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Summary of Contents for Lukas eDRAULIC
- Page 1 Instruction manual for rescue equipment eDRAULIC spreader 171255085 EN Edition 10.2019 replaces 07.2019 (Translation of the original instruction manual)
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Page 2: Table Of Contents
3. Intended use 4. Functional description 4.1 Description 4.2 Unit in detail 4.3 Hydraulic circuit diagram 4.4 Operating movement controls 5. Operation 5.1 Battery for eDRAULIC device 5.2 Operating the star grip 6. Spreading, pulling, squeezing and peeling 6.1 Safety notes 6.2 Spreading 6.3 Pulling 6.4 Squeezing 6.5 Peeling... - Page 3 Content Page 10. Troubleshooting 11. Technical data 11.1 eDRAULIC spreader 11.2 Peeling 11.3 Noise emission (based on standard EN ISO 3744) 11.4 Operating and storage temperature ranges 11.5 Oscillation / vibration 12. EC Declaration of Conformity 13. Accessories 13.1 Batteries 13.2 Battery charger 13.3 Chain sets 14. Instructions regarding disposal 15. Notes...
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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 are not suitable for underwater use in saltwater or seawater. 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 systems. period of use.
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Page 8: Intended Use
Never work in a fatigued or intoxicated state! 3. Intended use LUKAS eDRAULIC spreaders 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 spreaders can also be used to free persons who have become trapped by pushing open doors or removing obstacles with the aid of a chain set. During other catastrophic events, spreaders can also be used to move objects to rescue persons who have been buried or trapped. CAUTION / PLEASE NOTE! Care must always be taken that the environment of the object to be processed remains stable and secured against unintentional shifting by using strong supports or underpinning. LUKAS eDRAULIC devices EWXT are suitable for underwater use, but not in saltwater or seawater. - 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 spreaders 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 spreader arms. This movement can be used to spread open, squeeze or pull open objects. 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. A battery must be connected as an energy source. The accumulator battery can be inserted into the opening provided in the body of the tool and is 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. The battery is not part of the delivery scope You will find suitable batteries in the LUKAS accessories list. eDRAULIC devices come with standard light fittings to facilitate work under poor light conditions. -
Page 11: Unit In Detail
4.2 Unit in detail SP 555 EWXT 1 Star grip 2 Main switch 3 Quick exchange battery 4 Release button for battery 5 Handle 6 Spreader arms with plug-on tips 7 Plastic housing 8 Tool body 9 Protective cover 10 Light 11 Squeezing device 12 Protective plate for spreader arm 13 Yoke cover... -
Page 12: Hydraulic Circuit Diagram
4.3 Hydraulic circuit diagram To enable comprehension of the function, a simplified hydraulic ram of the rescue equipment (A) + hand valve (B) are depicted here. pulling / squeezing spreading 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 for eDRAULIC device Commissioning Before initial operation, the battery of the rescue device must be fully loaded, using the external charger. -
Page 13: Operating The Star Grip
Procedure: 1. Fully pull the unlocking button and carefully pull the battery upwards out of the de- vice. Do not use force! Connection slot 2. 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). 3. Insert the recharged or new battery into the eDRAULIC device until it reaches the stop. The battery will be automatically locked when correctly operated. 5.2 Operating the star grip (also see chapter on "Operating movement control") 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, fully guaranteeing load retention. -
Page 14: Spreading, Pulling, Squeezing And Peeling
Worldwide safety guidelines pertaining to the specific country must be observed and complied with. In the Federal Republic of Germany, regular safety inspections according to the regulations of the Gesetzlichen Unfallversicherung (GUV; ‘Legal accident insurance’) are mandatory. 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: Spreading
It is strictly prohibited to reach into the path of the rescue device (e.g. between the spreader 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: Pulling
