User Manual - Hurst Jaws Of Life
Contents
1. 9 Maintenance and service 10 Repairs 10 1 General information 10 2 Preventative service 10 3 Repairs 11 Troubleshooting 12 Technical Data 12 1 Recommended hydraulic fluid 12 2 Hoses 12 3 Operating and storage temperature ranges 13 Notes 21 21 22 23 26 29 33 33 33 34 1 Hazard classes 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 specific hazard and possible consequences Damage ae Potentially dangerous situation WARNING Danger of damage CAUTION to device environment Advice for application and REMARK other important useful information and advice Wear helmet with face protection Wear safety gloves Wear safety shoes Proper recycling Observe principles of environmental protection Read and observe operating instructions SKIO 4 DANGER Immediate danger Death or major injury Potential death or major injury CAUTION Less dangerous Minor or slight situation injury Damage to the equipment damage to the environment damage to surrounding materials No injury damage to persons environment equipment 2 Product safety HURST 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 oper2. Coupling needs to be replaced immediately Hydraulic fluid Hydraulic fluid not adapted to must be replaced the application see chapter situation Recommended Hydraulic fluids Coupling defective Coupling needs to be replaced immediately C Repair by an authorised dealer by personnel specially trained by HURST or by HURST itself Relieve pump oupling defective Coupling needs to be replaced immediately Leak possible Replace hoses damage Mechanical Replace hoses damages or contact with aggressive agents 26 Trouble Control Cause Solution Hydraulic fluid leak on the piston rod Defective rod seal Repair by an Damage to the authorised dealer by piston personnel specially trained by HURST or by HURST itself Leak on the handhold Increase load Load increase Secure the loads and e g something move them by using has fallen onto the other tools Especially by usage of quick disconnect couplings Leak on the handhold Especially by usage of mono couplings part to be lifted Position ram on a thereby suddenly different place where increasing the the load to be moved load is lower Use supporting equipment to move the load Is the set pressure Pressure release Following the on the pump in the Rescue tool reduction in pressure adapted to comply no further leak is with the maximum present permissible Should however pressure for there be a further the res
3. Depending on the piston stage they have varying pressure forces However the pressure force remains constant within one piston stage An advantage offered by this range is the large stroke at a relatively low construction height 5 6 Hydraulic supply AHURST motor pump or hand pump only may be used to drive the equipment If the pump unit is a different make you must make sure that it complies with HURST specifications otherwise potential dangers may occur which are not the responsibility of HURST Ensure in particular that the authorised operating pressure is not exceeded REMARK i Before you use pumps from a different manufacturer you must contact HURST or an authorised dealer 5 Hoses The pump unit and the rescue ram are connected by hoses 13 6 Connecting the equipment 6 1 General information 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 REMARK The devices can be equipped with different coupling systems They differ only by the article number and not by the designation Of course the coupling systems can also be reequipped at a later time 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 HU
4. department is HURST JAWS OF LIFE HALE PRODUCTS INC A Unit of IDEX Corporation 711 N Post Road Shelby NC 28150 USA Phone 704 487 6961 Fax 704 487 7271 e mail contacthurst idexcorp com 28 12 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 schedules Tye R40 R42 R44 R430 Ref No 274040000 274050000 274060000 274070000 Pressure force kN 266 266 piston 1 lbf 59 802 59 802 Pressure force KN 133 133 piston 2 lbf 29 901 29 901 Pressure force KN 39 piston 3 lbf 8 768 max stroke mm 295 365 445 295 e max stroke mm 280 340 430 280 E max stroke mm 245 piston 3 in 9 65 Piston stroke mm 575 705 875 820 overall in 22 64 27 76 34 45 32 28 mm 480 550 625 475 Length retracted in 18 90 21 65 24 61 18 70 mm 1055 1255 1500 1295 Length extended in 41 54 49 41 59 06 50 98 Dimensions mm 112 x 211 112 x 210 wxh in 4 41 x 8 31 4 41 x 8 27 Weight including kg 16 9 18 9 21 1 17 8 hydraulic fluid filling Ibs 37 3 41 7 46 5 39 2 max operating MPa pressure psi 10 153 min needed 1 1 5 1 8 2 2 1 6 volume of hydraulic fluid gal US 0 40 0 48 0 58 0 42 coupling system mono coupling i 1 MPa 10 bar Necessary volume of hydraulic fluid in the hydraulic unit to operate the unit differential volume on piston rod s
