Lukas S 700 E2 User manual

172022085 EN
replaces 09.2017
Edition 01.2018
Instruction manual for rescue equipment
eDRAULIC cutters
(Translation of the original instruction manual)
S 700 E2
S 788 E2
S 312 E2
S 377 E2

2
Content Page
1. Dangerclassications 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 12
4.4 Operating movement controls 12
5. Operation 12
5.1 Battery or power supply for eDRAULIC device 12
5.2 Operating the star grip 13
6. Cutting 14
6.1 Safety notes 14
6.2 Cutting 15
7. Dismantlingtheequipment/deactivationfollowingoperation 16
8. Maintenanceandservice 17
8.1 Oil change 17
8.2 Overview of eDRAULIC cutting tools 18
8.3 Protective equipment 19
 8.4 Checkingthelterinthebatteryshaft 19
9. Repairs 20
9.1 General information 20
9.2 Preventive service 21
9.3 Repairs 21

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10.Troubleshooting 26
11.Technicaldata 28
11.1 eDRAULIC cutter 29
 11.2 Noiseemission(basedonstandardENISO3744) 31
11.3 Operating and storage temperature ranges 31
 11.4 Oscillation/vibration 31
 11.5 Torquesforcentralbolts 31
11.6 Cutting performance 32
11.7 Datasheets for the product performance 33
12.ECDeclarationofConformity 37
13.Accessories 38
13.1 Batteries 38
13.2 Battery charger 39
13.3 Power supply 39
14.Instructionsregardingdisposal 40
Content Page

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 Wearahelmetwithafaceguard.
 Wearprotectivegloves.
 Wearsafetyshoes
 Properrecycling
 Protecttheenvironment
 Readandfollowtheoperatinginstructions.
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
equipment,
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operatinginstructionsareintendedtohelpyouuseLUKASproductssafely.
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.
The equipment may only be operated by persons with appropriate training in the safety
aspectsofsuchequipment,otherwise,thereisariskofinjury.
Wewouldliketopointouttoallusersthattheyshouldcarefullyreadtheoperatinginstructions
andtheinstructionstheycontainbeforetheyusetheequipmentandcarefullyfollowthem.
Wefurtherrecommendthatyouhaveaqualiedtrainershowyouhowtousetheproduct.
WARNING / CAUTION!
Theoperatinginstructionsforaccessoriesmustalsobetakenintoaccount!
Evenifyouhavealreadyreceivedinstructionsonhowtousetheequipment,youshouldstill
readthroughthefollowingsafetyinstructionsagain.
WARNING / CAUTION!
Pleaseensurethattheaccessoriesyouuseareappropriateforthemaximum
operatingpressureandtheperformanceoftherescuedevice!
Pleaseensurethatnobody
partsorclothingarecaught
betweenthevisiblymoving
parts(e.g.bladearms).
Workingundersuspended
loadsisnotpermittedwhere
suchloadsarebeinglifted
onlybymeansofhydraulic
orelectro-hydraulicdevices.
Ifthisworkisunavoidable,
suitablemechanicalsupports
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.

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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!
Allboltedconnectionsmust
becheckedforleaksand
externallyvisibledamage,
whichmustberepaired
immediately!Escaping
hydraulicuidcancause
injuriesandres.
Intheeventofmalfunction,
immediatelydeactivatethe
deviceandsecureit.Repair
thefaultimmediately.
Donotcarryoutanychanges
(additionsorconversions)
totheequipmentwithout
obtainingthepriorapprovalof
LUKAS.
Observeallsafetyanddanger
informationonthedeviceand
intheoperatinginstructions.
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!
Repairstotheequipment
mayonlybecarriedoutby
atrainedservicetechnician
withspecicknowledgeofthe
device.
Safetydevicesmayneverbe
disabled!
OnlygenuineLUKAS
accessoriesandspareparts
aretobeusedforrepairs.
Beforeswitchingon/starting
upthedeviceandduringits
operation,makesurethat
nobodywillbeendangered
bythis.
Observeallintervals
forrecurringtestsand/
orinspectionsthatare
prescribedorstatedinthe
operatinginstructions.
Whenworkingclosetolive
componentsandcables,
suitablemeasuresmust
betakentoavoidcurrent
transfersorhigh-voltage
transferstotheequipment.
Pleasenotethatmaterial
couldfalldownorsuddenly
breakfreeduringcuttingasa
resultofshearing,tearingor
breaking;appropriatesteps
mustbetakentoavoidthis.

