Instruction manual for rescue equipment
Rescue Rams
alternative coupling system:
10
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
11
13 Quick-disconnect coupling
(male)
10
14 Quick-disconnect coupling
(female)
13
6
5
3
9
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!
1
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.
9
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.
10
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!
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 LUKAS directly!)
5.2 Circuit diagram
T o enable comprehension of the function, a simplifi ed circuit
diagram (hydraulic cylinder of the rescue equipment (A) +
hand valve (B) ) are depicted here.
Extend
piston
A
B
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, fi gure 3).
fi g. 3
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. 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
A LUKAS 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 LUKAS
specifi cations, otherwise potential dangers may occur which are not the responsibility of
LUKAS. Ensure in particular that the authorised operating pressure is not exceeded.
REMARK:
Before you use pumps from a different manufacturer, you must contact LUKAS
or an authorised dealer.
5.7 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 LUKAS
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)
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
mono-coupling
halve (female)
REMARK:
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).
X
Y
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 has been made and locked. Uncoupling is done in the reverse order.
CAUTION!
Always connect the return line fi rst 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.
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
7.1.1 Commissioning
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:
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.
7.1.2 Inspection of the pump unit
See separate operating instructions for the relevant pump unit (or for the hand
pump).
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
7.1.2 Support
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 fi gure 4). If this support is
inadequate, such as in the case of a pushed-away front of car (see fi gure 5) or when lifting
a vehicle (see fi gure 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 LUKAS accessories programme.
fi g. 4:
fi g. 5:
fi g. 6:
17
WARNING / CAUTION!
Never use a rescue ram without claw or adequate accessories! The cylinder could
slip away while moving and this could result ininjuries of the user. Furthermore
the piston rod or the adapter of the claw could be damage thereby.
WARNING / CAUTION!
When positioning the rescue ram (without LUKAS support bearings), it is
imperative that all four ends of both the piston claw and the cylinder claw are
fl ush.
When positioning the rescue ram (to a LUKAS support bearing), it is imperative
that the area between the four ends of the claw are fl ush 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!
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 fl ying fragments.
Further avoid unnecessary damage to property belonging to others, objects not involved by
the cylinder pistons / fl ying fragments.
Holding the piston rod during operation of the equipment is
strictly forbidden!
18
7.3 Operating the star grip (cover: item 1)
Extend piston ( ):
Turn the star grip in a clockwise direction (in the direction of the
relevant symbol) and keep in this position.
Retract piston ( ):
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
LUKAS extension (length = 250mm). No other rescue
ram may be operated with an extension: furthermore,
operation is only permitted using the original LUKAS
extension. The extension is assembled from the righthand side as depicted.
WARNING / CAUTION!
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!
Extension
Rescue Ram
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:
Due to fl uctuations 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 fl uid 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.
*) 1 mm = 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 equipment 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). In the Federal Republic of Germany, regular safety
inspections according to the regulations of the Gesetzlichen Unfallversicherung (GUV;
connoted ‘Legal accident insurance’) are mandatory.
CAUTION!
Clean off any dirt before controlling the equipment!
WARNING / CAUTION!
In order to carry out maintenance and repair works, tools appropriate for the job
and personal protecting equipment are essential.
Inspections to be carried out:
Visual inspection
Rescue ram
• Cylinder and piston rod are to be free of damage and deformation,
• Correct, fi rm fi t 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
• Visual control for visible damage,
• Control for leaks.
Function test
• That the piston stroke can be extracted / retracted to its full length (see chapter “T echnical
data”)
• Flawless extension / retraction upon activation of the star grip.
• 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 LUKAS dealers.
Only LUKAS 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!
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:
Always register your tool on the LUKAS Hydraulik GmbH internet site. This is the
only way to guarantee extended warranty cover.
REMARK:
Before you use couplings from a different company , you must contact LUKAS 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 equipped with a safety coupling (quickdisconnect coupling male, yellow). Unwanted overpressure (approx. 1.5 Mpa) is
automatically released via this nipple: hydraulic fl uid leaks.
Should an hydraulic fl uid leak on the coupling male be more frequent, please
contact your dealer or LUKAS 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 fl uid 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
LUKAS itself.
CAUTION!
Because LUKAS rescue equipments are appropriate for highest achievements,
only components may be exchanged, which are specifi ed in the spare parts list
of the appropriate equipment.ipment may only be exchanged, when:
- you have participated on a appropriate LUKAS service training.
- you have the explicit permission of the LUKAS 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 function and load
test must also be performed.
LUKAS offers appropriate test equipment to this end.
