coupling
system:
13
12
2
3
4
5
6
7
1
9
10 11
8
14
2
3
4
5
6
7
1
9
10 11
8
14

12
4.3 Wiring diagram
Tofacilitatehowthesystemfunctions,asimpliedschematicdiagram(hydrauliccylinderof
therescueequipment(A)+handvalve(B))isshownhere.
AB
cutting/closing/
pulling/squeezing
spreading/
opening
4.4 Operating movement controls
Thepistonmovementiscontrolledbythestargripontheattachedvalve.
Stargrip
Fig.3
4.5 Hydraulic supply
OnlyLUKASmotorpumpsorhandpumpsmaybeusedtodrivetheequipment.
Ifthepumpismadebyadi󰀨erentmanufacturer,itmustbeensuredthatithasbeenmade
according to LUKAS’ specications, otherwise dangerous torques can result for which
LUKASisnotresponsible.Ensure inparticularthat the authorizedoperating pressure for
LUKASequipmentisnotexceeded.
NOTE:
Before using other pumps made by other manufacturers, you should contact
LUKASoranauthorizeddealer.
Thepumpunitandtherescuedeviceareconnectedbyhoses.
4.6 Hose lines

13
5. Connecting the device
5.1 General
Twoshorthosesarettedonthedeviceandconnectedtothepumpunitviaapairofhoses.
Allhoselinesareidentiedbycolorandttedwithcouplingstopreventanyconnectionerrors.
Nipple
(malecoupling)
Sleeve
(femalecoupling)
Dustcaps
The device is connected to the hydraulic pump via quick-disconnect coupling halves
(sleeveandnipple),whicheliminatesconfusion.
NOTE:
Thedevicescanbeequippedwithdi󰀨erentcouplingsystems.
Theydi󰀨eronlybyarticlenumberbutnotbydesignation.
Ofcourse,thecouplingsystemscanalsobemodiedatalaterstage.
5.2 Coupling the mono-couplings
WARNING / CAUTION / ATTENTION!
Priortoconnectingthe devices, ensurethat all the components being used
aresuitableforthe maximum operating pressure of the pump unit.Incaseof
doubt,youmust contact LUKASdirectly!
0
0
1

14
Before coupling, remove the dust caps, then connect the nipple and sleeve and turn
thelocking sleeveof thefemale couplingin direction“1” untilthe lockingsleeve latches.
Theconnectionisnowestablishedandsecured.Decouplingisaccomplishedbyturningthe
lockingsleeveindirection“0”.
The devices can also be coupled under pressure, provided that the connected work
equipmentisnotactivated.
NOTE:
We recommendconnectingthecouplinghalvesinadepressurisedstatewhen
working in low ambient temperatures, and using extension hose assemblies/
hose reels, as otherwise the coupling may require the application of a great
dealofforce.
Thedustcapssuppliedmustbereplacedtoprovideprotectionagainstdust.
WARNING / CAUTION / ATTENTION!
Themono-couplingsmust notbe screwed o󰀨the hoselines and/orthe hose
linesmustnotbeconfused.
Mounting the dust caps:
Thedustcaps“A”havetwointernalpins“B”.Thedustcapsmustbeplacedonthecoupling
nippleinsuchawaythatthepinsareguidedintothegrooves“C”.Screwthedustcapson
untilthelimitstopattachesthemtothecouplingnipple.
A
B
C

15
The device is connected to the hydraulic pump via quick-disconnect coupling halves
(sleeveandnipple),whicheliminateconfusion.
Beforecoupling,removedustprotectioncaps,thenpullbackandholdthelockingsleeve
ofthecouplingsleeve(positionX).Pushnippleandcouplingsleevetogetherandrelease
the locking sleeve. Finally, turn the locking sleeve to position Y. The connection is now
establishedandsecured.Uncouplingiscarriedoutinthereverseorder.
WARNING / CAUTION / ATTENTION!
Someofthequick-disconnectcouplingshavespecialfunctionsandmaytherefore
notbeunscrewedfromthehoselinesand/orinterchanged!
X
Y
Thedustcapssuppliedmustbereplacedtoprovideprotectionagainstdust.
NOTE:
Couplingthedevicesisonlypossibleifthehosesaredepressurized.
5.3 Coupling the plug couplings
ATTENTION!
Alwaysconnectthereturnlinerstandthenthesupplyline!
6.1 Preparatory measures
6. Operation
6.1.1 Commissioning
Beforeinitialoperationandafterrepairs,thedevicemustbebled:
 - Connectthedevicetothehydraulicpump(seechapter“Connectingthedevice”).
 - Completelyopenandclosethebladearmsoftheequipmentseveraltimeswithoutany
load(see“Operatingthestargrip”chapter).
NOTE:
We recommend that when bleeding the system, the attached power unit for
thehydraulicsupplyshouldstandonahigherlevelthanthebodyoftherescue
device.
Recommended procedure for bleeding the rescue device:
1.) Fullyopenandclose1xwiththebladearmsfacingupwards
2.) Fullyopenandclose1xwiththebladearmsfacingdownwards
3.) Fullyopenandclose1xwiththebladearmsfacingupwards
4.) Fullyopenandclose1xwiththebladearmsfacingdownwards

