Cutter - Hurst Jaws of Life

Operating instructions for rescue equipment
Cutter
159R195 US
Edition 03.2012
(Original operating instructions)
Content
Page
1. Hazard classes
4
2. Product safety
5
3. Intended use
8
4. Description of the functions
9
4.1Description
9
4.2 Tool in detail
9
4.3 Circuit diagram
10
4.4 Control of the operating movements
10
4.5 Hydraulic supply
10
4.6Hoses
10
5. Connecting the equipment
11
5.1 General information
11
5.2 Coupling the mono-couplings
11
5.3 Coupling the quick-disconnect couplings
12
6.Operation
12
6.1Preparations
13
6.2 Operating the star grip
13
7.Cutting
14
7.1 Safety notes
14
7.2Cutting
14
8. Dismantling the equipment / deactivation following operation
15
8.1Cutters
15
8.2 Hydraulic unit
15
8.3Hoses
15
9. Maintenance and service
16
9.1 Cutters, overall
16
9.2 Protective equipment
17
10.Repairs
17
10.1 General information
17
10.2 Preventative service
18
10.3Repairs
19
2
11.Troubleshooting
25
12. Technical Data
27
12.1Cutter
27
12.2 Torque of the pivot bolt
30
12.3 Recommended hydraulic fluid
30
12.4 Operating and storage temperature Ranges
30
12.5Conversions
30
13.Notes
31
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 specific hazard
and possible consequences.
Damage /
injury to
device
human
Pictogram
Key word
Definition
Consequences
DANGER!
Immediate danger
Death or major
injury
WARNING!
Potentially
dangerous
situation
Potential death or
major injury
CAUTION!
Less dangerous
situation
Minor or slight
injury
CAUTION!
Danger of
damage to device
/ environment
Damage to the
equipment,
damage to the
environment,
damage to
surrounding
materials
REMARK
Advice for
application and
other important /
useful information
and advice
No injury /
damage to
persons /
environment /
equipment
-
Wear helmet with face protection
Wear safety gloves
Wear safety shoes
Proper recycling
Observe principles of environmental protection
Read and observe operating instructions
4
2. Product safety
JAWS OF LIFE 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 JAWS OF LIFE 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 the operating instructions
carefully 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!
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. blade arms).
Wear protective clothing, safety
helmet with visor, protective
gloves
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
The responsible department
is to be informed immediately
of any changes (including to
the operating behavior)! 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.
Inspect all cables, hoses
and screwed connections
for leaks and externally
visible damage! If necessary,
repair immediately! Squirting
hydraulic fluid 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.
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!
Comply with all specified
dates or dates specified in
the operating instructions
pertaining to regular controls /
inspections on the equipment.
Safety devices may never be
deactivated!
The maximum permitted
operating pressure noted on
the equipment must not be
exceeded.
Before the equipment is
switched on/started up, and
during its operation, it must be
ensured that nobody will be
endangered by the operation of
the equipment.
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 caught in the
looped hoses and trip.
Please note that, when
cutting or spreading, 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.
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.
Only touch any broken-off parts
or the cut-off parts wearing
protective gloves, since the
torn / cut edges can be very
sharp.
The equipment is filled with a
hydraulic fluid. These hydraulic
fluids can be dangerous to
health if swallowed or their
vapors 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.
Ensure adequate lighting when
you are working.
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.
Before transporting the
equipment, always ensure that
the accessories are positioned
such that they cannot cause an
accident.
6
Always keep these operating
instructions within reach where
the equipment is used.
Ensure the proper disposal of
all removed parts, left-over oil
and hydraulic fluid as well as
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.
W A R N I N G
/
C A U T I O N !
The equipment is to be used exclusively for the purpose stated in the operating
instructions (see chapter “Intended use”). Any other or further use is not considered
Intended use. The manufacturer / supplier is not liable for any damages resulting from not
intended 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 Intended use.
Never work when you are overtired or intoxicated!
WARNING / CAUTION!
HURST BLUE hydraulic fluid is a custom blended fluid. In case of skin contact,
wash off with soap and water. In case of eye contact, flush with generous
amounts of running water for at least 15 minutes. If discomfort persists following
flushing, see physician for symptomatic treatment.
