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Summary of Contents for Lukas S 700 E2
- Page 1 Instruction manual for rescue equipment eDRAULIC cutters S 700 E2 S 788 E2 S 312 E2 172022085 EN S 377 E2 Edition 01.2018 replaces 09.2017 (Translation of the original instruction manual)
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Page 2: Table Of Contents
Content Page 1. Danger classifications 2. Product safety 3. Proper use 4. Functional description 4.1 Description 4.2 Structure of rescue devices 4.3 Hydraulic circuit diagram 4.4 Operating movement controls 5. Operation 5.1 Battery or power supply for eDRAULIC device 5.2 Operating the star grip 6. Cutting 6.1 Safety notes 6.2 Cutting... - Page 3 Content Page 10. Troubleshooting 11. Technical data 11.1 eDRAULIC cutter 11.2 Noise emission (based on standard EN ISO 3744) 11.3 Operating and storage temperature ranges 11.4 Oscillation / vibration 11.5 Torques for central bolts 11.6 Cutting performance 11.7 Datasheets for the product performance 12. EC Declaration of Conformity 13. Accessories 13.1 Batteries 13.2 Battery charger 13.3 Power supply 14. Instructions regarding disposal...
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Page 4: Danger Classifications
1. Danger classifications We differentiate between various different categories of safety instructions. The table shown below provides an overview of the assignment of symbols (pictograms) and signal words to the specific danger and the possible consequences. Damage / Pictogram Keyword Definition Consequences injury to Death or severe DANGER! Immediate danger injury Potentially Potential death or WARNING! dangerous serious injury situation Less dangerous Minor or slight CAUTION! situation injury Damage to the equipment, Risk of damage damage to the ATTENTION! to property/ environment, environment damage to surroundings Handling tips and No injury/damage other important/ to persons/... -
Page 5: Product Safety
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 qualified trainer show you how to use the product. WARNING / CAUTION! - Page 6 In the event of malfunction, Do not carry out any changes immediately deactivate the (additions or conversions) device and secure it. Repair to the equipment without the fault immediately. obtaining the prior approval of LUKAS. Observe all safety and danger All safety and danger information on the device and instructions on the device in the operating instructions. must always be complete and in a legible condition. Any mode of operation which Repairs to the equipment compromises the safety and/ may only be carried out by or stability of the device is a trained service technician forbidden! with specific knowledge of the device. Safety devices may never be Only genuine LUKAS disabled! accessories and spare parts are to be used for repairs.
- Page 7 Please ensure that you do not Please ensure that the become entangled in cables battery contacts are not short- and trip when working with or circuited. transporting the device. The build-up of static charges Only touch broken-off or and therefore possible cut-off parts while wearing sparking must be avoided protective gloves, as the torn / when handling the device. cut edges can be very sharp. The eDRAULIC devices have The eDRAULIC devices are an IP54 protection class. not suitable for underwater They are suitable for use in use. wet weather conditions and are splash proof. The equipment is filled with When working with or storing hydraulic fluid. This hydraulic the equipment, ensure that fluid can be detrimental to the function and the safety health if it is swallowed or of the equipment are not its vapor is inhaled. Direct impaired by the effects of contact with the skin must severe external temperatures be avoided for the same and that the equipment is not reason. Also, when handling damaged in any way. Please hydraulic fluid, note that it can note that the equipment can negatively affect biological also heat up over a long...
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Page 8: Proper 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! 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. - Page 9 - 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.
