instruction manual for rescue equipment edraulic combi tools · sc 258 e2. 2. content page. 1....

273023085 EN

(Translation of the original instruction manual)

replaces 07.2017Edition 01.2018

Instruction manual for rescue equipment

eDRAULIC combi tools

SC 358 E2 SC 757 E2

SC 258 E2

2

Content Page1. Dangerclassifications 42. Productsafety 53. Intendeduse 84. Functionaldescription 10 4.1 Description 10 4.2 Structure of rescue devices 11 4.3 Hydraulic circuit diagram 12 4.4 Operating movement controls 125. Operation 12 5.1 Battery or power supply for eDRAULIC device 12 5.2 Operating the star grip 136. Cutting,spreading,pulling,squeezing 14 6.1 Safety notes 14 6.2 Cutting 15 6.3 Spreading 17 6.4 Pulling 19 6.5 Squeezing 237. Dismantlingtheequipment/deactivationfollowingoperation 248. Maintenanceandservice 24 8.1 Oil change 25 8.2 eDRAULIC combination tools 25 8.3 Protective equipment 26 8.4 Checkingthefilterinthebatteryshaft 269. Repairs 27 9.1 General information 27 9.2 Preventive service 28 9.3 Repairs 28

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10.Troubleshooting 3211.Technicaldata 34 11.1 eDRAULIC combination device 35 11.1 eDRAULIC combination device 36 11.2 Noise emission (based on standard EN ISO 3744) 37 11.3 Operating and storage temperature ranges 37 11.4 Oscillation / vibration 37 11.5 Torques for central bolts 37 11.6 Cutting performance 38 11.7 Datasheets for the product performance 3912.ECDeclarationofconformity 4213.Accessories 43 13.1 Batteries 43 13.2 Battery charger 44 13.3 Power supply 44 13.4 Chain sets 4514.Instructionsregardingdisposal 4515.Notes 46

Content Page

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Wearahelmetwithafaceguard.

Wearprotectivegloves.

Wearsafetyshoes

Properrecycling

Protecttheenvironment

Readandfollowtheoperatinginstructions.

Wedifferentiatebetweenvariousdifferentcategoriesofsafetyinstructions.Thetableshownbelowprovidesanoverviewoftheassignmentofsymbols(pictograms)andsignalwordstothespecificdangerandthepossibleconsequences.

1. Danger classifications

Pictogram Damage / injury to Keyword Definition Consequences

Persons

DANGER! Immediatedanger Deathorsevereinjury

WARNING!Potentiallydangeroussituation

Potentialdeathorseriousinjury

CAUTION! Lessdangeroussituation

Minororslightinjury

Property

ATTENTION!Riskofdamagetoproperty/environment

Damagetotheequipment,

damagetotheenvironment,damagetosurroundings

- NOTE

Handlingtipsandotherimportant/usefulinformation

andadvice

Noinjury/damagetopersons/environment/

device

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2. Product safetyLUKAS products are developed andmanufactured to ensure the best performance andqualitywhenusedasintended.Thesafetyoftheoperatoristhemostimportantconsiderationinproductdesign.Furthermore,theoperatinginstructionsareintendedtohelpyouuseLUKASproductssafely.Thegenerallyapplicablelegalandotherbindingregulationspertainingtothepreventionofaccidentsandprotectionoftheenvironmentapplyandaretobecompliedwithinadditiontotheoperatinginstructions.The equipmentmay only be operated by personswith appropriate training in the safetyaspectsofsuchequipment,otherwise,thereisariskofinjury.Wewouldliketopointouttoallusersthattheyshouldcarefullyreadtheoperatinginstructionsandtheinstructionstheycontainbeforetheyusetheequipmentandcarefullyfollowthem.Wefurtherrecommendthatyouhaveaqualifiedtrainershowyouhowtousetheproduct.

WARNING / CAUTION!Theoperatinginstructionsforaccessoriesmustalsobetakenintoaccount!

Evenifyouhavealreadyreceivedinstructionsonhowtousetheequipment,youshouldstillreadthroughthefollowingsafetyinstructionsagain.

WARNING / CAUTION!Pleaseensurethattheaccessoriesyouuseareappropriateforthemaximumoperatingpressureandtheperformanceoftherescuedevice!

Pleaseensurethatnobodypartsorclothingarecaughtbetweenthevisiblymovingparts(e.g.bladearms).

Workingundersuspendedloadsisnotpermittedwheresuchloadsarebeingliftedonlybymeansofhydraulicorelectro-hydraulicdevices.Ifthisworkisunavoidable,suitablemechanicalsupportsarealsorequired.

Wearprotectiveclothing,asafetyhelmetwithvisor,protectivefootwearandgloves.

Inspectthedevicebeforeandafteruseforvisibledefectsordamage.

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Immediatelyreportanychangesthatoccur(includingchangesinoperatingbehavior)totheappropriatepersons/departments!Ifnecessary,theequipmentistobeshutdownimmediatelyandsecured!

Allboltedconnectionsmustbecheckedforleaksandexternallyvisibledamage,whichmustberepairedimmediately!Escapinghydraulicfluidcancauseinjuriesandfires.

Intheeventofmalfunction,immediatelydeactivatethedeviceandsecureit.Repairthefaultimmediately.

Donotcarryoutanychanges(additionsorconversions)totheequipmentwithoutobtainingthepriorapprovalofLUKAS.

Observeallsafetyanddangerinformationonthedeviceandintheoperatinginstructions.

Allsafetyanddangerinstructionsonthedevicemustalwaysbecompleteandinalegiblecondition.

Anymodeofoperationwhichcompromisesthesafetyand/orstabilityofthedeviceisforbidden!

Repairstotheequipmentmayonlybecarriedoutbyatrainedservicetechnicianwithspecificknowledgeofthedevice.

Safetydevicesmayneverbedisabled!

OnlygenuineLUKASaccessoriesandsparepartsaretobeusedforrepairs.

Beforeswitchingon/startingupthedeviceandduringitsoperation,makesurethatnobodywillbeendangeredbythis.

Observeallintervalsforrecurringtestsand/orinspectionsthatareprescribedorstatedintheoperatinginstructions.