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Theequipment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equipment,ensurethat
thefunctionandthesafety
oftheequipmentarenot
impairedbythee󰀨ectsof
severeexternaltemperatures
andthattheequipmentisnot
damagedinanyway.Please
notethattheequipmentcan
alsoheatupoveralong
periodofuse.
Makesurethatthereis
adequatelightingwhile
working.
Beforetransportingthe
equipment,alwaysensure
thattheaccessoriesare
positionedinsuchaway
thattheycannotcausean
accident.
Alwayskeeptheseoperating
instructionseasilyaccessible
attheplaceofoperation.
Ensuretheproperdisposalof
allremovedparts,left-overoil
andhydraulicuidaswellas
packagingmaterials!
TheeDRAULICdeviceshave
anIP54protectionclass.
Theyaresuitableforusein
wetweatherconditionsand
aresplashproof.
TheeDRAULICdevicesare
notsuitableforunderwater
use.
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short-
circuited.
Thebuild-upofstaticcharges
andtherefore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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3. Proper 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cuttingdevicesareusedtofreeinjuredpersonsataccident
scenesbycuttingthroughdoors,roofbeamsandhinges.
LUKASeDRAULICdevicesareNOTsuitableforunderwateruse.
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 / ATTENTION!
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.
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 operating instructions and compliance with the
inspectionandmaintenanceconditions.
Never work in a fatigued or intoxicated state!
CAUTION / PLEASE NOTE!
Caremustalwaysbetakenthattheenvironmentoftheobjecttobeprocessed
remainsstableandsecuredagainstunintentionalshiftingbyusingstrongsupports
orunderpinning.

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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.
LUKASeDRAULICdevicesarenotexplosion-protected!
When using the devices in potentially explosive environment, the following
mustbeexcluded:
 - thatthedevicecouldtriggeranexplosion.
 - thatworkingwiththedevicecouldtriggeranexplosion;e.g.sparksmayresult
fromcuttinganobject.
TheresponsibilityforexplosionpreventionorforrulingoutworkwithaneDRAULIC
devicewiththeoperatorofthedeviceorwiththepersonresponsibleattheplace
ofuse.
When working in areas at risk of explosion, all applicable legal,
national and international regulations, standards and safety rules
for avoiding explosions must be observed without restriction!
Therescueequipmentshouldnotcomeintocontactwithacidsoralkalies.Ifthis
is unavoidable, clean the equipment immediately afterwards with a suitable
cleaningagent.
You can obtain accessories and replacement parts for the rescue devices from your
authorizedLUKASdealer!

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4. Functional description
4.1 Description
Thecutting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.
Foralldevices,themovementisactivatedbymeansofavalveintheformofastargrip.
Alldevicesguaranteethedeadman'sswitchandthefullload-supportingfunctionwhenthe
stargripisreleased.
LUKASeDRAULICdevicesdonotneedtobeconnectedtoanexternalhydraulicsource
(e.g.amotorpump).Generationoftherequiredhydraulicpressuretakesplacewithinthe
bodyofthedevice.
Eitherabatteryoranexternalpowersupplymustbeconnectedasanenergysource.
Youcanchoosewhichenergysourceyouwishtouse.Boththeaccumulatorbatteryand
themainspowerunitcanbeinsertedintotheopeningprovidedinthebodyofthetool.
Theyarethenautomaticallylockedintoposition.
YoucanextendtheoperatingtimeofyoureDRAULICdevicebyusingseveralbatteries.
Thebatteriescanberechargedafteruse,usingasuitableexternalcharger.
Ifyouaremakinguseofanexternalpowersupply,thedevicecanbeusedforanalmost
unlimitedtime.Thistimeisonlylimitedbytheexternalenergysourceandtheoverheating
switchofthepowersupply.
ToallowyoutoselectthebestpossibleenergysupplyforyoureDRAULICdevice,neither
thebatterynorthepowersupplyformpartofthedeliveryscope.Youwillndsuitablebat-
teriesandpowersuppliesintheLUKASaccessorieslist.
eDRAULICdevicescomewithstandardlightttingstofacilitateworkunderpoorlight
conditions.
Thelight-emittingdiodesattachedontheoperatingsidelightuptheworkarea.The
mainswitchhasalsobeenequippedwitharinglight,sothatyoucanimmediatelydetect
whetherthedeviceisswitchedonornot.Whenexchangingthebatteryorpowersupply,
theconnectionslotwilllightupforapproximately30seconds.