5. Attach new labels Ensure that you attach the labels in the right position If you are no longer sure about this then please contact your authorised HURST dealer or HURST itself 25 11 Troubleshooting Trouble Control Cause Solution Cylinder piston moves slowly or jerkily when activated Are the hoses connected properly Air in the hydraulic Deaerate pump Does the pump unit work Equipment doesn t come up with the full power the hydraulic fluid level in the supply pump Is it hard to move the star grip Following release the star grip doesn t return to the central position with mono coupling system Hoses cannot be coupled with mono coupling system It is frequently not possible to couple hose assemblies Is the pump working with quick disconnect coupling system Hoses cannot be coupled Are the hoses defective Hydraulic fluid leak on the hoses or the fixing ins Damages on the surface of the hydraulic hoses Have you checked Control the degree of viscosity and application temperature of the used hydraulic fluid Insufficient hydraulic fluid in the pump Top up hydraulic fluid deaerate Damage to the torsion spring for reset Soiled valve or star grip Defective valve Other mechanical damage e g star grip Pressure too high Set hydraulic pump e g caused by to pressureless too high ambient circulation temperature Coupling defective
6. Operating instructions SH HURST for rescue equipment JAWS OF LIFE HIGH PRESSURE 274010085 US Rescue Rams Issue 06 2008 replaces 09 2007 Star grip Control valve Hydraulic cylinder Piston rod R41x Piston rod 1 R42x R43x Piston rod 2 R42x R43x Handhold Claw piston side Claw cylinder side 10 Hose pressure 11 Hose return 12 Mono coupling male 13 Quick disconnect coupling male 14 Quick disconnect coupling female OONOOARWN 10 12 Content 1 Hazard classes 2 Product safety 3 Safety regulations for hydraulic hoses 3 1 3 2 3 3 3 4 3 5 3 6 Advices for hoses Safeguarding the environment in the event of failure of the hoses Storage of hoses Labelling the hoses Dates for inspections and replacement of hoses Examples of possible defects of hoses 4 Proper use 5 Description of the functions 5 1 5 2 5 3 5 4 5 5 5 6 5 7 Description Circuit diagram Control of the operating movements Type R 41x Type R 43x R 42x Hydraulic supply Hoses 6 Connecting the equipment 6 1 6 2 6 3 General information Coupling the mono couplings Coupling the quick disconnect couplings alternative system 7 Operation 7 1 7 2 7 3 7 4 Preparatory measures Danger notes Operating the star grip cover item 1 Use of extensions 8 Dismantling the equipment deactivation following operation 8 1 8 2 8 3 Rescue ram Hydraulic unit Hoses
7. RST directly 6 2 Coupling the mono couplings The equipment is connected to the hydraulic pump via mono coupling halves male and female dust protection caps mono coupling halve male mono coupling halve female 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 14 REMARK lil 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 off the hose assemblies and or the hose assemblies be confused 6 3 Coupling the quick disconnect couplings alternative system The equipment is connected to the hydraulic pump via quick disconnect coupling halves male and female Before coupling unlock the connect socket by turning the sleeve into position X Retract sleeve and connect plug and socket Release sleeve and turn it into position Y Now the connection
8. and the fitting Corrosion to the fitting or metal insert which impairs the function and stability Periods of storage and use have been exceeded 10 4 Proper use The HURST rescue equipment is designed specifically for the emergency services Their objective is to free people trapped in traffic accidents when the clearance distance of a spreader is insufficient e g by spreading or lifting car parts see figure below Their objective in other disasters is to rescue buried or trapped persons e g to remove pieces of concrete from collapsed houses The equipment can also be used under water at a depth of up to 40m 131 ft y CAUTION ra In this case you must strictly observe any leaks in order to avoid threats to the environment Basically objects can be pushed away or their position can be altered WARNING CAUTION All objects which have to be moved are to be secured using stable supports or substructures Furthermore it must be ensured that the rescue ram cannot slip We recommend that you use support bearings These are available in the HURST accessories programme WARNING CAUTION The following may not be squeezed live cables Q hardened parts such as 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 an
