Lukas KSV11 User manual

Traction device operating instructions
84150913085 EN
Chain sets
(Original operating instructions)
replaces 01.2020
Edition 11.2020
KSV11, KSV13,
KSV13/100
KSV8/50, KSV8/258
KSS20

2
Content Page
1. Dangerclassications 3
2. Productsafety 4
3. Properuse 6
4. Functionaldescription 8
4.1 Design and attachment of KSV11, KSV13, KSV13/100 8
4.2 Design and attachment of KSV8/50 and KSV8/258 11
4.3 Operation of traction devices KSV11, KSV13, KSV13/100, KSV8/50,
KSV8/258 12
4.4 Design, attachment and operation of KSS20 13
5. Maintenanceandservice 15
5.1 Visual inspection of traction devices 15
6. Tractiondeviceusageinstructions 17
7. Individualcomponentsfromtractiondevicesforreplacementrequirements 19
8. Notes 19

3
 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

4
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 instructions in this instruction manual, all generally applicable,
statutoryandotherbindingnationalandinternationalaccidentpreventionregulationsmust
beobservedandoperatorsmustbeinstructedaccordingly!
Thetractiondevicemayonlybeoperatedbypersonswhohavebeentrainedintherelevant
safetyregulations–otherwise,thereisariskofinjury.
We advise all users to read the operating instructions carefully before using the traction
deviceandtofollowthedirectionscontainedthereinwithoutrestriction.
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!
Makesurethatnobodypartsor
clothinggetcaughtbetweenthe
partsofthetractiondevice.
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safety
gloves.
Checkthetractiondevice
forvisibleawsordamage
beforeandafteruse.

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Immediatelyreportanychanges
thatoccur
(includingchangesinoperating
behavior)totheappropriate
persons/departments!Switcho󰀨
thetractiondeviceimmediately
ifnecessaryandsecure.
Whenworkingnearlive
componentsandcables,
suitableprecautionsmust
betakentoavoidcurrent
transfersorhigh-voltage
ashoverstothetraction
device.
Switcho󰀨thetractiondevice
intheeventofmalfunctions
andsecureit.Repairthe
faultimmediately(orhaveit
repaired).
Donotmakeanychanges
(additionsorconversions)
tothetractiondevice
withoutobtainingthe
approvalofLUKAS.
Observeallsafetyanddanger
informationonthetraction
deviceandintheoperating
instructions.
Allsafetyanddanger
informationonthetraction
devicemustbecomplete
andinalegiblecondition.
Safetydevicesmustneverbe
disabled!
OnlygenuineLUKAS
accessoriesandspareparts
aretobeusedforrepairs.
Beforeusingthetractiondevice,
makesurethatnobodyis
endangered.
Observeallintervals
forrecurringtestsand/
orinspectionsthatare
prescribedorstatedinthe
instructionmanual.
Makesurethatthereis
adequatelightingwhileworking.
Beforetransportingthe
tractiondevice,always
checkthattheaccessories
havebeenpositionedin
suchawaythattheycannot
causeanaccident.
Alwayskeeptheseoperating
instructionswithineasyreach
attheplaceofusenearthe
tractiondevice.
Disposeofalldisassembled
partsaswellaspackaging
materialsproperly.