Whenworkingclosetolivecomponentsandcables,suitablemeasuresmustbetakentoavoidcurrenttransfersorhigh-voltagetransferstotheequipment.

Pleasenotethatmaterialcouldfalldownorsuddenlybreakfreeduringspreading,cutting,squeezingoperationsasaresultofshearing,tearingorbreaking;appropriatestepsmustbetakentoavoidthis.

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Theequipmentisfilledwithhydraulicfluid.Thishydraulicfluidcanbedetrimentaltohealthifitisswallowedoritsvaporisinhaled.Directcontactwiththeskinmustbeavoidedforthesamereason.Also,whenhandlinghydraulicfluid,notethatitcannegativelyaffectbiologicalsystems.

Whenworkingwithorstoringtheequipment,ensurethatthefunctionandthesafetyoftheequipmentarenotimpairedbytheeffectsofsevereexternaltemperaturesandthattheequipmentisnotdamagedinanyway.Pleasenotethattheequipmentcanalsoheatupoveralongperiodofuse.

Makesurethatthereisadequatelightingwhileworking.

Beforetransportingtheequipment,alwaysensurethattheaccessoriesarepositionedinsuchawaythattheycannotcauseanaccident.

Alwayskeeptheseoperatinginstructionseasilyaccessibleattheplaceofoperation.

Ensuretheproperdisposalofallremovedparts,left-overoilandhydraulicfluidaswellaspackagingmaterials!

TheeDRAULICdeviceshaveanIP54protectionclass.Theyaresuitableforuseinwetweatherconditionsandaresplashproof.

TheeDRAULICdevicesarenotsuitableforunderwateruse.

Pleaseensurethatyoudonotbecomeentangledincablesandtripwhenworkingwithortransportingthedevice.

Pleaseensurethatthebatterycontactsarenotshort-circuited.

Thebuild-upofstaticchargesandthereforepossiblesparkingmustbeavoidedwhenhandlingthedevice.

Onlytouchbroken-offorcut-offpartswhilewearingprotectivegloves,asthetorn/cutedgescanbeverysharp.

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3. Intended useLUKASeDRAULICdeviceshavebeenspeciallydesignedtorescueorretrievethebodiesofvictimsofroad,railoraircraftaccidentsortobeusedduringrescueoperationsfrombuildings.LUKASeDRAULICcombinationdevicesareusedtofreeinjuredpersonsataccidentscenesbycuttingthroughdoors,roofbeamsandhinges.LUKASeDRAULICcombinationdevicescan also be used to free personswhohave become trapped by pushing open doors orremovingobstacleswiththeaidofachainset.

LUKASeDRAULICdevicesareNOTsuitableforunderwateruse.

The generally applicable, legal and other binding national and international regulationspertainingtothepreventionofaccidentsandprotectionoftheenvironmentapplyandaretobeimplementedinadditiontotheoperatinginstructions.

WARNING / CAUTION / ATTENTION!Thedeviceisintendedexclusively forthepurposestatedintheoperatinginstructions(seechapter"ProperUse").Any other use is not in accordance with its designated purpose. Themanufacturer/supplierisnotliableforanydamageresultingfromimproperuse.Theuserbearssoleresponsibilityforsuchuse.Proper use includes observance of the operating instructions and compliance with theinspectionandmaintenanceconditions.

Never work in a fatigued or intoxicated state!

CAUTION / PLEASE NOTE!Caremustalwaysbetakenthattheenvironmentoftheobjecttobeprocessedremainsstableandsecuredagainstunintentionalshiftingbyusingstrongsupportsorunderpinning.

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WARNING / CAUTION / PLEASE NOTE!Thefollowingmaynotbecut/squeezed: - live cables - prestressed and hardened parts such as springs, spring steels, steeringcolumnsandrollers - pipesundergasorliquidpressure, - compoundmaterials(steel/concrete) - explosivebodiessuchasairbagcartridges

Theoperatingpressureplacedontherescuedevicemayonlybedirectlychangedafter consultationwith LUKAS.A change in settingsmay result in damage topropertyand/orinjuries.

LUKASeDRAULICdevicesarenotexplosion-protected!Whenusing thedevices in potentially explosiveenvironment, the following mustbeexcluded: - thatthedevicecouldtriggeranexplosion. - thatworkingwiththedevicecouldtriggeranexplosion;e.g.sparksmayresult

fromcuttinganobject.TheresponsibilityforexplosionpreventionorforrulingoutworkwithaneDRAULICdevicewiththeoperatorofthedeviceorwiththepersonresponsibleattheplaceofuse.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!

Therescueequipmentshouldnotcomeintocontactwithacidsoralkalies.Ifthisis unavoidable, clean the equipment immediately afterwards with a suitablecleaningagent.

You can obtain accessories and replacement parts for the rescue devices from yourauthorizedLUKASdealer!

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4. Functional description 4.1 DescriptionThecombinationdeviceshavebeendesignedinsuchawaythatahydraulicallyoperatedpistonactivatesmechanicaljointssymmetricallytoopenorcloseasetoftwooppositebladearms,thusenablingobjectstobecut.

Foralldevices,themovementisactivatedbymeansofavalveintheformofastargrip.Alldevicesguaranteethedeadman'sswitchandthefullload-supportingfunctionwhenthestargripisreleased.

LUKASeDRAULICdevicesdonotneedtobeconnectedtoanexternalhydraulicsource(e.g.amotorpump).Generationoftherequiredhydraulicpressuretakesplacewithinthebodyofthedevice.Eitherabatteryoranexternalpowersupplymustbeconnectedasanenergysource.Youcanchoosewhichenergysourceyouwishtouse.Boththeaccumulatorbatteryandthemainspowerunitcanbeinsertedintotheopeningprovidedinthebodyofthetool.Theyarethenautomaticallylockedintoposition.YoucanextendtheoperatingtimeofyoureDRAULICdevicebyusingseveralbatteries.Thebatteriescanberechargedafteruse,usingasuitableexternalcharger.Ifyouaremakinguseofanexternalpowersupply,thedevicecanbeusedforanalmostunlimitedtime.Thistimeisonlylimitedbytheexternalenergysourceandtheoverheatingswitchofthepowersupply.ToallowyoutoselectthebestpossibleenergysupplyforyoureDRAULICdevice,neitherthebatterynorthepowersupplyformpartofthedeliveryscope.Youwillfindsuitablebat-teriesandpowersuppliesintheLUKASaccessorieslist.

eDRAULICdevicescomewithstandardlightfittingstofacilitateworkunderpoorlightconditions.Thelight-emittingdiodesattachedontheoperatingsidelightuptheworkarea.Themainswitchhasalsobeenequippedwitharinglight,sothatyoucanimmediatelydetectwhetherthedeviceisswitchedonornot.Whenexchangingthebatteryorpowersupply,theconnectionslotwilllightupforapproximately30seconds.

