Lukas SP 333 User manual

171081085 EN
Spreaders
(Translation of the original instruction manual)
Instruction manual for rescue equipment
Edition 03.2023
replaces 08.2019
SP 333
SP 555
SP 777

2
Content Page
1. Hazard classes 4
2. Product safety 5
3. Proper use 8
4. Description of the functions 9
4.1 Description 9
4.2 Unit in detail 10
4.3 Circuit diagram 11
4.4 Control of the operating movements 11
4.5 Hydraulic supply 11
4.6 Hoses 11
5. Connecting the equipment 12
5.1 General information 12
5.2 Coupling the mono-couplings 12
6. Operation 14
6.1 Preparatory measures 14
6.2 Operating the star grip 14
7. Spreading, pulling, squeezing and peeling 15
7.1 Safety notes 15
7.2 Spreading 16
7.3 Pulling 17
7.4 Squeezing 18
7.5 Peeling 19
8. Dismantling the equipment / deactivation following operation 20
9. Maintenance and service 20
8.1 Spreader 20
8.2 Hydraulic unit 20
8.3 Hoses 20
9.1 Spreader, overall 21
9.2 Protective equipment 21

3
10. Repairs 22
10.1 General information 22
10.2 Preventative service 22
10.3 Repairs 23
11. Troubleshooting 31
12. Technical data 33
12.1 Peeling 36
 12.2 Recommendedhydraulicuid 36
12.3 Operating and storage temperature ranges 36
12.4 Oscillation / vibration 36
13. Declaration of conformity 37
14. Notes 39
Content Page

4
1. Hazard classes
Wear helmet with face protection
Wear safety gloves
Wear safety shoes
Proper recycling
Observe principles of environmental protection
Read and observe operating instructions
We distinguish between various categories of safety notes. The table below gives you an
overview of the assignment of symbols (pictograms) and key words to the specic hazard
and possible consequences.
Pictogram Damage /
injury to Key word Denition Consequences
human
DANGER! Immediate danger Death or major
injury
WARNING!
Potentially
dangerous
situation
Potential death or
major injury
CAUTION! Less dangerous
situation
Minor or slight
injury
device
CAUTION!
Danger of damage
to device /
environment
Damage to the
equipment,
damage to the
environment,
damage to
surrounding
materials
- REMARK
Advice for
application and
other important /
useful information
and advice
No injury /
damage to
persons /
environment /
equipment

5
2. Product safety
LUKAS products are developed and manufactured in order 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 help 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 implemented 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 danger of injury occurring.
We would like to point out to all users that they should read carefully the operating instructions
and the instructions contained therein before they use the equipment, and that they should
carefully follow such.
We further recommend that a qualied trainer train you in the use of the product.
WARNING / CAUTION!
The operating instructions for the hoses, the accessories and the connected
hydraulic equipment must also be observed!
Even if you have already received instructions on how to use the equipment, you should still
read the following safety notes through again.
WARNING / CAUTION!
Ensure that the accessories and connected equipment used are suitable for
the max. operating pressure!
Please ensure that no body
parts or clothing get stuck
between the visibly moving
parts (e.g. spreader arms).
It is prohibited to work under
load if this load is lifted
exclusively by hydraulic
equipment. If this work
is absolutely imperative,
additional mechanical
supports must be used.
Wear protective clothing,
safety helmet with visor,
protective gloves
Inspect the equipment before
and after use for visible
defects or damage
The responsible department
is to be informed immediately
of any changes (including to
the operating behaviour)! If
necessary, the equipment is
to be deactivated immediately
and secured!
Inspect all cables, hoses
and screwed connections for
leaks and externally visible
damage! If necessary, repair
immediately! Squirting oil can
result in injuries and res.