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3. Proper use
LUKAStractiondevicesarespeciallydesignedforusewithLUKASspreadersandcombi
tools.
LUKAScombitoolsandspreadersmayonlybeoperatedinconjunctionwiththerespectively
approved traction devices(seeoperatinginstructionsfortherescueequipmentortablein
point6Tractiondeviceusageinstructions).
Thetractiondevicesmayonlybeusedtopull,forexample,forpullingawayobstaclesor
enlargingopeningstofreetrappedpeople.
Use as a lifting aid during hoisting is not permitted.
In addition to the safety instructions in this instruction manual, 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!
WARNING / CAUTION!
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 / ATTENTION!
• Onlyusefaultless,testedtractiondevices.
• Beforeandduringuseofthetractiondevice,itmustbeensuredthatnooneis
endangeredbytheactualuseofthetractiondevice.Thisespeciallyincludes
theriskofmechanicalfailure(e.g.pullingortearingo󰀨)ofthetractiondevice,
orthetractionchainslippingo󰀨theobjecttobepulled.
• Thechainsmaynotbeshortenedbytheformationofknots.
• Chainlinksmaynotbeboundtogetherwithwireorheldtogetherwithscrews
• Hooksmustnotbehookedbytheirtipintoachainlink.
• Hooksmaynotbeloadedattheirtips.
• Chainsmaynolongerbeusedafterbreakageordeformationofachainlink.
• Itisprohibitedtopullchainsunderloadoversharpedges.
• Chainslyingonthegroundmustnotberolledoverbyaload.
WARNING / CAUTION / ATTENTION!
Whentractiondevicesareusedinpotentiallyexplosiveatmospheres,makesure
that:
 - anexplosioncannotbetriggeredbythetractiondevice.
 - workingwiththetractiondevicecannotcauseanexplosion,e.g.sparkscan
beproduced.
Theresponsibilityforthepreventionofexplosionsorforprohibitingworkwitha
tractiondevicelieswiththeoperatorofthedeviceorwiththepersonresponsible
atitsplaceofuse.
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!
Thetractiondeviceshouldnotcomeintocontactwithacids oralkalis.Ifthisis
unavoidable,cleantheequipmentimmediatelyafterwardswithasuitablecleaning
agent.

8
3
86
7
2
5
4
1
99
4
5
3
2
8
10
11
4. Functional description
4.1 Design and attachment of KSV11, KSV13, KSV13/100
1 Spreadertip
2 Connector
3 Loadbolt
4 Shorteninghookofthe
connector
5 Tractionchainoftheconnector
6 Shorteninghookofthetractionchain
7 Tractionchain
8 Keyring
9 Locationholefortractiondevice
10 Clampingsleeveforspreadertip
11 Lockingboltforspreadertip

9
Attaching the traction device to the LUKAS spreader or combi tool
(excluding SC 358 , SC 757 E2 and SC 758)
1. Completelyopenthearmsofthespreaderorofthecombitool.
2. Pullouttheloadbolt(3)onthekeyring(8)uptothestop.
3. Pushtheconnector(2)overthespreadertip(1)asillustrated.
4. Completelyinserttheloadbolt(3)intothelocationhole(9)providedforthepurposein
thespreadertip(1)untilitengages.
WARNING / CAUTION / ATTENTION!
Oncertainspreaders,thespreadertipisattachedtotherescueequipmentarm
withaclampingsleeve(10).
Under no circumstances may the traction devices be xed in the hole of the
clamping sleeve. Failure to observe this can lead to overloading the traction
deviceorthespreader.
Attaching the traction device to the LUKAS SC 358, SC 757 E2 and SC 758
TobeabletoattachthetractiondevicetotheSC358,SC757E2andSC758,thespreader
tipmustrstberemoved.
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.
3.
2.
1.
A

10
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 pulling attachment to the SC 358, SC 757 E2 and SC 758
Todoso,startbypullingouttheboltofthetractionattachmentuntilitreachestheend
stop,pushthetractionattachmentontothearmandinserttheboltallthewayagainuntilit
clicksintoplace.
Thecorrespondingchainlock“C”canthenbexedinhole“B”ofthetractionattachment.
SC 757 E2
SC 358 and SC 758
2.
1.
A
C
B
2.
1. AC
B

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3
4
7
8
6
4.2 Design and attachment of KSV8/50 and KSV8/258
3 Connector
4 Lockingboltoftheconnector
6 Shorteninghookoftheconnector
7 Tractionchain
8 Shorteninghookofthetractionchain
Attaching the traction device to the traction attachment of the combi tool
1. Completelyopenthearmsofthecombitool.
2. Pullouttheloadbolt(3)onthekeyring(8)uptothestop.
3. Pushtheconnector(2)overthetractionattachment.
4. Completelyinserttheloadbolt(3)intothelocationholeprovidedforthepurposeinthe
tractionattachmentuntilitengages.