11

13

4.2.1 Combination tool

13 Exchangeabletipat-tachments

4.2 Structure of rescue devices

11 SC 358 E2 SC 757 E2

9

12

11

123

45

6

7

8

10

SC 258 E2

1 Stargrip 2 Mainswitch 3 Quickexchangebattery

orpowersupply 4 Releasebuttonforbat-

teryandpowersupply 5 Handle 6 Ventilationslots 7 Bladearms 8 Pivotboltwithsecured

nut 9 Plastichousing10 Toolbody11 Protectivecover12 Light

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4.4 Operating movement controlsThepistonmovementiscontrolledbythestargripontheattachedvalve(seeillustrationbelow).

Stargrip

5.1 Battery or power supply for eDRAULIC device5. Operation

CommissioningBeforeinitialoperation,thebattery(whereused)oftherescuedevicemustbefullyloaded,usingtheexternalcharger.

4.3 Hydraulic circuit diagram

A B

cutting/gripping/pulling/squeezing

spreading/opening

Belowasimplifiedhydraulicramrepresentingthetoolisdepicted.A=toolB=stargripvalve

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Procedure: 1. Unplugthepowersupply(whereused)fromthemains. 2. Fullypressdownthetwounlockingbuttonsandcarefullypullthebatteryorpower

supplyoutofthedevice. Do not use force!

3. Thebatterycannowberechargedinthecharger(pleasetakenoteoftheseparateoperatinginstructionsforthechargerandthebatteriestobeused);alternatively,thepowersupplycanbereplaced.

4. InserttherechargedornewbatteryintotheeDRAULICdeviceuntilitreachesthestop.Thebatteryorpowersupplywillbeautomaticallylockedwhencorrectlyoper-ated.

Connectionslot

Open the device ( ):

Turnthestargripinthedirectionofthecorrespondingsymbol(open)andholditinthisposition.

Close the device ( ):

Turnthestargripinthedirectionofthecorrespondingsymbol(close)andholditinthisposition.

"Dead-man’s" function: Followingrelease,thestargripautomaticallyreturnstothecentralposition,fullyguaranteeingloadretention.

5.2 Operating the star grip (alsoseechapteron"Operatingmovementcontrol")

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6. Cutting, spreading, pulling, squeezing 6.1 Safety notesBefore rescuework cancommence, theobjectmustbe stabilized in its current position.Ensurethattheobjectstobeworkedonareadequatelyunderpinnedand/orsupportedtoensurethatthereisnoriskofslidingorshifting.Worldwide safety guidelines pertaining to the specific country must be observed andcompliedwith.

WARNING / CAUTION / PLEASE NOTE!LUKASeDRAULICdevicesarenotexplosion-protected!Whenusingthedevicesinpotentiallyexplosiveenvironments,the following mustbeexcluded: - thatthedevicecouldtriggeranexplosion. - thatworkingwiththedevicecouldtriggeranexplosion;e.g.sparksmayresult

fromcuttinganobject.TheresponsibilityforexplosionpreventionorforrulingoutworkwithaneDRAULICdevicelieswiththeoperatorofthedeviceorwiththepersonresponsibleattheplaceofuse.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!

Thefollowingaretobewornwhenworkingwiththerescueequipment:- protectiveclothing,- safetyhelmetwithvisororprotectivegoggles,- protectivegloves,- and,ifnecessary,earprotection.

Beforeoperatingtherescuedevice,youshouldensurethatnoparticipantsorbystandersareatriskfromthemovementsoftherescuedeviceorfromflyingfragments!Avoidunnecessarydamagetopropertybelongingtoothersortoobjectsnotinvolvedintherescueordamagecausedbyflyingfragments.

Note on the operation of the eDRAULIC with a rechargeable battery:IftherechargeablebatteryremainsintheeDRAULICdevicewiththemainswitchon,butwithoutactivatingthestargrip,therechargeablebatterywillswitchitselfoffaftersometime(approximately10-60minutes,dependingonthetypeofbattery). If thestargrip isthenactivated,theeDRAULICdevicewillnotswitchitselfon.Inordertoresumeworkwiththedevice,theeDRAULICdevicemustfirstbeswitchedoffatthemainsandthenswitchedonagain.Alternatively,thecapacitydisplayontherechargeablebatterycanbeactivatedorthebatterymaybebrieflyunpluggedandrepluggedagain.

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It is strictly prohibited to reach into the path of the rescue device (e.g. between the blades and the material/object to which the force is to be applied)!

CAUTION / PLEASE NOTE!Thestrongeffect of the forceof the rescueequipment duringoperation couldcausepiecesof thevehicle tobreakofforflyoff,posingadanger topersons.Those not involved in the rescue operation should therefore keep at a safe distance appropriate to thesituation.Any trappedorenclosedpersonsmustbeprotected.

6.2 CuttingThebladesshouldbepositionedata90°angletotheobjecttobecut,ifpossible.

RIGHT

WRONG

12

9 3

15° 15°

90°

Highercuttingcapacitiescanbeachievedbycuttingascloseaspossibletotheblade’spivotpoint.

RIGHT

WRONG

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During cutting, the gap between the blade tips (in the transverse direction)must not beexceeded,otherwisethebladeisindangerofbreaking:

ATTENTION!Wherepossible,avoidcuttingthroughhigh-strengthpartsofthevehiclebody(e.g.side impactprotection).Thismay result indamage to thebladesor toincreasedwearandtear!

eDRAULIC cutting device max. gap at the blade tips[mm] / [in.]