10.2.3 Changing the hydraulic fl uid
- The hydraulic fl uid 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 fl uid for the accompanying pump
(motor / hand pump) is changed. This is to prevent the fresh hydraulic fl uid from becoming
contaminated by the used fl uid from the rescue equipment.
Procedure:
1. Completely retract rescue ram.
2. Change the hydraulic fl uid 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 fl uid still in the
equipment.
5. Slowly extend the rescue ram (the pump must be working during this time). The old
hydraulic fl uid from the ring space side runs via the return hose into the separate collecting
basin, and is to be disposed of in the same manner as the old hydraulic fl uid 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
- 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
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
8. Deaerate the rescue ram as described in the chapter “Preparatory measures”.
= 40 Nm!)
A
= 40 Nm!)
A
= 35 Nm!)
A
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
REMARK when using mono-couplings:
If you want to change the hoses, you have to dismantle the mono-couplings.
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 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-disconnectcoupling (female).
= 40 Nm!)
A
Procedure:
BC
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.
D
EF
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
on and correctly assembled.
5. Tighten the hose connection on the safety valve. (Please note! Observe the necessary
torque of M
= 40 Nm!)
A
dismantle
assemble
6. Then replace handle sleeve, protective sleeves and screws, tighten (Torque: 5Nm) and
secure it with threadlocking fl uid (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 fl uid continually leaking in a coupled/uncoupled state.
WARNING / CAUTION!
Never repair couplings: they are to be replaced by original LUKAS parts!
During assembly , tighten the connection nut of the hose assembly with a torque of M
= 40 Nm.
A
Procedure:
1. Remove the cover from the couplings.
2. Loosen the connection nuts of the hose assembly and remove the coupling.
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.
A
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 fl uid continually leaking in a coupled/uncoupled state.
WARNING / CAUTION!
Never repair couplings: they are to be replaced by original LUKAS parts!
During assembly , tighten the connection nut of the hose assembly with a torque of M
= 35 Nm.
A
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.
A
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-disconnectcoupling (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. 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 LUKAS dealer or LUKAS itself.
25
11. Troubleshooting
Trouble Control Cause Solution
Cylinder piston
moves slowly or
jerkily when activated
Equipment doesn’t
come up with the full
power.
Following release,
the star grip doesn’t
return to the central
position
with mono-couplingsystem: Hoses
cannot be coupled
with monocoupling-system:
It is frequently not
possible to couple
hose assemblies
with quickdisconnect-couplingsystem: Hoses
cannot be coupled
Hydraulic fl uid leak
on the hoses or the
fi xing-ins
Damages on the
surface of the
hydraulic hoses
Are the hoses
connected
properly?
Does the pump
unit work?
Have you checked
the hydraulic fl uid
level in the supply
pump?
Is it hard to move
the star grip?
Control the
degree of viscosity
and application
temperature of
the used hydraulic
fl uid
Is the pump
working?
Are the hoses
defective?
Air in the hydraulic
system
Insuffi cient
hydraulic fl uid in
the pump
Damage to the
torsion spring for
reset
Soiled valve or
star grip
Defective valve
Other mechanical
damage (e. g. star
grip)
Pressure too high
(e.g. caused by
too-high ambient
temperature)
Coupling defective Coupling needs to be
Hydraulic fl uid
not adapted to
the application
situation
Coupling defective Coupling needs to be
Pressurized Relieve pump
Coupling defective Coupling needs to be
Leak, possible
damage
Mechanical
damages or
contact with
aggressive agents
Deaerate pump
system
Top up hydraulic fl uid,
deaerate
Repair by an
authorised dealer, by
personnel specially
trained by LUKAS, or
by LUKAS itself
Set hydraulic pump
to pressureless
circulation
replaced immediately
Hydraulic fl uid
must be replaced
(see chapter
“Recommended
Hydraulic fl uids”)
replaced immediately
replaced immediately
Replace hoses
Replace hoses
26
Trouble Control Cause Solution
Hydraulic fl uid leak
on the piston rod
Leak on the handhold Increase load? Load increase
Is the set pressure
on the pump
adapted to comply
with the maximum
permissible
pressure for
the rescue
equipment?
Hoses in handhold
loose?
Check the
connections of the
mono-coupling
(female)
Especially by usage
of quick-disconnectcouplings: Leak on
the handhold
Especially by usage
of mono-couplings:
Leak on the handhold
Is the return
hose connected
correctly?
check the
connections of the
hoses
Defective rod seal Repair by an
Damage to the
piston
(e.g. something
has fallen onto the
part to be lifted,
thereby suddenly
increasing the
load)
Pressure release
in the Rescue tool.