6
In the event of malfunctions,
immediately deactivate the
equipment and secure it. The
malfunction is to be repaired
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
notes on the equipment and
in the operating instructions.
All safety and danger notes
on the equipment are to be
kept complete in a legible
condition.
Any mode of operation which
impairs safety and/or stability
of the equipment is forbidden!
Comply with all specied
dates or dates specied in
the operating instructions
pertaining to regular controls /
inspections on the equipment.
Safety devices may never be
deactivated!
The maximum permitted
operating pressure noted on
the equipment must not be
exceeded.
Before the equipment is
switched on/started up, and
during its operation, it must
be ensured that nobody is
endangered by the operation
of the equipment.
Only original LUKAS
accessories and spare parts
may be used for repairs.
Please ensure that, when
working with this equipment
or during transportation of
such, you don’t get stuck in
the looped hoses and trip.
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, when
spreading, tearing or breaking
can cause falling material, or
sudden removal of such can
cause it to suddenly catapult
o󰀨: necessary precautions
need to be taken.
The build-up of static
charge with the potential
consequence of spark
formation is to be avoided
when handling the equipment.
Only touch any broken-o󰀨
parts wearing protective
gloves, since the torn edges
can be very sharp.

7
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!
The equipment is to be used exclusively for the purpose stated in the operating
instructions (see chapter “Proper Use”). Any other or further use is not considered
proper use. The manufacturer / supplier is not liable for any damages resulting from improper
use. The user bears sole responsibility for such.
Observance of the operating instructions and compliance with the inspection and maintenance
conditions are part of the proper use.
Never work when you are overtired or intoxicated!
The equipment is lled
with a hydraulic uid.
These hydraulic uids 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 e󰀨ect on
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
stark external temperatures
or that the equipment is
damaged in any way. Please
note that the equipment can
also heat up over a long
period of use.
Ensure adequate lighting
when you are working.
Before transporting the
equipment, always ensure
that the accessories are
positioned such that they
cannot cause an accident.
Always keep these operating
instructions within reach
where the equipment is used.
Ensure the proper disposal
of all removed parts, left-over
oil, left-over hydraulic uid
and packaging materials!

8
3. Proper use
LUKAS spreaders and combi tools can also be used under water at a depth of up to 40m
(131 ft).
CAUTION!
In this case, you must strictly observe any leaks in order to avoid threats to the
environment.
CAUTION!
All objects which are to be worked on are to be secured using stable supports or
substructures.
g. 1 g. 2
LUKAS spreaders are designed especially for rescue services. They are used to release
persons trapped as a result of a road accident e.g. by forcing open the car doors (see
below Fig. 1) or by squashing other parts of the vehicle. In other catastrophic situations they
are used to lift (by spreading) or to displace objects in order to rescue buried or trapped
persons, e.g. by concrete components in collapsed houses (see below Fig. 2), and to squash
constructional components, e.g. pipes.
In principle, objects can be pulled, spread, squashed or compressed in length.
All objects to be worked on are to be secured using stable supports or substructures.
When lifting loads, additional risks to the operator and/or persons not involved may be
posed if the load moves in an uncontrolled manner or if the spreader slips or tips over.
When applying the tool and lifting, make sure that there is no danger, if necessary by using
additional supports or safety devices.

9
WARNING / CAUTION!
The following may not be squeezed:
- live cables
- hardened parts such as springs, spring steels, steering columns
and rollers
- explosive bodies such as airbag cartouches
NEVER operate the rescue equipment at a higher operating pressure than that
stated in the chapter “Technical data”. A higher setting can result in material
damage and/or injuries.
LUKAS rescue equipment may only be used in areas at risk of explosion if an
explosion has been prevented by appropriate measures You must also take into
account that sparks may be created, for example by spreading or squashing an
object.
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 limitation!
Spare parts and accessories for the rescue tool can be ordered from your authorisied
LUKAS-dealer!
4. Description of the functions
4.1 Description
The equipment is designed such that, via a hydraulically activated piston, two equal, opposite
spreader arms are symmetrically opened by mechanical joints, thereby spreading objects.
Closing the spreader arms is also carried out hydraulically and mechanically by reverse
order of the piston.
All spreaders ensure full load-holding function when disconnected from the hydraulic supply
(e. g. when being unintentional decoupled; defective hose, and so on).