9. ating 4 0 131 F HM 10 VG 10 ee recommended viscosity range 10 200 mm s 10 200 cSt Supplied with HM 10 ISO 6743 4 CAUTION Before using hydraulic fluids which do not correspond to the above mentioned specifications and or are not purchased from HURST you have to contact HURST itself 12 2 Hoses Bending radius Rmin 38 mm Rmin 7 5 in a Pai Burst pressure max Operating pressure Temperature resistance 40 C 100 C 40 F 212 F Operating fluid Mineral oil according to ISO 6743 4 12 3 Operating and storage temperature ranges Operating temperature C 20 55 Ambient temperature device in operation C 25 45 Storage temperature device not in operation C 30 60 Operating temperature F 4 131 Ambient temperature device in operation F 13 lt a 113 Storage temperature device not in operation F 22 140 33 13 Notes 34 35 Please dispose all packaging materials and dismantled parts properly HURST JAWS OF LIFE S HURST HALE PRODUCTS INC a e A Unit of IDEX Corporation JAWS OF LIFE D HIGH PRESSURE 711 N Post Road Shelby NC 28150 USA Phone 704 487 6961 Fax 704 487 7271 IBEX e mail contacthurst idexcorp com FIRE g SAFETY ee ee eee eee Rescue _ Ram _BA DRUCK US 274010085 0608 indd Copyright 2008 Hale Products Inc subject to revision
10. ating instructions are intended to help the safe use of HURST 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 qualified trainer train you in the use of the product WARNING CAUTION A 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 piston claw and cylinder Wear protective clothing safety helmet with visor protective gloves The responsible department is to be informed immediately of any changes including to the operating beha
11. cks Leaking hydraulic fluid under high pressure can cause serious injuries to the skin In the event of injuries immediately consult a doctor Hydraulic fluid must immediately be removed from wounds Do not use your fingers to detect leaks Relieve the hydraulic system before you loosen connections 3 3 Storage of hoses Even when stored correctly and used properly hoses are subject to a natural ageing process This means that their period of storage and period of use are restricted The following is to be observed when storing the hoses Store in a cool dry and low dust condition possibly wrap in plastic film Avoid direct sunlight and UV rays Screen from heat sources in the vicinity Do not use any ozone forming lighting fixtures such as fluorescent light sources mercury vapour lamps or electrical equipment close to the equipment Store hoses such that they are stress free in a flat position If storing in rings the smallest bending radius stated by the manufacturer may not be exceeded 3 4 Labelling the hoses The hose is to bear the name of the manufacturer and the authorised operating pressure The press sleeve is to bear the maximum authorised operating pressure and the manufacturers identification and month year of manufacture manufacturers identification month year operating pressure 3 5 Dates for inspections and replacement of hoses After each use inspect the hoses for external damage tear
12. cue leak on the handhold equipment immediately deactivate the rescue equipment and contact an authorised dealer or HURST itself Hoses in handhold Hoses in handhold Tighten hoses loose not tightened Check the Supply and return Reconnect the connections of the connection of the hoses of the mono mono coupling mono coupling cooupling female in female female inverted the right way Is the return Return hose is not Re connect the return hose connected coupled correctly hose and secure it correctly or not connected check the hose connection reconnect the hoses connections of the to the couplings to the coupling in the Leak on the handhold hoses interchanged right way Returnline disconnect the disabled returnline from the coupling clean it and reconnect it 27 Trouble Control Cause Solution with mono coupling s the coupling coupling damaged Coupling must be system EA inthe damaged replaced immediately couplings with quick Is the coupling coupling damaged Coupling must be disconnect coupling damaged replaced immediately system Leak in the couplings Is the leak only Safety valve After pressure on the coupling reacted release there is no male in uncoupled more leakage status If it isn t possible to rectify the malfunctions inform an authorised HURST dealer or the HURST customer service department immediately The address for the HURST customer service