7
3. Intended use
JAWS OF LIFE cutters are designed specifically for rescuing victims in traffic, rail or air
accidents and for making rescues from buildings. They serve the purpose of freeing injured
people in accidents e. g. by cutting doors, roof bars and hinges
Basically, JAWS OF LIFE cutters can only be used to cut objects. All objects which are to be
worked on are to be secured using stable supports or substructures.
Sample application of the cutters:
JAWS OF LIFE cutters 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.
CAUTION!
All objects which are to be worked on are to be secured using stable supports or
substructures.
WARNING / CAUTION!
The following may not be cut:
-
live cables
-
hardened parts such as springs, spring steels, steering columns and rollers
- tubes / hoses under gas or liquid pressure,
- compound materials (steel/concrete)
- explosive bodies such as SRS Systems
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.
HURST rescue cutters may NOT be used where there is a risk of explosions!
The rescue equipment should not come into contact with acids or alkalis. If this is
unavoidable, clean the equipment immediately afterwards with a suitable cleaning
agent.
8
4. Description of the functions
4.1Description
The equipment is designed such that, via a hydraulically activated piston, two equal, opposite
blade arms are symmetrically opened / closed by mechanical joints, thereby opening blade
arms or cutting objects.
All cutters ensure full load-holding function when disconnected from the hydraulic supply (e.
g. when being accidentally decoupled; defective hose, etc.).
4.2 Tool in detail
11
10
quick-disconnect coupling
system:
1
13
2
12
9
3
8
4
1 Star grip
2 Control valve
3 Body of rescue tool
4Handle
5 Hand guard
6 Blade arm
7 Pivot bolt with self-locking nut
8Handhold
9 Pressure hose
10 Return hose
11 Mono-coupling male
12 Quick-disconnect coupling (male)
13 Quick-disconnect coupling (female)
5
7
6
9
4.3 Circuit diagram
To enable comprehension of the function, a simplified hydraulic cylinder of the rescue
equipment (A) + hand valve (B) are depicted here.
cut / close
A
opening
B
4.4 Control of the operating movements
The blade arm movement is controlled via the star grip on the mounted valve.
star grip
4.5 Hydraulic supply
A HURST 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 authorized operating pressure for HURST equipment is not
exceeded.
REMARK:
Before you use pumps from a different manufacturer, you must contact HURST
or an authorized dealer.
4.6Hoses
The pump unit and the rescue tool are connected by hoses.
10
5. Connecting the equipment
5.1 General information
There are two short hoses on the side of the equipment: they are connected to the pump unit
via two hoses. All hoses 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 HURST
directly!
5.2 Coupling the mono-couplings
The equipment is connected to the hydraulic pump via mono-coupling halves (male and
female).
dust protection caps
mono-coupling
half (male)
mono-coupling
half (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.
11
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 coupling may require a 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!
5.3 Coupling the quick-disconnect couplings
The equipment is connected to the hydraulic pump via quick-disconnect-coupling halves
(male and female).
X
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 in the direction shown in the
right picture above till stop.
Now the connection has been made and locked. Uncoupling is done in the reverse order.
CAUTION!
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.
WARNING/CAUTION!
The quick-disconnect-couplings partly have special functions. Therefore it is not
permitted to screw them off from the hoses or to exchange them!
6. Operation
WARNING/CAUTION!
Check the equipment before and after use for visible defects or damage!
See Section 9 for more information.
12
6.1Preparations
6.1.1Commissioning
Before commissioning and following repairs, the equipment must be deaerated.
- Connect the equipment to the hydraulic pump (see chapter “Connecting the
equipment”).
- Open / close the blade arms of the equipment without any load at least twice (see
chapter “Operation of the star grip”).
REMARK:
We recommend that during deaeration, the attached aggregate for the hydraulic
supply should stand on a higher level than the body of the rescue tool.
Recommended procedure for deaeration of the rescue tool:
1.) open and close fully with the blade arms facing upwards.
2.) open and close fully with the blade arms facing downwards.