SC 258 E2 3 / 0.12SC 358 E2 3 / 0.12SC 757 E2 3 / 0.12

Cutting with SC 358 E2 and SC 757 E2

ThespreadertipoftheSC757E2canberemoved.Thispreventsthematerialfrombe-comingstuckbetweenthespreadertips,hinderingthecuttingprocess.

Removing the spreader tip

Step 1: Toremovethespreadertips,firstpushoutbolt“A”alittle,usingafingeroranobject.Afairamountofforceneedstobeappliedinitially,asthebolthasaballcatchtopreventitfromfallingoutunintentionally.

3.

2.

1.

A

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6.3 SpreadingUsethefrontofthetipsonlytoincreaseanexistinggap.Toincreasegripandtoavoidhavingthetipssliporbreakoutoftheparttobeprocessed,thegripshouldbereappliedatanearlystage.Thehighestforcedevelopsintherearareaoftheplug-ontiporintherearspreadingareaofthecombinationblades.

WARNING / CAUTION / PLEASE NOTE! The light metal alloy arms may not be damaged.

Spreading Enlargingagap

approx25mmapprox. 1 in

Step 2: Theboltcanthenbegrippedbytheflangeandpulledoutuptothelimitstop.Thelimitstopwillpreventtheboltfrombeingpulledoutentirely.Thismeansthatitcannotbelost.

Step 3: Pullthespreadertipforwardstoremoveit.

Attaching the spreader tip:

Attachmentofthespreadertiptakesplaceinthereversesequence.

Ensurethattheboltisalwayscompletelypushedinandengages.Ifthebolthasnotengaged,thismayresultinthetipinadvertentlycomingloosewhileinuse.Thisinturncouldresultindamagetotherescueequipment.Therescuedevicecouldalsosliporpartscouldbeflungoff,resultingininjuriestoboththeoperatorandthecrashvictim.

Caremustalsobetakenthattheboltdoesnotinadvertentlycomeloosewhilethedeviceisinuse.

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Workingsurfaceistoosmall,tipsslipoff.

Onlyforincreasingthesizeofagap(notsuitablefor

spreading)

Tipsgetasafegrip. Workwiththetipsonly.Donotdamagethespreaderarms!

Everyeffortshouldbemadetofullyengagethewidthofthetipduringaspreading/liftingmaneuver(seepicturebelow).Failuretodoso,couldresultindebrisflying.

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6.4 Pulling

WARNING / CAUTION / PLEASE NOTE! The light metal alloy arms may not be damaged.

- LUKASchainsetsmustbeusedforpulling.- Whenusingachainforpulling,makesurethatthepinsandhooksarepositionedcorrectly

sothatthechaincannotslip.- Onlychainsetsinperfectconditionmaybeused.- Thepullingchainsmustbecheckedbyanexpertatleastonceayear.- Alsoconsulttheseparateoperatinginstructionsforthecorrespondingchainset!

Attachmentholeforchainsets

ATheconnectingpiecesforLUKASchainsetsarefastenedtothebladesusingloadboltsinholes"A".(seeillustrationontheright)

Chain sets:forSC258E2: KSV8/258forSC358E2: KSV 11forSC757E2: KSV13

NOTE:Alsotakenoteofalltheinstructionsandregulationsintheseparatelyprovidedoperatinginstructionsforthechainsets.

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Pulling with SC 757 E2 TousetheSC757E2forpulling,thespreadertipmustfirstberemoved(see6.2).Thepullingattachment“A”isthenmounted.Firstpullouttheboltofthepullingattachmentuptothelimitstop,slipthepullingattachmentontothearmandpushintheboltcompletelyuntilitengages(alsoseeSection6.2,“RemovingandattachingtheSpreaderTip”)inthisregard.

Thematchingchain lock“C”can thenbefixed tohole “B”of thepullingattachment (seeseparateoperatinginstructionsforchainlock).

2.

1.

A

C

B

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WARNING / CAUTION / PLEASE NOTE! Thepullingattachmentsmustbemountedinsuchawaythatthetwosurfaces,„A“and„B“arealwaysinthesameplane.Thisensuresthatthepullingforceissymmetricallyapplied.Ifthisinstructionisdisregarded,thismayresultinexcessiveloadbeingplacedonthecuttingarms,resultingininjuriestotheoperatororcrashvictim.

RIGHT

WRONG

WRONG

B A

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Pulling with SC 358 E2 TousetheSC358E2forpulling,thespreadertipmustfirstberemoved(see6.2).Thepullingattachment“A”isthenmounted.Firstpullouttheboltofthepullingattachmentuptothelimitstop,slipthepullingattachmentontothearmandpushintheboltcompletelyuntilitengages(alsoseeSection6.2,“RemovingandattachingtheSpreaderTip”)inthisregard.

Thematchingchain lock“C”can thenbefixed tohole “B”of thepullingattachment (seeseparateoperatinginstructionsforchainlock).

2.

1.A C

B

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Squeezingmayonlytakeplacenearthetips(seefigurebelow).

Squeezingarea

6.5 Squeezing

WARNING / CAUTION / PLEASE NOTE! The light metal alloy device arms may not be damaged.

Squeezingarea

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7. Dismantling the equipment / deactivation following operationOnceworkhasbeencompleted,thedevicearmsshouldbecloseduntilthetipsareonlyafewmillimetersapart.Thisrelievesthehydraulicandmechanicalstrainontheequipment.

Clean the rescue device after each operation and grease both the metallic and themechanicallymovableparts.Thelockoftheplug-ontipsshouldalsobegreasedfromtimetotime.Greasingprovidesprotectionagainstexcessivewearandtearorcorrosion.Avoidstoringtherescueequipmentinadampenvironment.

NOTE:NeverstoretheeDRAULICdeviceswithfullyclosedarms!Byfullyclosingthearms,hydraulicandmechanicaltensionmaydevelopinthedevice.