13. d or injuries Spare parts and accessories for the rescue tool can be ordered from your authorisied HURST dealer 11 5 Description of the functions 5 1 Description The rescue rams are double acting hydraulic cylinders Extension retraction are carried out hydraulically The direction of travel is controlled via a valve with star grip All rescue rams ensure full load holding function when disconnected from the hydraulic supply e g when being unintentional decoupled defective hose and so on For reasons of safety rams R414 are internally safeguarded from 63 MPa 630bar When the safeguarding valve responds a screeching noise can occur Even if the screeching noise occurs in unloaded condition deactivate the equipment immediately and contact your authorized dealer or HURST directly 5 2 Circuit diagram To enable comprehension of the function a simplified circuit diagram hydraulic cylinder of the rescue equipment A hand valve B are depicted here Extend piston Retract piston 5 3 Control of the operating movements The piston movement is controlled via the star grip of the mounted valve see cover item 1 and below figure 3 ug star grip 12 5 4 Type R 41x Type R 41x rescue rams are one stage cylinders for applying pressure with a constant pressure force along the entire stroke 5 5 Type R 43x R 42x Type R 43x R 42x rescue rams are multi stage cylinders for applying pressure
14. e flush When positioning the rescue ram to a HURST support bearing it is imperative that the area between the four ends of the claw are flush with the round bar of the bearing This avoids a one sided application of force into the cylinder Lifted objects must then be secured by means of stable supports or substructures mn 7 2 Danger notes Before activating the rescue ram always ensure that there is no danger to persons either involved uninvolved in the action by the movement of the piston rod or by flying fragments Further avoid unnecessary damage to property belonging to others objects not involved by the cylinder pistons flying fragments T Holding the piston rod during operation of the equipment is i strictly forbidden 18 7 3 Operating the star grip cover item 1 Extend piston amp Turn the star grip in a clockwise direction in the direction of the relevant symbol and keep in this position Retract piston EEF Turn the star grip in an counterclockwise direction in the direction of the relevant symbol and keep in this position Dead man function Following release the star grip automatically returns to the central position guaranteeing the full load holding 7 4 Use of extensions The R410 rescue ram may only be operated with the HURST extension length 250mm No other rescue Ext ram may be operated with an extension furthermore operation is only permitted usin
15. e lighting Before transporting the when you are working equipment always ensure that the accessories are positioned such that they cannot cause an accident Always keep these operating Ensure the proper disposal instructions within reach of all removed parts left over where the equipment is used hydraulic fluid left over oil and packaging materials 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 A Never work when you are overtired or intoxicated A 3 Safety regulations for hydraulic hoses CAUTION Never bring the hoses into contact with brake fluid The hoses are to be cleaned immediately should they come into contact with the following fluids acids lyes solvents alcohol fuel and ATF Automatic Transmission Fluid battery acid phosphate ester It is also i
16. function and load test must also be performed HURST offers appropriate test equipment to this end ae 2 3 Changing the hydraulic fluid The hydraulic fluid must be changed after the equipment has been used approx 200 times after three years at the latest It must always be changed whenever the hydraulic fluid for the accompanying pump motor hand pump is changed This is to prevent the fresh hydraulic fluid from becoming contaminated by the used fluid from the rescue equipment Procedure 1 Completely retract rescue ram 2 Change the hydraulic fluid of the pump Please observe the separate operating instructions for the pump being used 3 Screw off the return hose on the pump when the hose connection is directly into the pump completely unscrew the connection nut of the connection piece of the blue return hose when the hose connection is via mono coupling to the pump remove the cover from the mono coupling male completely unscrew the connection nut of the blue returnhose on the mono coupling male when the hose connection is via quick connect coupling to the pump completely unscrew the connection nut on the quick disconnect coupling of the blue return hose 4 Put the return hose into a separate collecting basin for the hydraulic fluid still in the equipment 5 Slowly extend the rescue ram the pump must be working during this time The old hydraulic fluid from the ring space side runs via the return hose i