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Page 10: Functional Description
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 find suitable bat- teries and power supplies in the LUKAS accessories list. eDRAULIC devices come with standard light fittings 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. -
Page 11: Structure Of Rescue Devices
4.2 Structure of rescue devices S 700 E2 S 788 E2 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 9 Plastic housing 10 Tool body 11 Protective cover 12 Light S 312 E2... -
Page 12: Hydraulic Circuit Diagram
4.3 Hydraulic circuit diagram Below a simplified hydraulic ram representing the tool is depicted. A = tool B = star grip valve cutting opening 4.4 Operating movement controls The piston movement is controlled by the star grip on the attached valve (see illustration below). Star grip 5. Operation 5.1 Battery or power supply for eDRAULIC device Commissioning Before initial operation, the battery (where used) of the rescue device must be fully loaded, using the external charger. -
Page 13: Operating The Star Grip
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! Connection slot 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. 5.2 Operating the star grip (also see chapter on "Operating movement control") 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. -
Page 14: Cutting
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 specific 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. -
Page 15: Cutting
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 effect of the force of the rescue equipment during operation could cause pieces of the vehicle to break off or fly off, posing a danger to persons. -
Page 16: Dismantling The Equipment / Deactivation Following Operation
[mm] / [in.] S 312 E2 / 0.12 S 377 E2 / 0.12 S 700 E2 / 0.12 S 788 E2 5 / 0.20 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! 7. -
Page 17: Maintenance And Service
ATTENTION! Clean off 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 staff must have adequate technical and specialized knowledge. LUKAS offers 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. -
Page 18: Overview Of Edraulic Cutting Tools
8.2 Overview of eDRAULIC cutting tools 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 M see "Technical Data"). • Blade arms free of cracks and nicks or deformations on the cutting surfaces, • Cutting surfaces fit 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... -
Page 19: Protective Equipment
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!). 8.4 Checking the filter in the battery shaft The air suction filter is to be checked at least once a year or after use in a dusty environment. The filter can be checked from the outside if the mains unit (or battery) is removed (see illustrations below). If the filter is severely contaminated, it will need to be replaced. Procedure: Tilt the respective device as shown in the illustration. -
Page 20: Repairs
Protective clothes must be worn when repairs are being carried out, as the devices may also be pressurized when not in operation. NOTE: Always register your tool on the LUKAS Jaws of Life internet site. This is the only way to guarantee extended warranty cover. ATTENTION! Because LUKAS rescue devices are designed for highest performance, only components specified 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 certificate required!) ATTENTION! When cleaning units and equipment, note that no cleaning agent may be used that has a pH value outside the range 5 - 8! -
Page 21: Preventive Service
If there is any doubt regarding the safety or reliability of a device, a function and stress test must also be performed. LUKAS offers appropriate test equipment for this. 9.3 Repairs 9.3.1 Replacing the blade, protective cover and hand grip of the cutter S 700 E2, S 788 E2, S 312 E2 and S 377 E2 Components to be Required work steps replaced Protective cover 1., 2. and 7. Pivot bolt 1. - 4. and 7. - Page 22 Work steps: 1. First of all, carefully clean the rescue equipment. 2. Remove the two fixing screws "A" and remove the protective cover "B". To do this, first pull the rounded rear edge outwards and then backwards through the hand grip, as the edges of the protective cover adjoining the cylinder body are kept in place by guide grooves. If necessary, loosen the hand grip and move it backwards to obtain sufficient space to pull it out. CAUTION / PLEASE NOTE! When operating the device with the hand guard removed, there is an increased risk of injury caused by the exposed, moving elements. 3. Move the blade arms on the until bolt “E” is easily accessible. Now switch off the device and remove the battery or unplug the power supply from the device.
- Page 23 4. First remove the grub screw "G", then the central bolt nut "H" and then pull out the central pin "J". 5. Remove the locking rings “M” and push the pin “N” out. You can then pull out the blades “O” and the slide plates “P”. 6. Release the fixing screws “K” and remove them. The handle “L” can now be pulled out forwards. 7. The work steps must be carried out in reverse order to fit the new parts. ATTENTION! Apply LUKAS special grease to all sliding surfaces! NOTE: The torque required can be taken from the spare parts list of your particular unit.
