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.

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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