17. g the original HURST extension The extension is assembled from the right hand side as depicted Rescue Ram i WARNING CAUTION i Rescue rams with extensions are to be carefully monitored during their use If there are signs of a serious change to its behaviour work is to be interrupted immediately and if necessary even stopped altogether After every use interruption to use carefully control the cylinder and the extension for damage 8 Dismantling the equipment deactivation following operation 8 1 Rescue ram Once work has been completed the rescue rams are to be retracted so that just a few mm protrude This relieves the hydraulic and mechanical strain on the equipment REMARK i Due to fluctuations to the ambient temperature the storage of rescue rams can cause small lifting motions in the equipment This effect is a physical reaction to the expansion of the hydraulic fluid enclosed in the piston and rod side For this reason the storage room for rescue rams is to be designed such that there is up to 30mm 1 18 in space to allow for a potential extension to the length 1mm 0 04 in 19 8 2 Hydraulic unit Upon completion of work the unit must be deactivated 8 3 Hoses 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 9 Maintenance and service The e
18. has been made and locked Uncoupling is done in the reverse order _ CAUTION t a Always connect the return line first and afterwards the supply line REMARK Coupling of the devices is only possible when the hoses are depressurized To protect them from dust the accompanying dust protection caps must be put back on A WARNING CAUTION The quick disconnect couplings partly have special functions Therefore it is not allowed to screw them off from the hoses or to exchange them 15 7 Operation 7 1 Preparatory measures 7 1 1Commissioning Before commissioning and following repairs the equipment must be deaerated Connect the equipment to the hydraulic pump see chapter Connecting the equipment Extend retract the equipment without any load at least twice see chapter Operation of the star grip REMARK lil 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 piston rod facing upwards 2 open and close fully with the piston rod facing downwards 3 open and close fully with the piston rod facing upwards 4 open and close fully with the piston rod facing downwards 7 1 2Inspection of the pump unit gt See separate operating instructions for the relevant pump unit or for the hand p
19. he cover from the couplings 3 Position the new coupling and tighten the connection nuts of the hose assemblies with a torque of M 40 Nm and push the cover of the couplings back on CAUTION Take care that the port T of the rescue ram is always connected to the port T of the mono coupling 24 10 3 3 Quick disconnect couplings The quick disconnect couplings on the connection hoses on the equipment must be replaced in the event of external visible damage the locking device not working hydraulic fluid continually leaking in a coupled uncoupled state A WARNING CAUTION Never repair couplings they are to be replaced by original HURST parts During assembly tighten the connection nut of the hose assembly with a torque of M 35 Nm Procedure 1 Loosen the connection nut of the hose assembly and remove the coupling 2 Position the new coupling and tighten the connection nut of the hose assemblies with a torque of M 35 Nm CAUTION The return hose which is screwed onto the port T of the rescue ram must be equipped with a quick disconnect coupling male always However the supplying hose line must be equipped with a quick disconnect coupling female 10 3 4 Labels All damaged and or illegible labels safety notices type plate etc must be renewed Procedure 1 Remove damaged and or illegible labels 2 Clean the surfaces using acetone or industrial alcohol 3
20. ide 29 Type RAO TR AIZ R4 Ref No 274010000 274020000 274030000 Pressure force in kN 135 122 all operating ranges fbf 30 351 27 428 mm 300 500 700 Piston stroke in 11 81 19 69 27 56 mm 450 680 900 Length retracted in 17 72 26 77 35 43 mm 750 1180 1600 Length extended in 29 53 46 46 62 99 Dimensions mm 86 x 174 wxh fin 3 39 x 6 85 Weight including kg 13 1 17 8 24 3 hydraulic fluid filling lbs 28 9 39 2 53 6 max operating Mpa 70 pressure psi 10 153 min needed i 0 5 0 8 1 2 volume of hydraulic fluid gal US 0 13 0 21 0 32 j 1 MPa 10 bar Necessary volume of hydraulic fluid in the hydraulic unit to operate the unit differential volume on piston rod side 30 Tye R40 R42 R424 Rao Ref No 244070000 214040000 214060000 214050000 Pressure force kN piston 1 lbf 59 802 59 802 Pressure force KN 133 piston 2 lbf 29 901 pret Pressure force KN 39 piston 3 lbf 8 768 max stroke mm 295 365 445 295 piston 1 fin 11 61 14 37 17 52 11 61 max stroke mm 280 340 430 280 piston 2 fin 11 02 13 39 16 93 11 02 max stroke mm 245 piston 3 in ae Piston stroke mm 575 705 875 820 overall in 22 64 27 76 34 45 32 28 mm 480 550 625 475 Length retracted in 18 90 21 65 24 61 18 70 mm 1055 1255 1500 1295 Length extended in 41 54 49 41 59 06 50 98 Dimensions mm 112 x 211 112 Ea w