8. Maintenance and serviceThedevicesaresubjecttoveryhighmechanicalstresses.Avisualinspectionmustthereforebecarriedoutaftereveryuseandatleastonevisualinspectionmustbecarriedouteverysixmonths.Theseinspectionsenabletheearlydetectionofwearandtear,whichmeansthatpunctualreplacementofthesewearingpartspreventsbreakage.Regularlycheckthetorqueofthepivotboltonthecombinationtools.(Youwillfindthetorquesforthepivotboltinthechapteron"TechnicalData".)Anannualinspectionofthetoolisdueonceayear.Thisinspectionmustbeperformedbyapersonwiththenecessaryexpertise.Thismeansthatthepersonmustpossessadequatespecialistknowledgeandexperienceinthefieldsofelectricalengineeringandhydraulics,sothattheycanobjectivelyassesstheconditionofthetool.Everythreeyearsalsoacracktestofthebladesareessential.Thereforeaspecialcracktestingkitisisavailable.A function test is also to be carried out every three years or should there beanydoubtregardingthesafetyorreliabilityoftheequipment.(Pleasealsoobservetherelevantvalidnationalandinternationalregulationspertainingtoserviceintervalsofrescueequipment).IntheFederalRepublicofGermany,regularsafetyinspections according to the regulations of the Gesetzlichen Unfallversicherung (GUV;connoted‘Legalaccidentinsurance’)aremandatory.

ATTENTION!Cleanoffanydirtbeforecheckingtheequipment!

WARNING / CAUTION / PLEASE NOTE!Toperformmaintenanceandrepairs,personalsafetyequipmentappropriatefortheworkisamandatoryrequirement.Themaintenanceandrepairstaffmusthaveadequatetechnicalandspecializedknowledge.LUKASoffersappropriatetrainingcoursesforthis.

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Inspections to be carried out:

Visual Inspection

Combination tool• Openingwidthofthebladearmsonthetips(seechapter"Technicaldata"),• Generaltightness(leaks),• Operabilityofthestargrip-checktheautomaticreturnintomiddlepositionafterrelease

(deadman’sfunction),• Existenceandstabilityofhandle,• Labelscompleteandlegible,• Coversinperfectcondition,• Checkthetorqueofthepivotbolt(fortorqueMA,see"TechnicalData").• Bladearmsfreeofcracksandnicksordeformationsonthecuttingsurfaces,• Cuttingsurfacesfitontopofeachotherwithoutmakingcontact,• Theslidingplates,boltsandretainingringsofthebladearmsareinplaceandingood

condition,• Illuminationofmainswitch,workareaandconnectionshaftfullyfunctional.

Battery and power supply• Casingundamaged• Electricalcontactsurfacescleanandundamaged• Cableundamaged• Battery(-ies)fullycharged(whenused)• Chargingstatedisplayoflithium-ionbatteryorbatteriesfullyfunctional

Functional test• Easyopeningandclosingofstargripcontrols,• Nounusualnoises• No further movement of cutter arms when interrupting the valve function during the

process(deadman'sswitch).

8.2 eDRAULIC combination tools

8.1 Oil change

Under normalworking conditions routine oil changes are not necessarywith eDRAULICtools.Theprerequisiteisthat:• thetoolsarealwaysproperlyhandledandstowedaspertheapplicableoperatingmanual• thetoolsaretestedonaregularbasisasperourinstructionsonpreventivemaintenance

(seechapter8)• after10yearsservicelifeanoilchangeisrecommendedRegular tests, oil change and/or repairsmust be carried out by repair andmaintenancepersonnelthatistrainedandauthorizedbythemanufacturer.

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8.3 Protective equipmentInspections to be carried out:• Checktheprotectiveequipmentusedon/inthevicinityoftherescuedevice.Payparticular

attentiontotheprotectivecoverforthemovableparts(theremaybenocracks!).

Theairsuctionfilteristobecheckedatleastonceayearorafteruseinadustyenvironment.Thefiltercanbechecked fromtheoutside if themainsunit (orbattery) is removed(seeillustrationsbelow).Ifthefilterisseverelycontaminated,itwillneedtobereplaced.

Procedure:1. Tilttherespectivedeviceasshownintheillustration. 2.Removethebatteryorthepowersupply. 3.Removethefiltergridbyactivatingthereleasehook.4.Replacethedirtyfilterelementswithnewfilterelements.

8.4 Checking the filter in the battery shaft

Releasehook

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ATTENTION!Whencleaningunitsandequipment,notethatnocleaningagentmaybeusedthathasapHvalueoutsidetherange5-8!

9.1 General information9. Repairs

ServiceworkmayonlybeperformedbythedevicemanufacturerorbypersonneltrainedbythedevicemanufacturerandauthorizedLUKASdealers.OnlyLUKASsparepartsmaybeusedtoreplaceallcomponents(seesparepartslist),asspecialtoolsandcompliancewith,assemblyinstructions,safetyaspectsandinspectionsarerequired(seealsochapter"MaintenanceandServicing").During assembly, ensure that all components are particularly clean, as dirt can damage the rescue equipment!

WARNING / CAUTION / PLEASE NOTE!Protective clothesmustbewornwhen repairsarebeingcarriedout, as thedevicesmayalsobepressurizedwhennotinoperation.

ATTENTION!Because LUKAS rescue devices are designed for highest performance, onlycomponentsspecifiedinthesparepartslistfortheappropriateequipmentmaybereplaced.Othercomponentsinthedevicemayonlybereplacedif:- YouhaveparticipatedinanappropriateLUKASservicetrainingcourse.- You have been explicitly granted permission by LUKASCustomer Service

(validLUKAScertificaterequired!)

NOTE:AlwaysregisteryourtoolontheLUKASJawsofLifeinternetsite.Thisistheonlywaytoguaranteeextendedwarrantycover.

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9.2 Preventive service

9.2.1 Care instructions

Theoutsideof thedeviceshouldbecleanedwithadampcloth fromtimeto time(not the electrical contacts in the connection slot, on the battery and on the power supply).In addition,themetalsurfacesaretocoatedwithasuitablemediumtocounteractcorrosion(not the electrical contacts in the connection slot, on the battery andonthepowersupply).(In case of doubt, contact your authorized LUKAS dealer or LUKAS directly!)

