Lukas R 430 User Manual
Instruction manual for rescue equipment
Rescue Rams
alternative coupling system:
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12
11
8
14
4
1 Star grip
2 Control valve
3 Hydraulic cylinder
2
1
7
3
2
4 Piston rod (R41x)
5 Piston rod 1 (R42x; R43x)
6 Piston rod 2 (R42x; R43x)
7 Handhold
1
8 Claw, piston side
9 Claw, cylinder side
7
10 Hose, pressure
11 Hose, return
12 Mono-coupling male
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13 Quick-disconnect coupling
(male)
10
14 Quick-disconnect coupling
(female)
13
6
5
3
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174010085 EN
9
(Translation of the original instruction manual)
12
Edition 10.2014
replaces 01.2014
Content Page
1. Hazard classes 4
2. Product safety 5
3. Safety regulations for hydraulic hoses 8
3.1 Advices for hoses 9
3.2 Safeguarding the environment in the event of failure of the
hoses 9
3.3 Storage of hoses 9
3.4 Labelling the hoses 10
3.5 Dates for inspections and replacement of hoses 10
3.6 Examples of possible defects of hoses 10
4. Proper use 11
5. Description of the functions 12
5.1 Description 12
5.2 Circuit diagram 12
5.3 Control of the operating movements 12
5.4 Type R 41x 13
5.5 Type R 43x / R 42x 13
5.6 Hydraulic supply 13
5.7 Hoses 13
6. Connecting the equipment 14
6.1 General information 14
6.2 Coupling the mono-couplings 14
6.3 Coupling the quick-disconnect couplings (alternative system) 15
7. Operation 16
7.1 Preparatory measures 16
7.2 Danger notes 18
7.3 Operating the star grip
7.4 Use of extensions 19
8. Dismantling the equipment / deactivation following operation 19
8.1 Rescue ram 19
8.2 Hydraulic unit 20
8.3 Hoses 20
9. Maintenance and service 20
(cover: item 1) 19
2
10. Repairs 21
10.1 General information 21
10.2 Preventative service 22
10.3 Repairs 23
11. Troubleshooting 26
12. Technical Data 29
12.1 Recommended hydraulic fl uid 33
12.2 Hoses 33
12.3 Operating and storage temperature ranges 33
13. EC Declarations of conformity 34
14. Notes 35
3
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 specifi c hazard
and possible consequences.
Pictogram
Wear helmet with face protection
Damage /
injury to
human
device
- REMARK
Key word Defi nition Consequences
DANGER! Immediate danger
WARNING!
CAUTION!
CAUTION!
Potentially
dangerous
situation
Less dangerous
situation
Danger of damage
to device /
environment
Advice for
application and
other important /
useful information
and advice
Death or major
injury
Potential death or
major injury
Minor or slight
injury
Damage to the
equipment,
damage to the
environment,
damage to
surrounding
materials
No injury /
damage to
persons /
environment /
equipment
Wear safety gloves
Wear safety shoes
Proper recycling
Observe principles of environmental protection
Read and observe operating instructions
4
2. Product safety
LUKAS products are developed and manufactured in order to guarantee the best performance
and quality when used properly.
Operator safety is the most important aspect of the product design.
Moreover, the operating instructions are intended to help the safe use of LUKAS products.
The generally applicable, legal and other binding regulations pertaining to the prevention of
accidents and protection of the environment apply and are to be implemented in addition to
the operating instructions.
The equipment may only be operated by persons with appropriate training in the safety
aspects of such equipment – otherwise, there is a danger of injury occurring.
We would like to point out to all users that they should read carefully the operating instructions
and the instructions contained therein before they use the equipment, and that they should
carefully follow such.
We further recommend that a qualifi ed trainer train you in the use of the product.
WARNING / CAUTION!
The operating instructions for the hoses, the accessories and the connected
hydraulic equipment must also be observed!
Even if you have already received instructions on how to use the equipment, you should still
read the following safety notes through again.
WARNING / CAUTION!
Ensure that the accessories and connected equipment used are suitable for
the max. operating pressure!
Please ensure that no body
parts or clothing get stuck
between the visibly moving
parts (e.g. 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 behaviour)! 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 fi res.
Do not carry out any changes
(additions or conversions)
to the equipment without
obtaining the prior approval of
LUKAS.