21. ion retraction upon activation of the star grip e no further movement of the piston upon interruption of the valve activation during the process dead man s function 20 10 Repairs 10 1 General information Servicing may only be carried out by the manufacturer or personnel trained by the manufacturer and by authorised HURST dealers Only HURST spare parts may be used to replace all components see spare parts list since special tools assembly advice safety aspects inspections might have to complied with see also chapter Maintenance and Service During assembly ensure the complete cleanliness of all components since dirt can damage the rescue equipment A WARNING CAUTION Protective clothes must be worn when repairs are being carried out since parts of the units can also be pressurised in an idle state REMARK i Please always return the guarantee registration card to HALE PRODUCTS INC Only then are you entitled to the extended guarantee REMARK Before you use couplings from a different company you must contact HURST or an authorised dealer REMARK when using the quick disconnect coupling system Overpressure protection of the rescue equipment model with yellow coupling nipple on the return hose If the equipment s short hoses are not connected to a hydraulic unit temperature increases can inadvertently cause pressure to build up in the equipment Hence the return hose of the equipment is eq
22. mperative that the hoses be inspected for damage following cleaning If necessary the hose assemblies are to be replaced 3 1 Advices for hoses The determined operating pressure may not be exceeded Tensile load and torsion to the hoses must be avoided see figure 2 item 1 1 Do not kink the hoses see figure 2 item 2 2 Do not drag or lay hoses across sharp edges see figure 2 item 3 3 Do not connect twisted hoses see figure 2 item 4 4 Never drive over the hoses with a motorised vehicle Hoses laid loosely across roads or paths are to be protected from damage e g by hose protection ramps see figure 2 item 5 In the event of high external temperatures the hoses are to be installed either at an adequate distance from the heat radiating components or are to be protected by suitable measures see figure 2 item 6 Do not hang any weights on the hoses 3 2 Safeguarding the environment in the event of failure of the hoses Hoses must be laid or secured such that in the event of a failure of the hose danger is avoided as far as possible Danger can be caused by The hose thrashing about following a tear caused by external influences for example The pressure media leaking under pressure The lighting of leaking pressure media within the vicinity of an ignition source The danger can be avoided by means of protective coverings or screening for example WARNING CAUTION for hairline cra
23. nto the separate collecting basin and is to be disposed of in the same manner as the old hydraulic fluid of the pump 6 Switch the pump off motor pump no longer activate it e g hand pump 7 Reconnect the return hose to the pump when the hose connection is directly into the pump screw the connection nut of the connection piece of the blue return hose back on Please observe the necessary torque of M 40 Nm when the hose connection is via mono coupling to the pump screw the connection nut of the blue return hose back onto the mono coupling male Please observe the necessary torque of M 40 Nm Pull back the cover on the couplings as far as the limit stop when the hose connection is via quick connect coupling to the pump screw the connection nut back onto the quick disconnect coupling of the blue return hose Please observe the necessary torque of M 35 Nm 8 Deaerate the rescue ram as described in the chapter Preparatory measures 22 10 3 Repairs 10 3 1 Changing or tightening hoses Hoses of the pressure and or return pipe leaks or hoses are defective Tighten the hoses on the safety valve Please note Observe torque of M 40 Nm CAUTION by usage of mono coupling system Take care that the port T of the rescue cylinder is always connected to the port T of the mono coupling CAUTION by usage of quick disconnect coupling system The return hose which is screwed onto the