9.2.2 Function and load test Ifthereisanydoubtregardingthesafetyorreliabilityofadevice,afunctionandstresstestmustalsobeperformed.LUKASoffersappropriatetestequipmentforthis.

9.3.1 Replacing the blade, protective cover and hand grip of the combination tool SC 258 E2, SC 358 E2 and SC 757 E2

9.3 Repairs

Components to be replaced Required work steps

Protectivecover 1.,2.and7.Pivotbolt 1.-4.and7.Handle 1.-6.and7.Blade 1.-5.and7.

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2.Removethetwofixingscrews"A"andremovetheprotectivecover"B".Todothis,firstpulltheroundedrearedgeoutwardsandthenbackwardsthroughthehandgrip,astheedgesoftheprotectivecoveradjoiningthecylinderbodyarekeptinplacebyguidegrooves.Ifnecessary,loosenthehandgripandmoveitbackwardstoobtainsufficientspacetopullitout.

3. Movethebladearmsontheuntilbolt“E”iseasilyaccessible.

Nowswitchoffthedeviceandremovethebatteryorunplugthepowersupplyfromthedevice.

Work steps:

1. Firstofall,carefullycleantherescueequipment.

CAUTION / PLEASE NOTE!When operating the device withthehandguardremoved,thereisanincreasedriskofinjurycausedbytheexposed,movingelements.

E

E

B

A

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4. Firstremovethegrubscrew"G",thenthecentralboltnut"H"andthenpulloutthecentralpin"J".

6.Releasethefixingscrews“K”andremovethem.Thehandle“L”cannowbepulledoutforwards.

NOTE:Thetorquerequiredcanbetakenfromthesparepartslistofyourparticularunit.

7. Theworkstepsmustbecarriedoutinreverseordertofitthenewparts.

5. Removethelockingrings“M”andpushthepin“N”out.Youcanthenpullouttheblades“O”andtheslideplates“P”.

ATTENTION!ApplyLUKASspecialgreasetoallslidingsurfaces!

N

P

N

M

O

M

HG

J

K

L

31

9.3.2 DecalsAlldamagedand/orillegibledecals(safetynotices,typeplateetc.)mustbereplaced.

Procedure:1.Removedamagedand/orillegibledecals.2.Cleansurfaceswithindustrialalcohol.3. Affixnewdecals.Takecaretoaffixthelabelsinthecorrectpositions.Ifthisisnolongerknown,youshouldaskyourauthorizedLUKASdealerorcontactLUKASdirectly.

32

10. TroubleshootingFault Check Cause Solution

Themotordoesnotstartafteractivatingthestargrip.

Themainswitchisnotilluminated,althoughithasnotbeenswitchedoff.

Thestargripwasnotusedforsometime(atleast10minutes)duringbatteryoperation.Therechargeablebatteryhasswitcheditselfoff.

Inordertoresumeworkwiththedevice,theeDRAULICdevicemustfirstbeswitchedoffatthemainsandthenswitchedonagain.Alternatively,thecapacitydisplayontherechargeablebatterycanbeactivatedorthebatterymaybebrieflyunpluggedandrepluggedagain.

Bladearmsmoveslowlyorjerkilywhenoperated

Batteryfullycharged?

Batteryflat ChargebatteryBatterydefective ReplacebatteryAirinthehydraulicsystem

Repairbyanauthorizeddealer,bypersonnelspeciallytrainedbyLUKAS,orbyLUKASitself

Powersupplycableconnected?

PowersupplynotproperlyconnectedtotheeDRAULICdevice(notautomaticallylocked).

Reinsertpowersupplyintotheconnectionshaft

Powersupplycablenotproperlyconnectedtotheexternalpowersupply.

Reconnectexternalpowersupply

Powersupplyorpowersupplycabledefective.

Replacepowersupplyorpowersupplycable

Externalpowersourcedefective.

Useotherexternalpowersource

33

Fault Check Cause SolutionBladearmsdonotmovewhenoperated.

Batteryfullycharged?

Batteryflat ChargebatteryBatterydefective Replacebattery

Powersupplycableconnected?

Powersupplycabledefective

Replacepowersupplycable

Devicedefective Repairbyanauthorizeddealer,bypersonnelspeciallytrainedbyLUKAS,orbyLUKASitself

Devicedoesnotperformatitsgivenpower

Devicedefective Repairbyanauthorizeddealer,bypersonnelspeciallytrainedbyLUKAS,orbyLUKASitself

Followingrelease,thestargripdoesn’treturntothecentralposition

Casingdamagedorstargripoperationnotworkingsmoothly?

Damagetothetorsionspringforreset

Repairbyanauthorizeddealer, bypersonnelspeciallytrainedbyLUKAS,orbyLUKASitself

Soiledvalveorstargrip

DefectivevalveOthermechanicaldamage(e.g.stargrip)

Hydraulicfluidleakingfromthepistonrod

Defectiverodseal Repairbyanauthorizeddealer, bypersonnelspeciallytrainedbyLUKAS,orbyLUKASitself

Damagetothepiston

Theusefuloperatingtimebetweentheindividualchargingcyclesislessthan5minutes,despitechargingthebatteriesaccordingtotheinstructions.

Batterydefective Replacebattery

34

11. Technical data

NOTE:Thefollowingtablescontainonlythetechnicaldatanecessaryforoperationandstorage.FurtherinformationaboutyourdeviceisavailabledirectlyfromLUKAS.

Sinceallvaluesaresubjecttotolerances,minordifferencesmayoccurbetweenthedataonyourequipmentandthedatainthefollowingtables.The values may also differ because of reading inaccuracies and/or tolerances in themeasuringequipmentused.