- Page 24 9.3.2 Sharpening the blades Remove and smoothen any burrs! Chips or deep grooves cannot be ground away. The blades must be replaced in this case. ATTENTION! Only grind in the grinding area (see illustration)! The sliding faces, in particular, must not be reground! Grinding area Pivot point Blade arm Direction of movement Slide surface Blade arm plane 1. Jaw protection on clawing device (e.g. vice) in order not to Tools required: damage the blades. 2. Grinder (e.g. angle grinder or belt grinder) with abrasive having a grain size of 80. Procedure: 1. Clamp the blade securely into the clamping device so that it cannot move, but with the grinding area exposed. 2. Carefully grind the burr away evenly until you reach the sliding surface level (see illustration).
- Page 25 9.3.3 Decals All damaged and/or illegible decals (safety notices, type plate etc.) must be replaced. Procedure: 1. Remove damaged and/or illegible decals. 2. Clean surfaces with industrial alcohol. 3. Affix new decals. Take care to affix the labels in the correct positions. If this is no longer known, you should ask your authorized LUKAS dealer or contact LUKAS directly.
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Page 26: Troubleshooting
Blade arms move Battery fully Battery flat Charge battery slowly or jerkily charged? Battery defective Replace battery when operated Air in the hydraulic Repair by an system authorized dealer, by personnel specially trained by LUKAS, or by LUKAS itself Power supply cable Power supply Reinsert power connected? not properly supply into the connected to the connection shaft eDRAULIC device (not automatically locked). Power supply Reconnect external cable not properly power supply connected to the external power supply. - Page 27 Solution Blade arms do Battery fully Battery flat Charge battery not move when charged? Battery defective Replace battery operated. Power supply cable Power supply cable Replace power connected? defective supply cable Device defective Repair by an authorized dealer, by personnel specially trained by LUKAS, or by LUKAS itself Device does not Device defective Repair by an perform at its given authorized dealer, by power personnel specially trained by LUKAS, or by LUKAS itself Following release, Casing damaged or Damage to the Repair by an the star grip star grip operation torsion spring for authorized dealer, doesn’t return to...
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Page 28: Technical Data
Contact an authorised LUKAS dealer or the LUKAS Customer Service Department directly if the malfunctions cannot be rectified. The address for the LUKAS Customer Service department is: LUKAS Hydraulik GmbH Weinstraße 39, D-91058 Erlangen Tel.: 0049 (0) 91 31 / 698 - 348 Fax.: 0049 (0) 91 31 / 698 - 353 http://www.lukas.com 11. Technical data Since all values are subject to tolerances, minor differences may occur between the data on your equipment and the data in the following tables. The values may also differ because of reading inaccuracies and/or tolerances in the measuring equipment used. NOTE: The following tables contain only the technical data necessary for operation and storage. Further information about your device is available directly from LUKAS. Operating pressure: S 312 E2: 70 MPa... -
Page 29: Edraulic Cutter
11.1 eDRAULIC cutter Device type S 312 E2 S 377 E2 S 700 E2 Item number 90-20-32 90-20-23 90-20-72 Dimensions [mm] 905 x 237 x 281 934 x 237 x 281 920 x 296 x 262 (excluding battery) [in.] 35.6 x 9.3 x 11.1 36.8 x 9.3 x 11.1 36.2 x 11.7 x 10.3... - Page 30 Device type S 788 E2 Item number 90-20-42 Dimensions [mm] 988 x 266 x 281 (excluding battery) [in.] 38.9 x 10.5 x 11.1 L x W x H [mm] Min. cutting opening [in.] 7.97 [kg] 22,7 Mass (excl. battery) [lbs.] 50.0 Nominal electrical voltage [V DC] (with power supply) Nominal electrical voltage [V DC] 25,2 (with lithium-ion battery)
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Page 31: Noise Emission (Based On Standard En Iso 3744)