24. port T of the rescue cylinder must be equipped with a quick disconnect coupling male always However the supplying hose line must be equipped with a quick disconnect coupling female Procedure 1 Loosen the 2 B screws in the handle sleeve with quick disconnect protective sleeves C hexagon socket A 2 Remove handle sleeve A and tighten screwed connection If necessary renew seals F E D 3 Dismantle hose D and sealing ring E There is no need to carry out this point if the hoses are just being tightened 4 Screw the hose with sealing ring back on Please ensure that the insulating washer F is dismantle on and correctly assembled lt a ssemble 5 Tighten the hose connection on the safety valve Please note Observe the necessary torque of M 40 Nm 6 Then replace handle sleeve protective sleeves and screws tighten Torque 5Nm and secure it with threadlocking fluid e g LOCTITE 243 23 10 3 2 Mono couplings The mono couplings on the connection hoses of the equipment must be replaced in the event of external visible damage the locking device not working hydraulic fluid continually leaking in a coupled uncoupled state A WARNING CAUTION D Never repair couplings they are to be replaced by original HURST parts During assembly tighten the connection nut of the hose assembly with a torque of M 40 Nm Procedure 1 Remove t
25. quipment is filled with a hydraulic fluid These hydraulic fluids 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 effect on biological systems All safety and danger notes on the equipment are to be kept complete in a legible condition Comply with all specified dates or dates specified in the operating instructions pertaining to regular controls inspections on the equipment The maximum permitted operating pressure noted on the equipment must not be exceeded Only original HURST 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 Please note that when applying pressure tearing or breaking can cause falling material or sudden removal of such can cause it to suddenly catapult off necessary precautions need to be taken Only touch any broken off parts wearing protective gloves since the torn edges can be very sharp When working with or storing the equipment ensure that the function and the safety of the equipment are not impaired by the effects 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 adequat
26. quipment 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 CAUTION Clean off any dirt before controlling the equipment A WARNING CAUTION In order to carry out maintenance and repair works tools appropriate for the job D and personal protecting equipment are essential Inspections to be carried out Visual inspection Rescue ram e Cylinder and piston rod are to be free of damage and deformation Correct firm fit of the claws Condition of the claws chipped spots General tightness leaks Operability of the star grip Existence and stability of handhold Labels completely existent and legibly Couplings must be easy to couple Dust protection caps must be available Hoses e Visual control for visible damage e Control for leaks Function test e That the piston stroke can be extracted retracted to its full length see chapter Technical data e Flawless extens
27. s kinks and swollen points The operator is responsible for ensuring that the hoses are replaced at regular intervals even if there are no visible safety defects on the hoses The hoses must be replaced 10 years after its manufacture see labelling at the latest Hoses are to be inspected by an expert to ensure that they are safe before they are used for the first time and then at least once per year Please see the following for possible defects An expert is somebody who due to his professional education and experience has sufficient knowledge in the field of hydraulic hoses and who is familiar with the relevant national health and safety regulations at work guidelines and generally acknowledged technical regulations e g EN standards such that he can assess the safe condition of the hydraulic hoses 3 6 Examples of possible defects of hoses Damage to the external layer through to the inside e g abrasive spots cuts or tears Embrittlement of the external layer formation of cracks on the hose material Distortions not in line with the natural form of the hoses in pressure free or in pressurised condition or bend e g separation of the layers blistering squashed parts kinks Leaks Installation requirements have not been complied with Shifting of the hose from its fitting Damage or deformations to the fitting which impair the function and stability of the fitting or the connection between the hose