Hoses in handhold
not tightened
Supply and return
connection of the
mono-coupling
(female) inverted
Return hose is not
coupled correctly
or not connected.
hose connection
to the couplings
interchanged
Returnline
disabled
authorised dealer, by
personnel specially
trained by LUKAS, or
by LUKAS itself
Secure the loads and
move them by using
other tools
Position ram on a
different place, where
the load to be moved
is lower
Use supporting
equipment to move
the load.
Following the
reduction in pressure,
no further leak is
present.
Should, however,
there be a further
leak on the handhold,
immediately
deactivate the rescue
equipment, and
contact an authorised
dealer or LUKAS
itself.
Tighten hoses.
Reconnect the
hoses of the monocooupling (female) in
the right way
Re-connect the return
hose and secure it.
reconnect the hoses
to the coupling in the
right way
disconnect the
returnline from the
coupling, clean it and
reconnect it.
27
Trouble Control Cause Solution
with mono-couplingsystem: Leak in the
couplings
with quickdisconnect-couplingsystem: Leak in the
couplings
If it isn’t possible to rectify the malfunctions, inform an authorised LUKAS dealer or the
LUKAS customer service department immediately!
The address for the LUKAS customer service department is:
Is the coupling
damaged?
Is the coupling
damaged?
Is the leak only
on the coupling
male (in uncoupled
status)?
coupling damaged Coupling must be
coupling damaged Coupling must be
Safety valve
reacted
replaced immediately
replaced immediately
After pressure
release there is no
more leakage.
LUKAS
Weinstraße 39, D-91058 Erlangen
Postfach 2560, D-91013 Erlangen
Tel.: (+49) 09131 / 698 - 348
Fax.: (+49) 09131 / 698 - 353
Hydraulik GmbH
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!
Type R 420 R 422 R 424 R 430
Ref. No.
Pressure force
(piston 1)
Pressure force
(piston 2)
Pressure force
(piston 3)
max. stroke
(piston 1)
max. stroke
(piston 2)
max. stroke
(piston 3)
Piston stroke
overall
Length (retracted)
Length (extended)
Dimensions
w x h
Weight including
hydraulic fl uid
fi lling
max. operating
pressure
min. needed
volume of
hydraulic fl uid
coupling system mono-coupling
classifi cation acc. to
DIN EN 13204
* 1 MPa = 10 bar
** Necessary volume of hydraulic fl uid in the hydraulic unit to operate the unit
(differential volume on piston / rod side)
[kN] 269 269
[lbf.] 60474 60474
[kN] 134 134
[lbf.] 30124 30124
[kN] - 39
[lbf.] - 8800
[mm] 295 365 445 295
[in.] 11.6 14.4 17.5 11.6
[mm] 280 340 430 280
[in.] 11.0 13.4 16.9 11.0
[mm] - 245
[in.] - 9.65
[mm] 575 705 875 820
[in.] 22.6 27.8 34.5 32.3
[mm] 480 550 625 475
[in.] 18.9 21.7 24.6 18.7
[mm] 1055 1255 1500 1295
[in.] 41.5 49.4 59.1 51.0
[mm] 112 x 221
[in.] 4.41 x 8.70
[kg] 16,8 18,8 21,1 17,7
[lbs.] 37.0 41.4 46.5 39.0
[MPa]* 70
[psi.] 10000
[l]** 1,5 1,8 2,2 1,6
[gal.US]
81-40-30
(174040000)
0.40 0.48 0.58 0.42
TR 266/295-
133/280-17
81-40-32
(174050000)
TR 266/365-
133/340-19
29
81-40-34
(174060000)
TR 266/445-
133/430-21
81-40-40
(174070000)
Type R 410 R 412 R 414
Ref. No.