11.2 Noise emission (based on standard EN ISO 3744) S 312 E2, S 377 E2, Device type S 700 E2, S 788 E2 Battery type used for device Lithium/ion Idling [dB(A)] (measured at a distance of 1 m, according to EN) Full load [dB(A)] (measured at a distance of 1 m, according to EN) Idling [dB(A)] (measured at a distance of 4 m, according to NFPA) Full load... -
Page 32: Cutting Performance
2.99x0.16 2.76x0.16 3.94x1.97x0.16 130x10 88.9x4,0 70x4,0 100x50x5,0 S 377 E2 1.30 5.12x0.39 3.5x0.16 2.76x0.16 3.94x1.97x0.20 140x10 101.6x4,0 70x5,0 100x50x5,0 S 700 E2 1.57 5.51x0.39 4.00x0.16 2.76x0.20 3.94x1.97x0.20 140x10 101.6x4,0 70x5,0 100x50x5,0 S 788 E2 1.65 5.51x0.39 4.00x0.16 2.76x0.20 3.94x1.97x0.20 The tensile strength of all materials meets the testing criteria of DIN EN 13204. -
Page 33: Datasheets For The Product Performance
11.7 Datasheets for the product performance Manufacturer LUKAS Hydraulik GmbH Name and type of the device S 312 E2 (90-20-32) Classification given Classification based on Dimensions [Kg] Cutter opening Performance Type the minimum (measured to one [mm] of the cutter performance of decimal place) the cutter... - Page 34 Manufacturer LUKAS Hydraulik GmbH Name and type of the device S 377 E2 (90-20-23) Classification given Classification based on Dimensions [Kg] Cutter opening Performance Type the minimum (measured to one [mm] of the cutter performance of decimal place) the cutter 19,3 1I-2J-3I-4J-5J 1 Round material 2 Flat material...
- Page 35 Manufacturer LUKAS Hydraulik GmbH Name and type of the device S 700 E2 (90-20-72) Classification given Classification based on Dimensions [Kg] Cutter opening Performance Type the minimum (measured to one [mm] of the cutter performance of decimal place) the cutter 21,8 1J-2K-3K-4K-5K 1 Round material 2 Flat material...
- Page 36 Manufacturer LUKAS Hydraulik GmbH Name and type of the device S 788 E2 (90-20-42) Classification given Classification based on Dimensions [Kg] Cutter opening Performance Type the minimum (measured to one [mm] of the cutter performance of decimal place) the cutter 22,7 1K-2K-3K-4K-5K 1 Round material 2 Flat material...
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Page 37: Ec Declaration Of Conformity
12. EC Declaration of Conformity... -
Page 38: Accessories
13. Accessories 13.1 Batteries Only LUKAS lithium-ion rechargeable batteries may be used to operate eDRAULIC devices. These guarantee optimum performance and maximize the operating time of the eDRAULIC devices. NOTE: To ensure maximum Charging state operating time and display maximum uptime, you must make sure that the battery is always Query button fully charged before connecting it to a rescue device. Technical Data nom. Voltage Capacity Energy Weight Unit V DC Battery type 1 25.2 0.92 2.03 Battery type 2 25.2 0.94 2.07 Battery Type 1: Display code Capacity = 75...100% - LED 1-4 lights up... -
Page 39: Battery Charger
13.2 Battery charger Only the "eDRAULIC Power Pack Charger" may be used for the lithium-ion batteries. NOTE: Pay strict attention to the separate operating instructions for the battery charger. 13.3 Power supply The eDRAULIC devices have a specially developed power supply with which the devices can be directly connected to the power grid. The power supply converts the alternating current from the power grid into direct current, which means that it can be used instead of the battery. Mains plug Cable Adapter Cable Filter Structure: There is an adapter on one side of the power supply which can be simply inserted into the connection slot of the devices and locked. The other side has a mains plug. Both are connected by a cable. The mains plug is a Schuko plug with Protection Classification IP 68 or a US plug. The integrated filter is appropriate for the conversion of AC voltage to DC... -
Page 40: Instructions Regarding Disposal
A Unit of IDEX Corporation Weinstraße 39, D-91058 Erlangen Tel.: 0049 (0) 91 31 / 698 - 0 Fax.: 0049 (0) 91 31 / 698 - 394 e-mail: lukas.info@idexcorp.com www.lukas.com Made in GERMANY eDRAULIC2_manual_172022085_en.indd © Copyright 2018 LUKAS Hydraulik GmbH...
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