Operating pressure: SC258E2: 70MPa SC358E2: 70MPa SC757E2: 75MPa

If it isn’t possible to rectify themalfunctions, inform an authorised LUKAS dealer or theLUKAScustomerservicedepartmentimmediately!TheaddressfortheLUKAScustomerservicedepartmentis:

LUKAS Hydraulik GmbH

Weinstraße39, D-91058ErlangenTel.: 0049(0)9131/698-348Fax.: 0049(0)9131/698-353http://www.lukas.com

35

11.1 eDRAULIC combination device

Device type SC 258 E2 SC 358 E2Item number 90-30-14 90-30-23

Dimensions (excluding Battery) LxWxH

[mm] 874x215x281 956x237x281[in.] 34.4 x 8.46 x 11.1 37.7 x 9.3 x 11.1

Min. cutting opening[mm] 233 309

[in.] 9.2 12.2

Max. cutting force (rearmostcuttingpoint)

[kN] 280 492[lbf.] 63000 110600

Minimum spreading force (atadistanceof25mm/ 0.98inchesfromthetips)

[kN] 32 38

[lbf.] 7200 8543

LSF spreading force (accordingtoNFPA)

[kN] 24 33[lbf.] 5400 7419

HSF spreading force (accordingtoNFPA)

[kN] 29 43[lbf.] 6500 9667

Max. possible spreading force[kN] 700 1500[lbf.] 157000 337230

Maximum spreading path[mm] 321 372

[in.] 12.6 14.7

Maximum pulling force (withapprobiatechainset)

[kN] 34 61[lbf.] 7640 13714

Pulling path (withapprobiatechainset)

[mm] 330 382[in.] 13.0 15

HPF pulling force (accordingtoNFPA)

[kN] 37 62[lbf.] 8320 13940

LPF pulling force (accordingtoNFPA)

[kN] 28 43[lbf.] 6300 9667

Mass (excl. battery)[kg] 14,9 18,7

[lbs.] 32.8 41.2Nominal electrical voltage (withpowersupply) [V DC] 25 25

Nominal electrical voltage (withlithium-ionbattery) [V DC] 25,2 25,2

Protection category IP54 IP54Cutting Class F IClassification (NFPA 1936) A6/B6/C6/D7/E7 A7/B8/C7/D8/E7

36

11.1 eDRAULIC combination device

Device type SC 757 E2Item number 90-30-32

Dimensions (excluding battery) LxWxH

[mm] 1033x294x285[in.] 40.7 x 11.5 x 11.2

Min. cutting opening[mm] 369

[in.] 14.5

Max. cutting force (rearmostcuttingpoint)

[kN] 880[lbf.] 198000

Minimum spreading force (atadistanceof25mm/ 0.98inchesfromthetips)

[kN] 41

[lbf.] 9218

LSF spreading force (accordingtoNFPA)

[kN] 39[lbf.] 8770

HSF spreading force (accordingtoNFPA)

[kN] 49[lbf.] 11000

Max. possible spreading force[kN] 1300[lbf.] 292000

Maximum spreading path[mm] 450

[in.] 17.7

Maximum pulling force (withapprobiatechainset)

[kN] 98[lbf.] 22000

Pulling path (withapprobiatechainset)

[mm] 297[in.] 11.7

HPF pulling force (accordingtoNFPA)

[kN] 66[lbf.] 14800

LPF pulling force (accordingtoNFPA)

[kN] 48[lbf.] 10800

Mass (excl. battery)[kg] 24

[lbs.] 52.9Nominal electrical voltage (withpowersupply) [V DC] 25

Nominal electrical voltage (withlithium-ionbattery) [V DC] 25.2

Protection category IP54Cutting Class (EN 13204) JClassification (NFPA 1936) A8/B9/C8/D9/E9

37

11.2 Noise emission (based on standard EN ISO 3744)

Device typeSC 258 E2, SC 358 E2, SC 757 E2

Battery type used for device Lithium/ion

Idling (measuredatadistanceof1m,accordingtoEN) [dB(A)] 74

Full load (measuredatadistanceof1m,accordingtoEN) [dB(A)] 77

Idling (measuredatadistanceof4m,accordingtoNFPA) [dB(A)] 69

Full load (measuredatadistanceof4m,accordingtoNFPA) [dB(A)] 71

11.3 Operating and storage temperature ranges

Operating temperature [°C]/[°F] -20 … +55 -4 … +131Storage temperature (devicenotinoperation) [°C]/[°F] -30 … +60 -22 … +140

11.4 Oscillation / vibrationThetotaloscillationvalue/vibrationvaluetowhichtheupperlimbsareexposed,isusuallybelow2.5m/s².Highervaluesmaybemeasuredforshortperiodsasaresultofinteractionwiththematerialstobeprocessed.

(The oscillations / vibrations were determined in accordance with DIN EN ISO 20643.)

11.5 Torques for central bolts

Device type SC 258 E2 SC 358 E2 SC 757 E2Pivot bolt M24x1,5 M28x1,5 M32x1,5

Wrench size[mm] 36 38 46[in.] 1.42 1.50 1.81

Torque[Nm] 130+10 130+10 160+10

[lbf∙in] 1151 + 90 1151 + 90 1416 + 90

38

Device type Max. cutting material dimensionsRound

material[mm][in.]

Flat material

[mm][in.]

Round tube[mm][in.]

Square tube[mm][in.]

Rectangular tube[mm][in.]

SC 258 E2 261.02

80x103.15x0.39

60,3x2,92.37x0.11

50x41.97x0.16

80x40x3,03.15x1.57x0.12

SC 358 E2 351.8

130x105.12x0.39

88,9x4,03.5x0.16

70x42.76x0.16

100x50x4,03.94x1.97x0.16

SC 757 E2 381.5

140x105.51x0.39

88,9x5,03.5x0.2

70x52.76x0.2

100x50x5,03.94x1.97x0.2

ThetensilestrengthofallmaterialsmeetsthetestingcriteriaofDINEN13204.