5
Observe all safety and danger
notes on the equipment and in
the operating instructions.
All safety and danger notes on
the equipment are to be kept
complete in a legible condition.
Any mode of operation which
impairs safety and/or stability
of the equipment is forbidden!
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 equipment is fi lled with a
hydraulic fl uid. These hydraulic
fl uids can be dangerous to
health if swallowed or their
vapours inhaled. Direct contact
with the skin is to be avoided
for the same reason. Please
also note that hydraulic liquids
can also have a negative effect
on biological systems.
Comply with all specifi ed
dates or dates specifi ed 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 LUKAS
accessories and spare parts
may be used for repairs.
Please ensure that, when
working with this equipment
or during transportation of
such, you don’t get stuck in the
looped hoses and trip.
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.
6
Ensure adequate lighting when
you are working.
Always keep these operating
instructions within reach where
the equipment is used.
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.
Before transporting the
equipment, always ensure that
the accessories are positioned
such that they cannot cause an
accident.
Ensure the proper disposal
of all removed parts, left-over
hydraulic fl uid, left-over oil and
packaging materials!
WARNING / CAUTION!
The equipment is to be used exclusively for the purpose stated in the operating
instructions (see chapter “Proper Use”). Any other or further use is not considered
proper use. The manufacturer / supplier is not liable for any damages resulting from improper
use. The user bears sole responsibility for such.
Observance of the operating instructions and compliance with the inspection and maintenance
conditions are part of the proper use.
Never work when you are overtired or intoxicated!
7
3. Safety regulations for hydraulic hoses
WARNING / CAUTION / ATTENTION!
- Never bring the hoses into contact with brake fl uid.
- The hoses are to be cleaned immediately should they come into contact with the
following fl uids:
• acids, lyes, solvents
• alcohol, fuel and ATF (Automatic Transmission Fluid)
• battery acid
• phosphate ester
It is also imperative that the hoses be inspected for damage following cleaning! If necessary ,
the hose assemblies are to be replaced!
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2
3
4
5
8
6
Fig. 2
3.1 Advices for hoses
- The determined operating pressure may not be exceeded.
- Tensile load and torsion to the hoses must be avoided (see fi gure 2, item 1). 1).
- Do not kink the hoses (see fi gure 2, item 2). 2).
- Do not drag or lay hoses across sharp edges (see fi gure 2, item 3). 3).
- Do not connect twisted hoses (see fi gure 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 fi gure 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 fi gure 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 infl uences, 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
- Leaking hydraulic fl uid under high-pressure can cause serious injuries to the
skin.
- In the event of injuries, immediately consult a doctor!
Hydraulic fl uid must immediately be removed from wounds!
- Do not use your fi ngers to detect leaks!
- Relieve the hydraulic system before you loosen connections!
for hairline cracks!
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 fi lm). Avoid direct
sunlight and UV rays. Screen from heat sources in the vicinity.
- Do not use any ozone-forming lighting fi xtures such as fl uorescent light sources,
mercury vapour lamps) or electrical equipment close to the equipment.
- Store hoses such that they are stress-free in a fl at position. If storing in rings, the
smallest bending radius stated by the manufacturer may not be exceeded.
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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 identifi cation and month / year of manufacture.
manufacturers identifi cation
month / year operating pressure
3.5 Dates for inspections and replacement of hoses
- After each use, inspect the hoses for external damage, tears, 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 fi rst 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 suffi cient
knowledge in the fi eld 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 fi tting.
- Damage or deformations to the fi tting which impair the function and stability of the fi tting
or the connection between the hose and the fi tting.
- Corrosion to the fi tting or metal insert which impairs the function and stability.
- Periods of storage and use have been exceeded.
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4. Proper use
The LUKAS rescue equipment is designed specifi cally for the emergency services. Their
objective is to free people trapped in traffi c accidents when the clearance distance of a
spreader is insuffi cient e.g. by spreading or lifting car parts (see fi gure 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).
CAUTION!
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 LUKAS
accessories programme.
WARNING / CAUTION!
The following may not be squeezed:
- live cables
- 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 and/or injuries.
Spare parts and accessories for the rescue tool can be ordered from your authorisied
LUKAS-dealer!
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