Only work with the tips, small, tips slip off. Only so that the spreader for increasing the size is not damaged in the of a gap (not suitable area of the light metal for spreading) arms. 6.3 Pulling WARNING / CAUTION / PLEASE NOTE! The light metal alloy spreader arms may not be damaged. - LUKAS chain sets must be used for pulling. - When using a chain for pulling, make sure that the pins and hooks are positioned correctly so that the chain cannot slip. - Only chain sets in perfect condition may be used. - The pulling chains must be checked by an expert at least once a year. - Also consult the separate operating instructions for the corresponding chain set! Mounting bore for chain set... -
Page 17: Squeezing
The 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 555 EWXT: KSV 11 NOTE: Also take note of all the instructions and regulations in the separately provided operating instructions for the chain sets. 6.4 Squeezing Squeezing is allowed - In the area of the tips. Squeezing... -
Page 18: Peeling
- With the special squeezing plates „A“ in the arms. 6.5 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 9.3.1 Tip changing. -
Page 19: Dismantling The Equipment / Deactivation Following Operation
WARNING / CAUTION! With particularly hard materials, chips may break out in an uncontrolled manner. Please maintain the safety distance! 7. Dismantling the equipment / deactivation following operation Once work has been completed, the device arms should be closed until the tips are only a few millimeters apart. This relieves the hydraulic and mechanical strain on the equipment. NOTE: Never store the eDRAULIC devices with fully closed arms! By fully closing the arms hydraulic and mechanical tension may develop in the device. Clean the rescue device after each operation and grease both the metallic and the mechanically movable parts. The lock of the spreader plug-on tips should also be greased from time to time. Greasing provides protection against excessive wear and tear or corrosion. Avoid storing the rescue equipment in a damp environment. -
Page 20: Maintenance And Service
To perform maintenance and repairs, personal safety equipment appropriate for the work is a mandatory requirement. Where appropriate, the maintenance and repair staff must prove that they have adequate technical and specialised knowledge. 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 manual • the tools are tested on a regular basis as per our instructions on preventive maintenance 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 21: Overview Of Edraulic Spreader
• Use a clean, dust free, moist towel to wipe the tool and battery down to remove residual dirt and debris. • Allow tool and battery to air dry at room temperature as long as possible before next use. 36-48 hours is recommended. • Lubricate all exposed steel parts (spreader tips, squeezing plates, protective plates, etc.) with a rust inhibitor, like WD-40 Long Term Rust Inhibitor. • Carry out functional test as described in 8.3 8.3 Overview of eDRAULIC spreader Inspections to be carried out: Visual Inspection Spreader • Opening width of arms at the tips (see chapter on "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, • Spreader arms not cracked, • Pins and retaining rings on the spreader arms are present and in a proper condition, • Corrugation of the tips clean and well-edged, no tears. -
Page 22: Repairs
9.2 Preventive service 9.2.1 Care instructions The outside of the device should be cleaned with a damp cloth from time to time (not the electrical contacts in the connection slot, on the battery). In addition, the metal surfaces are to coated with a suitable medium to counteract corrosion (not the electrical contacts in the connection slot, on the battery). (In case of doubt, contact your authorized LUKAS dealer or LUKAS directly!) -
Page 23: Repairs
9.2.2 Function and load test 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 plug-on tips Procedure: 1. In order to remove the plug-on tips “G”, you need to push the buttons “J” on both sides of a spreader arm completely and simultaneously and then remove the plug-on tip from the spreader arm by pulling it forwards. 2. Place the new tips onto the arm until they automatically click in place on the spreader arm. NOTE: Always replace both plug-on tips. When inserting the new tips, push both buttons “J” until the tip can be slid over them. After fitting, make sure that both buttons “J” are locked on each arm (that they are back in their original position). - Page 24 9.3.2 Replacing the handle 1. Close the rescue unit until a gap of only a few mm remains between the tips. Now switch off the device and remove the battery from the device. Clean the rescue equipment carefully. 2. Remove the fixing screws “A” and remove the top section of the handle “B”.
- Page 25 3. Remove the fixing screws “C” and remove the bottom section of the handle “D”. 4. Attachment of the handle takes place in the reverse sequence. NOTE: The torque required can be taken from the spare parts list of your particular unit.
- Page 26 9.3.3 Replacing the yoke cover 1. Remove the fixing screws “A” and remove the yoke cover “B”. yoke 2. Install the new cover.