16
Opening the device ( ):
Turnthestargripinaclockwisedirection(inthedirectionofthe
relevantsymbol)andkeepinthisposition.
Closing the device ( ):
Turnthestargripinaclockwisedirection(inthedirectionofthe
relevantsymbol)andkeepinthisposition.
“Dead-man’s” function:
Followingrelease,thestargripautomaticallyreturnstothe
central/neutralposition,fullyguaranteeingretentionoftheload.
7. Cutting, spreading, pulling and squeezing
7.1 Safety instructions
Beforetherescueworkcancommence,thepositionoftheobjectinvolvedintheaccident
mustbestabilized.
Youmustensureanadequatesubstructureand/oradequatesupportfortheobject.
Worldwide safety guidelines pertaining to the specic country must be observed and
compliedwith.IntheFederalRepublicofGermany,regularsafetyinspectionsaccordingto
theregulations of theGesetzlichenUnfallversicherung(GUV;“Legalaccidentinsurance”)
aremandatory.
Inareasatriskofexplosion,theequipmentshouldonlybeusedifanexplosionhasbeen
preventedbyappropriatemeasures.
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
6.1.2 Inspecting the pump unit
   Seetheseparateoperatinginstructionsfortheappropriatepowerunit
   (orthehandpump).
NOTE:
Before starting up the hydraulic unit each time, make sure that the actuating
valvesaresettodepressurizedcirculation.
NOTE:
Before coupling the quick-disconnect couplings, the actuating valves of the
pumppowerunitmustbesettodepressurizedcirculation.
Ifyouusemono-couplings,youcanalsocouplewhenthehosesarepressurized.
6.2 Operating the star grip

17
Reaching between the blade arms is strictly forbidden!
WARNING / CAUTION!
Theparticularforceactionoftherescueequipmentduringoperationcouldcause
piecesofthevehicletobreako󰀨oryo󰀨,posingadangertopersons.Therefore,
thosenotinvolvedintherescueoperationshouldkeep at a distance appropriate
to the situation.Personsandpatientswithintherescueequipment’soperational
rangemustbeprotectedbyplacingashatterguardorsuitablealternativedevice
betweentheworkingareaandtheperson.
7.2 Cutting
Beforeoperatingtherescuedevice,youmustensurethatnoparticipantsorbystandersare
atriskfromthemovementsoftherescuedeviceorfromyingfragments.Avoidunnecessary
damagetopropertybelongingtoothersortoobjectsnotinvolvedintherescueordamage
causedbyyingfragments.
Thebladesshouldbepositionedata90°angletotheobjecttobecut,ifpossible.
RIGHT
WRONG
12
93
15°
15°
90°
Highercuttingcapacitiescanbeachievedbycuttingascloseaspossibletotheblade’spivot
point.
RIGHT
WRONG
WARNING / CAUTION / ATTENTION!
If the cutter twists to the side at an angle of 15° during the cutting process,
thecutmustbere-positioned,otherwisethetransverseloadonthebladewillbe
toohighandthiscoulddamagethedevice,particularlytheblades.

18
During cutting, the gap between the blade tips (in the transverse direction) must not be
exceeded,otherwisethebladeisindangerofbreaking:
ATTENTION!
Avoid cutting particularly high-strength parts of the vehicle’s bodywork
(e.g.side-impactprotection):thisalmostalwayscausesdamagetothecutter/
combinationtool.
Cutting with SC 358 and SC 758
ThespreadingtipcanberemovedfromtheSC358andSC758.Thispreventstheobject
tobecutfromgettingstuckbetweenthespreadertips,hinderingthecuttingprocess.
Cutter/combination tool max. gap at the blade tips
[mm] / [in.]
S 120 2/ 0.08
S 312
3/ 0.12
S 377
S 378
S 700
SC 358
SC 557
SC 758
S 788
5/ 0.20S 789
S 799
3.
2.
1.
A

19
Removing the tip
Step 1:
Toremovethespreadertips,rstpushoutbolt“A”alittle,withyourngeroranobject.
Afairamountofforceneedstobeappliedinitially,asthebolthasaballcatchtopreventit
fromfallingoutunintentionally.
Step 2:
Theboltcanthenbegrippedbytheangeandpulledoutuptothelimitstop.Thelimitstop
willpreventtheboltfrombeingpulledoutentirely.Thismeansthatitcannotbelost.
Step 3:
Pullthespreadertipforwardstoremoveit.
Attaching the spreader tip:
Attachmentofthespreadertiptakesplaceinthereversesequence.
Ensurethattheboltisalwayscompletelypushedinandengages.Ifthebolthas
notengaged,thismayresultinthetipinadvertentlycomingloosewhileinuse.
Thisinturncouldresultindamagetotherescueequipment.Therescuedevice
couldalsosliporpartscouldbeungo󰀨,resultingininjuriestoboththeoperator
andthecrashvictim.
Caremustalsobetakenthattheboltdoesnotinadvertentlycomeloosewhile
thedeviceisinuse.

20
Whencarryingoutspreadingandliftingwork,makesurethatthetipsareforce-ttedacross
theirfullwidth(seegurebelow).
Otherwisethereisariskthatthepartswilljumpaway.
7.3 Spreading (combination tools only)
Only use the front area of the tips to increase the gap. Full spreading capacity can be
achievedwhenapproximatelyhalfofthegroovedareaofthetipsisused.Thegreatestforce
iscreatedintherearareaofthespreadingrangeofthecombinationblade.
Workingsurfaceistoosmall,
tipsslipo󰀨.
Onlyforincreasingthesize
ofagap(notsuitablefor
spreading)
Tipsgetasafegrip.