3.) open and close fully with the blade arms facing upwards.
4.) open and close fully with the blade arms facing downwards.
6.1.2 Inspection of the pump unit
See separate operating instructions for the relevant 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!
6.2 Operating the star grip
Opening the device (
):
Turn the star grip in the direction of the relevant symbol and keep
in this position.
Closing the device (
):
Turn the star grip in the direction of the relevant symbol and keep
in this position.
“Dead-man’s” function:
Following release, the star grip automatically returns to the
central position, guaranteeing full load-holding.
13
7.1 Safety notes
7. Cutting
Before rescue work can commence, the position of the obstacle must be stabilized. You must
ensure an adequate substructure and / or adequate support of the object. World-wide, safety
guidelines pertaining to the specific country are to be observed and complied with.
In areas at risk of explosion, the equipment can only be used if an explosion has been
prevented by appropriate measures.
The following are to be worn when working with the rescue equipment:
- protective clothing,
- safety helmet with visor or protective goggles,
- protective gloves,
- protective shoes
- and, if necessary, ear protection
Before activating the rescue equipment, always ensure that there is no danger to persons
either involved / uninvolved in the action by the movement of the rescue equipment or by
flying fragments. Further avoid unnecessary damage to property belonging to others, objects
not involved by the rescue equipment / flying fragments.
Reaching between the blade arms is strictly forbidden!
WARNING / CAUTION!
The particular effect of the force of the rescue equipment during operation could
cause pieces of the vehicle to break off or fly off, posing a danger to persons.
Those not involved in the rescue operation should therefore keep at a distance
appropriate to the situation.
7.2Cutting
The blades must be positioned at a 90° angle to the object to be cut.
90°
WRONG
RIGHT
Higher cutting capacities can be achieved by cutting as close as possible to the blade’s pivot
point.
WRONG
RIGHT
14
During cutting, the gap between the blade tips (in the crosswise direction) may not be
exceeded, otherwise the blade is in danger of breaking:
Cutter
max. gap on the blade tips
[mm] / [in.]
JL-500
3 / 0.12
MOC
3 / 0.12
MOC II
3 / 0.12
MOC Ultra
3 / 0.12
X-Tractor
3 / 0.12
CAUTION!
Avoid cutting particularly high-strength parts of the vehicle’s bodywork (e.g. sideimpact protection): this almost always causes damage to the cutter!
8. Dismantling the equipment / deactivation following
operation
8.1Cutters
Once work has been completed, the blade arms are to be closed so that there is a tip distance
of just a few mm/in.. This relieves the hydraulic and mechanical strain on the equipment.
REMARK:
Never store the cutter with fully closed blade arms! The complete closure of the
blade arms can cause hydraulic and mechanical stress to build up again.
Free the rescue equipment of any stubborn dirt which may have become attached during
use.
If the equipment is to be stored for a longer period of time, the exterior is to be cleaned
completely and the mechanically mobile parts are to be lubricated.
Avoid storing the rescue equipment in a damp environment.
Also observe the separate manual for the hydraulic hoses.
8.2 Hydraulic unit
Upon completion of work, the unit must be deactivated.
8.3Hoses
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.
15
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 every
six months. These inspections enable the early detection of wear and tear, which means that
punctual replacement of the wearing parts prevents breakages from occurring. Also regularly
check the torque of the pivot bolt. (Torque MA see “Technical Data”)
Every three years a crack test of the blades is essential. Therefore a special crack testing
kit is available.
Every three years or if there is any doubt regarding the safety or reliability of the equipment,
a function test must also be performed. (Please also observe the relevant valid national and
international regulations pertaining to service intervals of rescue equipment).
CAUTION!
Clean off any dirt before actuating the equipment!
WARNING / CAUTION!
In order to carry out maintenance and repair work, tools appropriate for the job
and personal protective equipment are essential.
9.1 Cutters, overall
Inspections to be carried out:
Visual inspection
Cutter
• Opening width of the blade arms on the tips (see chapter “Technical data”),
• Open the blades fully, decommission the pump and visually inspect all lever elements,
bolts, nuts and the piston rod for wear, presence and proper alignment.