11.6 Cutting performance

39

ManufacturerName and type of the device

LUKASHydraulikGmbHSC258E2(90-30-14)

Classificationgiven

Type

Spreading force [kN] /

Spreading width [mm]

Classification based on

the minimum performance of

the cutter

Dimensions [Kg](measured to one

decimal place)

Performance of the cutter

1G-2F-3F-4F-5G

Profile type → 1 Round material 2 Flat material 3 Round tube 4 Square tube 5 Rectangular tube

Category letter ↓

A ≥14 30x5 21,3x2,3

B ≥16 40x5 26,4x2,3

C ≥18 50x5 33,7x2,6 35x3

D ≥20 60x5 42,6x2,6 40x4 50x25x2,5

E ≥22 80x8 48,3x2,9 45x4 50x30x3,0

F ≥24 80x10 60,3x2,9 50x4 60x40x3,0

G ≥26 100x10 76,1x3,2 55x4 80x40x3,0

H ≥28 110x10 76,1x4,0 60x4 80x40x4,0

I ≥32 120x10 88,9x4,0 60x5 80x40x5,0

J ≥36 130x10 88,9x5,0 70x4 100x50x4,0

K ≥40 140x10 101,6x4,0 70x5 100x50x5,0

[mm] [mm] [mm] [mm] [mm]

11.7 Datasheets for the product performance

40



Classificationgiven

Type





the cutter


decimal place)


1I-2J-3I-4J-5J


Category letter ↓

A ≥14 30x5 21,3x2,3

B ≥16 40x5 26,4x2,3

C ≥18 50x5 33,7x2,6 35x3

D ≥20 60x5 42,6x2,6 40x4 50x25x2,5

E ≥22 80x8 48,3x2,9 45x4 50x30x3,0

F ≥24 80x10 60,3x2,9 50x4 60x40x3,0

G ≥26 100x10 76,1x3,2 55x4 80x40x3,0

H ≥28 110x10 76,1x4,0 60x4 80x40x4,0

I ≥32 120x10 88,9x4,0 60x5 80x40x5,0

J ≥36 130x10 88,9x5,0 70x4 100x50x4,0

K ≥40 140x10 101,6x4,0 70x5 100x50x5,0


41



Classificationgiven

Type





the cutter


decimal place)


1J-2K-3J-4K-5K


Category letter ↓

A ≥14 30x5 21,3x2,3

B ≥16 40x5 26,4x2,3

C ≥18 50x5 33,7x2,6 35x3

D ≥20 60x5 42,6x2,6 40x4 50x25x2,5

E ≥22 80x8 48,3x2,9 45x4 50x30x3,0

F ≥24 80x10 60,3x2,9 50x4 60x40x3,0

G ≥26 100x10 76,1x3,2 55x4 80x40x3,0

H ≥28 110x10 76,1x4,0 60x4 80x40x4,0

I ≥32 120x10 88,9x4,0 60x5 80x40x5,0

J ≥36 130x10 88,9x5,0 70x4 100x50x4,0

K ≥40 140x10 101,6x4,0 70x5 100x50x5,0


42

12. EC Declaration of conformity

43

13. Accessories 13.1 BatteriesOnlyLUKASlithium-ionrechargeablebatteriesmaybeusedtooperateeDRAULICdevices.TheseguaranteeoptimumperformanceandmaximizetheoperatingtimeoftheeDRAULICdevices.

Chargingstatedisplay

Querybutton

Technical Data nom.Voltage Capacity Energy WeightUnit V DC Ah Wh kg lbsBattery type 1 25.2 2.6 65 0.92 2.03Battery type 2 25.2 5.0 126 0.94 2.07

Capacity=75...100%-LED1-4lightsupCapacity=62...75%-4thLEDlightsup,1-3lightsupCapacity=50...62%-LED1-3lightsupCapacity=37...50%-3rdLEDlightsup,1-2lightsupCapacity=25...37%-LED1-2lightsupCapacity=12...25%-2ndLEDlightsup,1lightsupCapacity=5...12%-LED1lightsupCapacity=0...5%-1stLEDlightsup

Battery Type 2: Display code

Battery Type 1: Display code

Capacity=75...100%-LED1-4lightsup



Capacity=0...25%-LED1lightsup

NOTE: Toensuremaximumoperatingtimeandmaximumuptime,youmustmakesurethatthebatteryisalwaysfullychargedbeforeconnectingittoa rescuedevice.

44

13.3 Power supply

NOTE:Paystrictattentiontotheseparateoperatinginstructionsforthepowersupply.

13.2 Battery chargerOnlythe"eDRAULICPowerPackCharger"maybeusedforthelithium-ionbatteries.

NOTE:Paystrictattentiontotheseparateoperatinginstructionsforthebatterycharger.

TheeDRAULICdeviceshaveaspeciallydevelopedpowersupplywithwhichthedevicescan be directly connected to the power grid. The power supply converts the alternatingcurrentfromthepowergridintodirectcurrent,whichmeansthatitcanbeusedinsteadofthebattery.

Structure:There is an adapter on one side of the power supplywhich canbe simply inserted intotheconnectionslotofthedevicesandlocked.Theothersidehasamainsplug.Bothareconnectedbyacable.Themainsplug isaSchukoplugwithProtectionClassification IP68oraUSplug.TheintegratedfilterisappropriatefortheconversionofACvoltagetoDCvoltage.

Adapter

Mainsplug

Cable

Filter

Cable

45

14. Instructions regarding disposal

Electrical equipment, accessories and packaging should always be disposed of in anenvironmentallycompatibleway.

Only for EU countries:Donotdisposeofelectricalequipmentwithyourhouseholdwaste!AccordingtotheEuropeanDirective2002/96/ECgoverningelectricalandelectronicwasteand their application in national legislation, old electrical equipment must be separatelycollectedandrecycledinanenvironmentallycompatiblemanner.

Please also take into account the notes in the separate operating instructions for the battery chargers.

Pleasedulydisposeofallpackagingmaterialsandremoveditems.

13.4 Chain setsChainsetsarerequiredinordertobeabletoperformpullingoperationswiththeeDRAULICcombinationtool(seechapter,"Pulling"). Suitable chain sets:forSC258E2: KSV8/258forSC358E2: KSV11forSC757E2: KSV13

46

15. Notes

Please duly dispose of all packaging materials and removed items.

Subj

ect t

o ch

ange

LUKAS Hydraulik GmbHA Unit of IDEX Corporation

Weinstraße 39, D-91058 ErlangenTel.: 0049 (0) 91 31 / 698 - 0Fax.: 0049 (0) 91 31 / 698 - 394e-mail: [email protected]

Made in GERMANY

© Copyright 2018 LUKAS Hydraulik GmbHeDRAULIC2_manual_173023085_en.indd

instruction manual for rescue equipment edraulic combi tools · sc 258 e2. 2. content page. 1....

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