12
4.3 Operation of traction devices KSV11, KSV13, KSV13/100,
KSV8/50, KSV8/258
1. Attachthetractiondeviceasdescribedunderpoint4.2.
2. Completelyopentherescuedevice.
3. Loop the traction chains around the pulling point or fastening point, and push the
shorteninghooksoverachainlink.Whiledoingso,makesurethatthetractionchainis
astautaspossibleontheobjectandcannotslip.
4. Hookthechainintotheshorteninghookoftheconnector.Pullthetractionchainastight
aspossible.
5. Beforetheactualtractionprocess,checkthechainsoncemoreforasecurehold.
6. Topull,closethespreaderorthecombitool.Whenpulling,alwaysmakesurethatthe
tractionchainisnotdeectedbyobstacles.
7. Ifthepullingdistanceisinsu󰀩cient,itmustrstbesecuredwithtensionchainsorother
means.Onlythenopenthespreaderandproceedaccordingtopoints4and5.
Attaching the traction device to the LUKAS spreader or combi tool
1. Completelyopenthearmsofthespreaderorofthecombitool.
2. Completelypressdownthereleasebutton(5)ontheconnector(3)(directionA).
3. Keepthereleasebutton(5)helddownandpushtheconnector(3)overthetip(1)ofthe
combiarmasshowninthepicture(directionB).
4. Letgoofthereleasebutton(5)andmakesurethatthelockingboltoftheconnector(4)
engagesintotheattachmenthole(2)ofthecombitoolarm.
5. Makesurethattheconnector(4)iscorrectlyengagedbypullingitbyhand.
6. Toremovethe connector(4) presstherelease button(5) downagain and pullo󰀨 the
connector.
1 Armtipofthecombitool
2 Attachmentholeforthe
tractiondevice
3 Connector
5 Releasebuttonofthe
connector
6 Shorteninghookofthe
connector
5
1
6
B
A
3
2

13
2.1
1
4
B
A
2.3
2.5
2.4 2.6
2.2
2.1
2
1 Spreadertip
2.1 Releasebutton
2.3 Insertionopening
2.4 Retaininglug
2.5 Throughduct
2.6 Holdingslot
4.4 Design, attachment and operation of KSS20
3
2 Connector
2.1 Releasebutton
2.2 Lockingbolt
3 Tractionchain
4 Chainhooks

14
Attaching the KSS20 traction device
1. Completelyopenthespreaderarms.
2. Pressthereleasebuttons(2.1)onbothsides(directionA).
3. Withthereleasebuttons(2.1)pressed,pushtheconnector(2)ontothespreadertip(1)
asillustratedintheimage(directionB).
4. Letgoofreleasebuttons(2.1)andmakesurethatthelockingbolts(2.2)oftheconnector
(2)securelyengageintothelocationholeofthespreadertip(1).
5. Makesurethattheconnector(2)iscorrectlyengagedbypullingitbyhand.
Operating the traction device
1. Placethetractionchainaroundthetractionpointorattachmentpointandformaloop
aroundthetractionpointbyhookinginthehook.
2. Pulltheendofthechainthroughtheconnector.Todoso,rstpull(directionC)theendof
thechainbyhandthroughtheinsertionopening(2.3).Keepthechainastautaspossible
whiledoingso.
3. Pushachainlinkthroughtheduct(2.5)aroundtheretaininglug(2.4)intotheholding
slot(2.6)(directionD).Unintentionallooseningofthechainispreventedbytheretaining
lug(2.4).
4. Beforetheactualtractionprocess,checkthechainsoncemoreforasecurehold.
5. Topull,closethespreaderorthecombitool.Whenpulling,alwaysmakesurethatthe
tractionchainisnotdeectedbyobstacles.
6. Ifthepullingdistanceisinsu󰀩cient,itmustrstbesecuredwithtensionchainsorother
means.Onlythenopenthespreaderandproceedaccordingtopoints1and2.
C D