28. uipped with a safety coupling quick disconnect coupling male yellow Unwanted overpressure approx 1 5 Mpa is automatically released via this nipple hydraulic fluid leaks Should an hydraulic fluid leak on the coupling male be more frequent please contact your dealer or HURST itself If couplings from a different company are used which do not have this function the overpressure protection can react in the valve of the rescue equipment Hydraulic fluid leaks in the area of the star grip Following the reduction in pressure the valve is once again tight Should the valve leak permanently please immediately contact your dealer or HURST itself CAUTION Because HURST rescue equipments are appropriate for highest achievements only components may be exchanged which are specified in the spare parts list of the appropriate equipment ipment may only be exchanged when you have participated on a appropriate HURST service training you have the explicit permission of the HURST Service department After inquiry examination for the distribution of permission Examination in each individual case necessary 21 10 2 Preventative service 10 2 1 Care regulations The exterior of the equipment is to be cleaned from time to time in order to protect it from external corrosion Oil is to be applied to the metallic surfaces 10 2 2 Function and load test If there is any doubt regarding the safety or reliability of the equipment a
29. ump 1 REMARK Before each start up of the hydraulic unit you have to make sure that the actuating valves are set to depressurized circulation REMARK Before coupling the quick disconnect couplings the actuating valves of the hydraulic unit are set to depressurized circulation If you use mono couplings you can also couple when the hoses are pressurized 16 7 1 2Support Before you can work using the rescue ram you must ensure adequate support this includes a necessary substructure The rescue rams come equipped with a claw on the cylinder side and on the piston side so that they can become hooked see figure 4 If this Support is inadequate such as in the case of a pushed away front of car see figure 5 or when lifting a vehicle see figure 6 additional support bearings cylinder attachments and if necessary protection using a belt for example are also necessary Appropriate support bearings and practical cylinder attachments are available from the HURST accessories programme fig 4 17 A WARNING CAUTION Never use a rescue ram without claw or adequate accessories The cylinder could D slip away while moving and this could result ininjuries of the user Furthermore E the piston rod or the adapter of the claw could be damage thereby WARNING CAUTION When positioning the rescue ram without HURST support bearings it is imperative that all four ends of both the piston claw and the cylinder claw ar
30. viour If necessary the equipment is to be deactivated immediately and secured In the event of malfunctions immediately deactivate the equipment and secure it The malfunction is to be repaired immediately 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 Inspect the equipment before and after use for visible defects or damage Inspect all cables hoses and screwed connections for leaks and externally visible damage If necessary repair immediately Squirting oil can result in injuries and fires Do not carry out any changes additions or conversions to the equipment without obtaining the prior approval of HURST Observe all safety and danger notes on the equipment and in the operating instructions Any mode of operation which impairs safety and or stability of the equipment is forbidden Safety devices may never be deactivated 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 When working close to live components and cables suitable measures must be taken to avoid current transfers or high voltage transfers to the equipment The build up of static charge with the potential consequence of spark formation is to be avoided when handling the equipment The e
31. xh in 4 41 x 8 31 Ea Weight including kg 16 9 18 9 17 8 hydraulic fluid filling Ibs 37 3 41 7 46 5 39 2 max operating MPa pressure psi 1 Ep Tod min needed 1 1 5 1 8 22 1 6 volume of hydraulic fluid gal US 0 40 0 48 0 58 0 42 coupling system quick disconnect coupling 1 MPa 10 bar Necessary volume of hydraulic fluid in the hydraulic unit to operate the unit differential volume on piston rod side 31 Type Rmo R2 R4 Ref No 244010000 214020000 214030000 Pressure force in kN 135 122 all operating ranges fbf 30 351 27 428 mm 300 500 700 Piston stroke in 11 81 19 69 27 56 mm 450 680 900 Length retracted in 17 72 26 77 35 43 mm 750 1180 1600 Length extended in 29 53 46 46 62 99 Dimensions mm 86 x 174 w xh in 3 39 x 6 85 Weight including kg 13 1 17 8 24 3 hydraulic fluid filling lbs 28 9 39 2 53 6 max operating Mpa 70 pressure psi 10 153 min needed I 0 5 0 8 1 2 volume of hydraulic fluid gal US 0 13 0 21 0 32 coupling system quick disconnect coupling 1 MPa 10 bar Necessary volume of hydraulic fluid in the hydraulic unit to operate the unit differential volume on piston rod side 32 12 1 Recommended hydraulic fluid Mineral oil ISO 6743 4 for HURST hydraulic equipment and others T Oil temperature range Viscosity rating 20 55 C HM 10 VG 10 i a Oil temperature range Viscosity r
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