• General tightness (leaks),
• Operability of the star grip (deadman-function),
• Existence and stability of handle,
• Labels completely existent and legible,
• Covers in perfect condition,
• Control of the torque of the pivot bolt (torque MA see “Technical Data”),
• Couplings must be easy to couple,
• Dust protection caps must be available.
Blade arms
• Blade arms free of cracks and without any chipped spots or deformations on the cutting
surfaces,
• Cutting surfaces go on top of each other without making contact,
• Bolts and retaining rings of the blade arms must be present and in correct working order,
Hoses (also refer to separate manual for the hydraulic hoses. )
• Visual check for visible damage,
• Check for leaks.
16
Function test
• Opening and closing function flawlessly upon activation of the star grip,
• no suspicious noises.
• no further movement of the blade arms upon interruption of the valve activation during the
process (“dead-man’s” function)
9.2 Protective equipment
• Control of the protective equipment on / around the rescue equipment, especially the
hand guard of the moveable parts (they must be free of tears!).
10. Repairs
10.1 General information
Servicing may only be carried out by JAWS OF LIFE manufacturer or personnel trained by
the manufacturer and by authorized 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!
WARNING / CAUTION!
Protective clothes must be worn when repairs are being carried out, since parts
of the units can also be pressurized in an idle state.
REMARK:
Please always return the guarantee registration card to HURST JAWS OF LIFE
or register your tool on the HURST website. Only then are you entitled to the
extended guarantee.
REMARK:
Before you use couplings from a different company, you must contact HURST
or an authorized dealer.
CAUTION!
Because HURST rescue equipment are appropriate for highest achievements,
only components may be exchanged, which are specified in the spare parts list
of the appropriate equipment.
Further components of the equipment may only be exchanged, when:
- you have participated in 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!)
Spare parts and accessories for the rescue tool can be ordered from your authorized
HURST-dealer!
17
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 be performed.
HURST offers appropriate test equipment to this end.
10.2.3 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. Close blade arms (until the tips are almost touching).
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 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 return hose 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
return hose.
4. Put the return hose into a separate collecting basin for the hydraulic fluid still in the equipment.
5.Slowly open the tool (the pump must be working during this time). The old hydraulic fluid
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 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 return hose back on.
(Please observe the necessary torque of MA = 40 Nm / 29.5 ft.lbs.!)
- when the hose connection is via mono-coupling to the pump:
screw the connection nut of the return hose back onto the mono-coupling (male).
(Please observe the necessary torque of MA = 40 Nm / 29.5 ft.lbs.!)
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 return hose.
(Please observe the necessary torque of MA = 35 Nm / 25.8 ft.lbs.!)
8.Deaerate the rescue tool as described in the chapter “Preparations”.
18
10.3 Repairs
NOTE:
The illustrations show the JL-500 cutter. Assembly and disassembly are nearly
identical for the other cutters!
10.3.1 Replacing blades, protective covers and handles
Work steps:
1. First of all, carefully clean the rescue equipment.
2.Next, close the blade arms so that the tips are almost touching. Turn the power unit off
and disconnect the cutter from the hydraulic supply (uncouple)
3. Remove the fixing screws ‘A’ and spring
washers ‘B’. Now you can remove the
handle ‘C’ in direction of the star grip
(see picture).”.
A
B
A
C
19
D
E
4. Remove the grub screw ‘D’ (only for
JL-500 cutter), then unscrew the nut
‘E’ and pull out the pivot bolt ‘F’.
H
J
G
G
F
K
5. Move the hand guard ‘G’ in the direction
of the star grip till stop. This will make it
easier to reach the safety bolts ‘H’.
Now remove the retaining rings ‘J’ and
push out the bolts ‘H’. Then you can
remove the blades ‘K’ and the sliding
plates ‘L’.
L
G
K
H
J
6. Fold the lever elements ‘M’
M
G
7. Finally, remove the hand guard ‘G’ from
the cutter as depicted.
20
8. The work steps must be carried out in reverse order to fit the new parts.
CAUTION!