15
5.1 Visual inspection of traction devices
5. Maintenance and service
ATTENTION!
Among other things, chains must no longer be used if at least one link has
beenelongatedby5%ormoreoriftheoriginalthicknessofachainlinkhas
decreasedbymorethan5%atanypoint.
Ensurethatthefollowingconditionsaremet:
1. Novisibledamagetothechainlinks(nodeformations,cracksorsignsofwear,nosurface
damagecausedbyusingabrasivemediaand/orcorrosion).
2. Connectionsforconnectingtotherescueequipmentarepresentandinperfectcondition.
ATTENTION!
Tractiondevicesmayneverbetestedunderloadorevenwhenoverloaded.
Traction devices are subject to extremely high mechanical loads. For this reason,
avisualinspectionmustbecarriedoutaftereachuse,butatleastonceeverysixmonths.
Theseinspectionsenabletheearlydetectionofwearandtear,whichmeansthatpunctual
replacementofthesewearingpartspreventsbreakage.
ATTENTION!
Cleanthetractiondevicebeforecheckingforcontamination.
WARNING / CAUTION / ATTENTION!
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.

16
3 Hooksforattaching the loadstobe movedarepresent, rmlyattachedandin perfect
condition.
4. Locksonthehooks(providedthattheycorrespondtothemanufacturer'sconditionon
delivery)arepresentandinperfectcondition.
5. Itmustbepossible tomoveaccessory shoes,shacklesandlocking pinswithminimal
e󰀨ort.
Chain set Target diameter [mm] /
target length of chain link [mm]
KSV8/50 8/24
KSV8/258
KSV11 10/30
KSS20
KSV13 13/39
KSV13/100

17
Chain set Order no. Bolt diameter Use Note Permitted load
on chain set *
KSV8/50 81-67-10 SC250E2
50kN
SC357
SC357E2
LKS35EN
LKE55
KSV8/258 81-67-11 SC258eWXT
35kN
SC258E2
KSV11 81-67-20 SP300E2
62kN
SP300
SP310E2
SP310
SP333eWXT
SP333E2
SP333
SP555eWXT
SP555E2
SP 555
SP777eWXT
SP777E2
SP777
SP 510
LSP60EN
LSP40EN
SC358eWXT onlyin
conjunction
withtraction
attachment
81-67-21
SC358E2
SC358
*)Theactualloaddependsontherescueequipmentused.
6. Traction device usage instructions
ATTENTION!
Thetractiondevicesmayonlybeusedfortheequipmentlistedinthetable.

18
Chain set Order no. Bolt diameter Use Note Permitted load
on chain set *
KSS20 81-67-40 SP300E2 onlypermitted
withmulti-
functiontip
64kN
SP310E2 onlypermitted
withmulti-
functiontip
SP300 onlypermitted
withmulti-
functiontip
SP310 onlypermitted
withmulti-
functiontip
LSP40EN
LSP40B
LSP100
KSV13 81-67-30 12mm SC757E2 onlyin
conjunction
withtraction
attachment
393R029
98kN
SC758eWXT onlyin
conjunction
withtraction
attachment
81-67-32
SC758E2
SC758
SC557
LSP100
KSV13/100 81-67-31 16mm SP512
98kN
SP80EN
*)Theactualloaddependsontherescueequipmentused.

19
Designation Item no. Traction chain
2.2 m
Connection
chain /
chain lock
Set of cotter
pins
permitted
load
KSV8 841509122 V84150912215 V841506245 45kN
KSV8/50 81-67-10 50kN
KSV8/258 81-67-11 V84150912217 173023150S 35kN
KSV11 81-67-20 HR149330018 HR149330044 V84150912703 62kN
KSV11/80 841509131 HR149330043 80kN
KSV13 81-67-30 HR149330030 HR149330035 V84150912703 98kN
KSV13/100 81-67-31 V84150912910 V84150912902
KSS20 81-67-40 V84150912610 64kN
7. Individual components from traction devices for
replacement requirements
8. Notes

LUKAS Hydraulik GmbH
A unit of the IDEX Corporation
Weinstrasse 39,D-91058 Erlangen, Germany
Tel.: [phone] / 698 - 0
Fax.: [phone] / 698 - 394
email: [email protected]
www.lukas.com
Made in GERMANY
© Copyright 2020 LUKAS Hydraulik GmbHZugvorrichtungen_84150913085_EN.indd
Subject to change
Please duly dispose of all packaging materials
and removed items.