- Page 27 9.3.4 Replacing the squeezing plates 1. Completely open the rescue equipment. Now switch off the device and remove the battery from the device. Clean the rescue equipment carefully. 2. Remove the fixing screws “A” and remove the squeezing plates “B”. squeezing plates 3. Install the new...
- Page 28 9.3.5 Replacing the protective plates 1. Close the rescue unit until a gap of only a few mm remains between the tips. Now switch off the device and remove the battery from the device. Clean the rescue equipment carefully. 2. Remove the fixing screws “A” and remove the protective plates “B”. protective 3. Install the new plates.
- Page 29 9.3.6 Replacing the protective covers 1. Remove the fixing screws “A” and remove the protective covers “B” using an appropriate tool. protective 2. Install the new covers. 9.3.7 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 30: Troubleshooting
10. Troubleshooting Fault Check Cause Solution The motor does not The main switch The star grip was In order to resume start after activating is not illuminated, not used for some work with the device, the star grip. although it has not time (at least 10 the eDRAULIC been switched off. minutes) during device must first battery operation. be switched off at The rechargeable the mains and then battery has switched on again. switched itself off. Alternatively, the capacity display on the rechargeable battery can be activated or the battery may be briefly unplugged and replugged again. Spreader arms Battery fully Battery flat... - Page 31 Fault Check Cause Solution 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 not working reset by personnel the central position smoothly? specially trained Soiled valve or star by LUKAS, or by grip LUKAS itself Defective valve Other mechanical damage (e.g. star grip) Hydraulic fluid Defective rod seal Repair by an leaking from the authorized dealer, piston rod by personnel Damage to the specially trained piston by LUKAS, or by LUKAS itself The useful...
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Page 32: 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.: (+49) 09131 / 698 - 348 Fax.: (+49) 09131 / 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: SP 555 EWXT: 70 MPa... -
Page 33: Edraulic Spreader
11.1 eDRAULIC spreader Device type SP 555 EWXT Item number 90-15-23 [mm] 923 x 265 x 253 Dimensions (excluding battery) L x W x H [in.] 36.3 x 10.4 x 9.96 Minimum spreading force [kN] (at a distance of 25 mm / [lbf.] 11690 0.98 inches from the tips) [kN] Max. possible spreading force * [lbf.] 147924 [kN]... -
Page 34: Peeling
11.2 Peeling Device type SP 555 EWXT [mm] Max. sheet steel thickness “t” [in.] 0.12 [mm] Max. possible opening [in.] 25.2 11.3 Noise emission (based on standard EN ISO 3744) Device type SP 555 EWXT Battery type used for device Lithium/ion Idling (measured at a distance of 1 m, [dB(A)]... -
Page 35: Ec Declaration Of Conformity
12. EC Declaration of Conformity... -
Page 37: 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. Query button NOTE: To ensure maximum Charging state operating time and display maximum uptime, you must make sure that the battery is always fully charged before connecting it to a rescue device. Technical Data nom. Voltage Capacity Energy Weight Unit V DC Battery type 1 25,2 2.65 Battery type 2 25,2 3.53 The charge status display is activated either by pressing a switch or activates automatically when reaching a certain charge level (see table below). Capacity... -
Page 38: 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 Chain sets Chain sets are required in order to be able to perform pulling operations with the eDRAULIC spreader (see chapter, "Pulling"). Suitable chain sets: for SP 555 EWXT: KSV 11 14. Instructions regarding disposal Please duly dispose of all packaging materials and removed items. Electrical equipment, accessories and packaging should always be disposed of in an environmentally compatible way. Only for EU countries: Do not dispose of electrical equipment with your household waste! -
Page 39: Notes
15. Notes... - Page 40 A Unit of IDEX Corporation Weinstrasse 39, D-91058 Erlangen Tel.: (+49) 0 91 31 / 698 - 0 Fax.: (+49) 0 91 31 / 698 - 394 E-mail: lukas.info@idexcorp.com www.lukas.com Made in GERMANY eDRAULIC2_manual_171255085_SP555EWXT_en.indd © Copyright 2019 LUKAS Hydraulik GmbH...
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