11
2
3
4
5
6
7
8
9
1
11
12
10
2
3
4
5
6
7
8
9
1
11
12
10
4.2 Structure of rescue devices
 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housing
10 Toolbody
11 Protectivecover
12 Light
S 700 E2
S 788 E2
S 312 E2
S 377 E2

12
4.4 Operating movement controls
Thepistonmovementiscontrolledbythestargripontheattachedvalve(seeillustrationbelow).
Stargrip
5.1 Battery or power supply for eDRAULIC device
5. Operation
Commissioning
Beforeinitialoperation,thebattery(whereused)oftherescuedevicemustbefullyloaded,
usingtheexternalcharger.
4.3 Hydraulic circuit diagram
AB
cutting
opening
Belowasimpliedhydraulicramrepresentingthetoolisdepicted.
A=toolB=stargripvalve

13
Procedure:
 1. Unplugthepowersupply(whereused)fromthemains.
 2. Fullypressdownthetwounlockingbuttonsandcarefullypullthebatteryorpower
supplyoutofthedevice.
Do not use force!
 3. Thebatterycannowberechargedinthecharger(pleasetakenoteoftheseparate
operatinginstructionsforthechargerandthebatteriestobeused);alternatively,the
powersupplycanbereplaced.
 4. InserttherechargedornewbatteryintotheeDRAULICdeviceuntilitreachesthe
stop.Thebatteryorpowersupplywillbeautomaticallylockedwhencorrectlyoper-
ated.
Connectionslot
Open the device ( ):
Turnthestargripinthedirectionofthecorrespondingsymbol
(open)andholditinthisposition.
Close the device ( ):
Turnthestargripinthedirectionofthecorrespondingsymbol
(close)andholditinthisposition.
"Dead-man’s" function:
Followingrelease,thestargripautomaticallyreturnstothe
centralposition,fullyguaranteeingloadretention.
5.2 Operating the star grip
(alsoseechapteron"Operatingmovementcontrol")

14
6. Cutting
6.1 Safety notes
Before rescue work can commence, the object must be stabilized in its current position.
Ensurethattheobjectstobeworkedonareadequatelyunderpinnedand/orsupportedto
ensurethatthereisnoriskofslidingorshifting.
Worldwide safety guidelines pertaining to the specic country must be observed and
compliedwith.
WARNING / CAUTION / PLEASE NOTE!
LUKASeDRAULICdevicesarenotexplosion-protected!
Whenusingthedevicesinpotentiallyexplosiveenvironments,the following
mustbeexcluded:
 - thatthedevicecouldtriggeranexplosion.
 - thatworkingwiththedevicecouldtriggeranexplosion;e.g.sparksmayresult
fromcuttinganobject.
TheresponsibilityforexplosionpreventionorforrulingoutworkwithaneDRAULIC
devicelieswiththeoperatorofthedeviceorwiththepersonresponsibleatthe
placeofuse.
When working in areas at risk of explosion, all applicable legal,
national and international regulations, standards and safety rules
for avoiding explosions must be observed without restriction!
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yingfragments!Avoidunnecessary
damagetopropertybelongingtoothersortoobjectsnotinvolvedintherescueordamage
causedbyyingfragments.
Note on the operation of the eDRAULIC with a rechargeable battery:
IftherechargeablebatteryremainsintheeDRAULICdevicewiththemainswitchon,but
withoutactivatingthestargrip,therechargeablebatterywillswitchitselfo󰀨aftersometime
(approximately10-60minutes,dependingonthetypeofbattery).Ifthestargripisthen
activated,theeDRAULICdevicewillnotswitchitselfon.
Inordertoresumeworkwiththedevice,theeDRAULICdevicemustrstbeswitchedo󰀨at
themainsandthenswitchedonagain.
Alternatively,thecapacitydisplayontherechargeablebatterycanbeactivatedorthebattery
maybebrieyunpluggedandrepluggedagain.

15
It is strictly prohibited to reach into the path of the
rescue device (e.g. between the blade arms and the
material/object to which the force is to be applied)!
CAUTION / PLEASE NOTE!
The strong e󰀨ect of the force of the rescue equipment during operation could
causepiecesofthe vehicle to breako󰀨oryo󰀨,posingadangerto persons.
Those not involved in the rescue operation should therefore keep at a safe
distance appropriate to the situation.Any trapped or enclosedpersons must
beprotected.
6.2 Cutting
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

16
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!
Wherepossible,avoidcuttingthroughhigh-strengthpartsofthevehiclebody
(e.g. side impact protection). This may result in damage to the blades or to
increasedwearandtear!
eDRAULICcuttingdevice max.gapatthebladetips
[mm] / [in.]
S 312 E2 3 / 0.12
S 377 E2 3 / 0.12
S 700 E2 3 / 0.12
S 788 E2 5/ 0.20
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.Thisrelievesthehydraulicandmechanicalstrainontheequipment.
Clean the rescue device after each operation and grease both the metallic and the
mechanicallymovableparts.
Greasingprovidesprotectionagainstexcessivewearandtearorcorrosion.
Avoidstoringtherescueequipmentinadampenvironment.
NOTE:
NeverstoretheeDRAULICdeviceswithfullyclosedarms!Byfullyclosingthe
armshydraulicandmechanicaltensionmaydevelopinthedevice.