10
4.2 Unit in detail
1
2
3
4
5
7
6
9
10
11
7
8
4
5
6
SP 555
SP 777
13
12
13
14
SP 333 1
2
3
4
5
7
6
9
10
11
7
8
4
5
6
13
12
13
14
15
1 Star grip
2 Spreader body
3 Handle
4 Protective cover
5 Spreading arm
6 Tip with borehole for chain set
7 Roll pin
8 Pressure hose
9 Return hose
10 Handhold
11 Mono-coupling male
12 Squeezing device
13 Protective plate for spreader arm
14 Yoke cover
15 Kink-protection

11
4.3 Circuit diagram
4.4 Control of the operating movements
4.5 Hydraulic supply
4.6 Hoses
AB
spreading
pulling /
squeezing
star grip
g. 3
To enable comprehension of the function, a simplied hydraulic cylinder of the rescue
equipment (A) + hand valve (B) are depicted here.
The spreading arms movement is controlled via the star grip of the mounted valve.
(see cover, item 1 and, below, gure 3).
A LUKAS motor pump or hand pump only may be used to drive the equipment.
If the pump unit is a di󰀨erent make, you must make sure that it complies with LUKAS
specications, otherwise potential dangers may occur which are not the responsibility of
LUKAS.
Ensure in particular that the authorised operating pressure for LUKAS equipment is not
exceeded.
REMARK:
Before you use pumps from a di󰀨erent manufacturer, you must contact LUKAS
or an authorised dealer.
The pump unit and the rescue tool are connected by hoses.

12
0
0
1
5.1 General information
5. Connecting the equipment
5.2 Coupling the mono-couplings
The equipment is connected to the hydraulic pump via mono-coupling halves (male and
female).
There are two short hoses on the side of the equipment: they are connected to the pump unit
via two hoses. All hose assemblies are marked with a colour and have couplings to enable
unmistakable connection.
dust protection caps
WARNING / CAUTION!
Before connecting the equipment you have to pay attention that all
used components are suitable to the max operation pressure of
the pump unit! In the case of doubt you have to inquire LUKAS
directly!
mono-coupling
halve (female)
mono-coupling
halve (male)

13
Before coupling, remove dust protection caps, then connect male and female, and turn
the locking sleeve of the female to direction „1“ until the locking sleeve locks into place.
The connection is now in place and secure. Decoupling is by turning the locking sleeve to
direction „0“.
The equipment can also be coupled under pressure provided the connected equipment is
not activated.
REMARK:
We recommend coupling the coupling halves in a pressureless state, when
working in areas with low ambient temperature and the usage of extension hose
assemblies / hose reels, otherwise decoupling could need very high expenditure
of force.
To protect them from dust, the accompanying dust protection caps must be put back on.
WARNING/CAUTION!
The mono-couplings may not be screwed o󰀨 the hose assemblies and / or the
hose assemblies be confused!
Using the dust protection caps:
The “A” dust protection caps have two internal pins “B”. The dust protection caps must be
placed on the coupling pins in such a way that the pins are guided into the “C” grooves.
Fasten the screw up to the limit stop to x the dust protection caps on the coupling pins.
A
B
C

14
6.1 Preparatory measures
6. Operation
6.2 Operating the star grip
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 an counterclockwise 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 position, guaranteeing the full load-holding.
REMARK:
We recommend that during the deaeration, the attached aggregate for the
hydraulic supply should stand on a higher level than the body of the rescue
tool.
Recommended procedure for the deaeration of the rescue tool:
1.) open and close fully with the spreader arms facing upwards.
2.) open and close fully with the spreader arms facing downwards.
3.) open and close fully with the spreader arms facing upwards.
4.) open and close fully with the spreader arms facing downwards.
6.1.1Commissioning
Before commissioning and following repairs, the equipment must be deaerated.
- Connect the equipment to the hydraulic pump (see chapter “Connecting the
equipment”).
- Open / close the spreader arms of the equipment without any load at least twice (see
chapter “Operation of the star grip”).
6.1.2Inspection of the pump unit
See separate operating instructions for the relevant unit (or for the hand pump).
REMARK:
Before each start-up of the hydraulic unit you have to make sure that the actuating
valves are set to depressurized circulation.
REMARK:
If you use mono-couplings, you can also couple when the hoses are pressurized!