Pressure force (in
all operating
ranges)
Piston stroke
Length (retracted)
Length (extended)
Dimensions
w x h
Weight including
hydraulic fl uid
fi lling
max. operating
pressure
min. needed
volume of
hydraulic fl uid
coupling system mono-coupling
classifi cation acc. to
DIN EN 13204
[kN] 137 124
[lbf.] 30799 27876
[mm] 300 500 700
[in.] 11.8 19.7 27.6
[mm] 450 680 900
[in.] 17.7 26.8 35.4
[mm] 750 1180 1600
[in.] 29.5 46.5 63.0
[mm] 95 x 174
[in.] 3.74 x 6.85
[kg] 13,1 17,8 24,3
[lbs.] 28.9 39.2 53.6
[Mpa] * 70
[psi.] 10000
[l] ** 0,5 0,8 1,2
[gal.US]
81-40-20
(174110000)
0.13 0.21 0.32
R 135/300-13R 135/500-18R 122/700-
81-40-22
(174120000)
81-40-24
(174130000)
24
* 1 MPa = 10 bar
** Necessary volume of hydraulic fl uid in the hydraulic unit to operate the unit
(differential volume on piston / rod side)
30
Type R 420 R 422 R 424 R 430
Ref. No. 114070000 114040000 114060000 114050000
Pressure force
(piston 1)
Pressure force
(piston 2)
Pressure force
(piston 3)
max. stroke
(piston 1)
max. stroke
(piston 2)
max. stroke
(piston 3)
Piston stroke
overall
Length (retracted)
Length (extended)
Dimensions
w x h
Weight including
hydraulic fl uid
fi lling
max. operating
pressure
min. needed
volume of
hydraulic fl uid
coupling system quick-disconnect-coupling
classifi cation acc. to
DIN EN 13204
[kN] 269 269
[lbf.] 60474 60474
[kN] 134 134
[lbf.] 30124 30124
[kN] - 39
[lbf.] - 8800
[mm] 295 365 445 295
[in.] 11.6 14.4 17.5 11.6
[mm] 280 340 430 280
[in.] 11.0 13.4 16.9 11.0
[mm] - 245
[in.] - 9.65
[mm] 575 705 875 820
[in.] 22.6 27.8 34.5 32.3
[mm] 480 550 625 475
[in.] 18.9 21.7 24.6 18.7
[mm] 1055 1255 1500 1295
[in.] 41.5 49.4 59.1 51.0
[mm] 112 x 221
[in.] 4.41 x 8.70
[kg] 16,8 18,8 21,1 17,7
[lbs.] 37.0 41.4 46.5 39.0
[MPa]* 70
[psi.] 10000
[l]** 1,5 1,8 2,2 1,6
[gal.-US] 0.40 0.48 0.58 0.42
TR 266/295-
133/280-17
TR 266/365-
133/340-19
TR 266/445-
133/430-21
* 1 MPa = 10 bar
** Necessary volume of hydraulic fl uid in the hydraulic unit to operate the unit
(differential volume on piston / rod side)
31
Type R 410 R 412 R 414
Ref. No. 114110000 114120000 114130000
Pressure force (in
all operating ranges)
Piston stroke
Length (retracted)
Length (extended)
Dimensions
w x h
Weight including
hydraulic fl uid fi lling
max. operating
pressure
min. needed volume
of hydraulic fl uid
coupling system quick-disconnect-coupling
classifi cation acc. to
DIN EN 13204
* 1 MPa = 10 bar
** Necessary volume of hydraulic fl uid in the hydraulic unit to operate the unit
(differential volume on piston / rod side)
[kN] 137 124
[lbf.] 30799 27876
[mm] 300 500 700
[in.] 11.8 19.7 27.6
[mm] 450 680 900
[in.] 17.7 26.8 35.4
[mm] 750 1180 1600
[in.] 29.5 46.5 63.0
[mm] 95 x 174
[in.] 3.74 x 6.85
[kg] 13,1 17,8 24,3
[lbs.] 28.9 39.2 53.6
[Mpa] * 70
[psi.] 10000
[l] ** 0,5 0,8 1,2
[gal.-US] 0.13 0.21 0.32
R 135/300-13R 135/500-18R 122/700-
24
32
12.1 Recommended hydraulic fl uid
Mineral oil DIN ISO 6743-4 for LUKAS hydraulic equipment and others
Oil temperature range Oil code Viscosity rating Remarks
A -20 .... +55°C HM 10 VG 10
Oil temperature range Oil code Viscosity rating Remarks
A
-4.0 .... +131°F HM 10 VG 10
recommended viscosity range: 10...200 mm²/s
Supplied with HM 10 DIN ISO 6743-4.
CAUTION!
Before using hydraulic fl uids, which do not correspond to the above-mentioned
specifi cations and/or are not purchased from LUKAS, you have to contact
LUKAS itself!
(10…200 cSt.)
12.2 Hoses
Bending radius Rmin = 38 mm (Rmin = 1.5 in.)
Pressure resistance
Temperature resistance - 40°C ... + 100°C
Operating fl uid Mineral oil according to DIN EN ISO 6743-4
Safety factor: Burst pressure / max. Operating pressure,
min. 4 : 1
(- 40°F … + 212°F)
12.3 Operating and storage temperature ranges
Operating temperature [°C] -20 … +55
Storage temperature (device not in operation) [°C] -30 … +60
Operating temperature [°F] -4 … +131
Storage temperature (device not in operation) [°F] -22 … +140
33
13. EC Declarations of conformity
34
14. Notes
35
Please dispose all packaging materials and
dismantled parts properly
LUKAS
A Unit of IDEX Corporation
Hydraulik GmbH
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
© Copyright 2014 LUKAS Hydraulik GmbHrescue_rams_manual_174010085_en.indd
subject to revision
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