17
8. Maintenance and service
Thedevicesaresubjecttoveryhighmechanicalstresses.Avisualinspectionmusttherefore
becarriedoutaftereveryuseandatleastonevisualinspectionmustbecarriedoutevery
sixmonths.Theseinspectionsenabletheearlydetectionofwearandtear,whichmeansthat
punctualreplacementofthesewearingpartspreventsbreakage.Regularlycheckthetorque
ofthepivotboltonthecuttingtools.(Youwillndthetorquesforthepivotboltinthechapter
on"TechnicalData".)
Anannualinspectionofthetoolisdueonceayear.Thisinspectionmustbeperformedby
apersonwiththenecessaryexpertise.Thismeansthatthepersonmustpossessadequate
specialistknowledgeandexperienceintheeldsofelectricalengineeringandhydraulics,so
thattheycanobjectivelyassesstheconditionofthetool.
Everythreeyearsalsoacracktestofthebladesareessential.Thereforeaspecialcrack
testingkitisisavailable.
A function test is also to be carried out every three years or should there be any doubt
regardingthesafetyorreliabilityoftheequipment.
(Pleasealsoobservetherelevantvalidnationalandinternationalregulationspertainingto
serviceintervalsofrescueequipment).IntheFederalRepublicofGermany,regularsafety
inspections according to the regulations of the Gesetzlichen Unfallversicherung (GUV;
connoted‘Legalaccidentinsurance’)aremandatory.
ATTENTION!
Cleano󰀨anydirtbeforecheckingtheequipment!
WARNING / CAUTION / PLEASE NOTE!
Toperformmaintenance andrepairs,personalsafety equipmentappropriate
fortheworkisamandatoryrequirement.
Themaintenanceandrepairsta󰀨musthaveadequatetechnicalandspecialized
knowledge.LUKASo󰀨ersappropriatetrainingcoursesforthis.
8.1 Oil change
Under normal working conditions routine oil changes are not necessary with eDRAULIC
tools.
Theprerequisiteisthat:
• thetoolsarealwaysproperlyhandledandstowedaspertheapplicableoperatingmanual
• thetoolsaretestedonaregularbasisasperourinstructionsonpreventivemaintenance
• after10yearsservicelifeanoilchangeisrecommended
Regular tests, oil change and/or repairs must be carried out by repair and maintenance
personnelthatistrainedandauthorizedbythemanufacturer.

18
Inspections to be carried out:
Visual Inspection
Cutting 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").
• Bladearmsfreeofcracksandnicksordeformationsonthecuttingsurfaces,
• Cuttingsurfacestontopofeachotherwithoutmakingcontact,
• Theslidingplates,boltsandretainingringsofthebladearmsareinplaceandingood
condition,
• Illuminationofmainswitch,workareaandconnectionshaftfullyfunctional.
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ofstargripcontrols,
• Nounusualnoises
• No further movement of cutter arms when interrupting the valve function during the
process(deadman'sswitch).
8.2 Overview of eDRAULIC cutting tools

19
8.3 Protective equipment
Inspections to be carried out:
• Checktheprotectiveequipmentusedon/inthevicinityoftherescuedevice.Payparticular
attentiontotheprotectivecoverforthemovableparts(theremaybenocracks!).
Theairsuctionlteristobecheckedatleastonceayearorafteruseinadustyenvironment.
Theltercan be checked from theoutsideifthe mains unit (orbattery)isremoved (see
illustrationsbelow).
Ifthelterisseverelycontaminated,itwillneedtobereplaced.
Procedure:
1. Tilttherespectivedeviceasshownintheillustration.
2.Removethebatteryorthepowersupply.
3.Removetheltergridbyactivatingthereleasehook.
4.Replacethedirtylterelementswithnewlterelements.
8.4 Checking the lter in the battery shaft
Releasehook

20
ATTENTION!
Whencleaningunitsandequipment,notethatnocleaningagentmaybeused
thathasapHvalueoutsidetherange5-8!
9.1 General information
9. Repairs
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").
During assembly, ensure that all components are particularly clean, as dirt can
damage the rescue equipment!
WARNING / CAUTION / PLEASE NOTE!
Protective clothes must be worn when repairs are being carried out, as the
devicesmayalsobepressurizedwhennotinoperation.
ATTENTION!
Because LUKAS rescue devices are designed for highest performance, only
componentsspeciedinthesparepartslistfortheappropriateequipmentmay
bereplaced.
Othercomponentsinthedevicemayonlybereplacedif:
- YouhaveparticipatedinanappropriateLUKASservicetrainingcourse.
- You have been explicitly granted permission by LUKAS Customer Service
(validLUKAScerticaterequired!)
NOTE:
AlwaysregisteryourtoolontheLUKASJawsofLifeinternetsite.Thisistheonly
waytoguaranteeextendedwarrantycover.