15
7.1 Safety notes
7. Spreading, pulling, squeezing and peeling
Before rescue works can commence, the position of the obstacle must be stabilised. You
must ensure an adequate substructure and / or adequate support of the object. World-wide,
safety guidelines pertaining to the specic country are to be observed and complied with.
In the Federal Republic of Germany, regular safety inspections according to the regulations
of the Gesetzliche Unfallversicherung (GUV; connoted ‘Legal accident insurance’) are
mandatory.
In the event of a potentially explosive situation, it is not permitted to use motor pumps (danger
of the formation of sparks). In such cases, hand pumps are to be used.
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 activating the rescue equipment, always ensure that there is no danger to persons
either involved / uninvolved in the action by the movement of the rescue equipment or by
ying fragments. Further avoid unnecessary damage to property belonging to others, objects
not involved by the rescue equipment / ying fragments.
Reaching between the spreader arms is strictly forbidden!
WARNING / CAUTION!
The particular 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 distance
appropriate to the situation.

16
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. Only work with the tips,
so that the spreader
is not damaged in the
area of the light metal
arms.
7.2 Spreading
Use the front area of the tips for increasing the gap only. 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 tip (refer to images to follow).
WARNING / CAUTION!
The light metal alloy spreader arms may not be damaged.
The spreaders have additional exchangeable plates to protect the arms against physical
damage.
Spreading Increasing a gap
approx 25 mm
approx. 1 in
Spreading is only allowed up to this point.

17
7.3 Pulling
- LUKAS chain sets are to be used for pulling purposes.
- Before the pulling process can be performed, ensure that the bolt and hook t correctly to
prevent the chain from slipping.
- Only chain sets in perfect condition may be used.
- The pull chains are to be inspected at least once per year by an expert.
- See separate operating instructions for the relevant chain set!
Mounting bore for
chain set
WARNING / CAUTION!
The light metal alloy spreader arms may not be damaged.
AThe connecting pieces for LUKAS chain
sets are fastened to the blades using
load bolts in holes "A". (see illustration
on the right)
Permissible chain sets:
for SP 333: KSV 11
for SP 555: KSV 11
for SP 777: KSV 11
NOTE:
Also take note of all the instructions and regulations in the separately provided
operating instructions for the chain sets.

18
7.4 Squeezing
Squeezing
Squeezing is allowed
- In the area of the tips.
- With the special squeezing plates „A“ in the arms.
A

19
7.5 Peeling
It is possible to peel sheet steel with the optional peeling tips of the spreader (max. panel
thickness t, see chapter “Technical Data”).
The spreader tip must be replaced with the peeling tip “A”, see 10.3.1 Tip changing.
A
WARNING / CAUTION!
With particularly hard materials, chips may break out in an uncontrolled manner.
Please maintain the safety distance!

20
9. Maintenance and service
The equipment is subject to very high mechanical stresses. A visual inspection is to be
carried out after every use: however, at least one visual inspection is to be carried out
annually. These inspections enable the early detection of wear and tear, which means that
punctual replacement of this wearing parts prevents breakages from occurring. 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.
CAUTION!
Clean o󰀨 any dirt before controlling the equipment!
WARNING / CAUTION!
In order to carry out maintenance and repair works, tools appropriate for the job
and personal protecting equipment are essential.
8. Dismantling the equipment / deactivation following
operation
8.1 Spreader
8.2 Hydraulic unit
8.3 Hoses
Once work has been completed, the spreader arms are to be closed so that there is a
tip distance of just a few mm. This relieves the hydraulic and mechanical strain on the
equipment.
Upon completion of work, the unit must be deactivated.
First of all, decouple the pressure hose then the return hose as described in chapter
“Connecting the equipment”. Ensure that you put the dust protection caps back on to the
couplings.