Don’t forget to apply HURST special grease to all sliding surfaces.
REMARK:
The torque required can be taken from the spare parts list.
10.3.2 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 MA = 40 Nm / 29.5 ft.lbs.!)
REMARK:
If you want to change the hoses, you have to dismantle the couplings.
CAUTION (by usage of mono-coupling-system)!
Take care that the port ‘T’ of the rescue tool 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 into the port “T” of the rescue tool, must
always be equipped with a quick-disconnect-coupling (male).
However the supplying hose line must be equipped with a quick-disconnectcoupling (female).
B
Procedure:
1. Loosen the 2 screws ‘B’ in the handle sleeve
(hexagon socket)
A
2. Remove handle sleeve ‘A’.
3. Dismantle hose ‘C’ and sealing ring ‘D’. (There
is no need to carry out this point if the hoses
are just being tightened).
dismantle
assemble
4. Screw the hose with sealing ring back on.
D C
5. Tighten the hose connection on the valve.
(Please note! Observe the necessary torque of MA = 40 Nm / 29.5 ft.lbs.!)
6. Then replace handle sleeve and screws, tighten (Torque: 5Nm / 3.7 ft.lbs.) and secure it
with threadlocking fluid (e. g. LOCTITE 243).
21
10.3.3 Sharpening the blades
Only remove and smoothen any burrs!
Chips or deep grooves cannot be ground away. The blades must be replaced in these
cases.
CAUTION!
Only grind in the grinding area (see illustration)!
The sliding faces, in particular, must not be reground!
Grinding area
Pivot point
Blade arm
Direction of movement
Blade arm
Slide surface
plane
Tools required:
1. Use jaw protection on clamping device (e.g. vice) in order not to
damage the blades
2. Grinder (e.g. angle grinder or belt grinder) with abrasive having
a grain size of 80.
Procedure:
1.Clamp the blade securely into the clamping device so that it cannot move, but with the
grinding area exposed.
2.Carefully grind the burr away evenly until you reach the sliding surface level. (see
illustration)
Slide surface plane
In addition, when grinding, you must make sure that the inclination of the cutting surface
in the direction of the blade arm movement is not changed. Check the incline and
smoothness of the ground surface, using a suitable measuring tool.
CAUTION!
If you have not maintained the smoothness or incline, the proper operation of the
blade is no longer guaranteed and the blades must be replaced.
22
10.3.4Mono-couplings
The mono-couplings must be replaced in the event of:
- external visible damage,
- the locking device not working,
- hydraulic fluid continually leaking in a coupled/uncoupled state.
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 MA = 40 Nm
/ 29.5 ft.lbs..
Procedure:
1. Remove the screws ‘A’.
A
A
2. Remove the cover from the couplings.
3. Loosen the connection nuts of the hose assembly and remove the coupling.
23
4. Position the new coupling and tighten the connection nuts of the hose assemblies with a torque of MA = 40 Nm / 29.5 ft.lbs.. After that, push the cover of the couplings back
on and replace screws “A”.
CAUTION!
Take care that the port ‘T’ of the rescue tool is always connected to the port ‘T’
of the mono-coupling.
10.3.5Quick-disconnect-couplings
The quick-disconnect-couplings must be replaced in the event of:
- external visible damage,
- the locking device not working,
- hydraulic fluid continually leaking in a coupled/uncoupled state.
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 MA = 35 Nm
/ 25.8 ft.lbs..
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 MA = 35 Nm / 25.8 ft.lbs..
CAUTION!
The return hose, which is screwed into the port “T” of the rescue tool, must
always be equipped with a quick-disconnect-coupling (male).
However the supplying hose line must be equipped with a quick-disconnectcoupling (female).
10.3.6 Control valve
Should the safety valve be deformed so severely that the star grip no longer functions
correctly (e. g. loss of the deadman-function, etc.), the valve must be replaced in its entirety.
Have repairs carried out by an authorized dealer, by personnel specially trained by HURST,
or by HURST customer service only.
10.3.7Labels
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 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 authorized HURST dealer or HURST itself.
24
11. Troubleshooting
Trouble
Check
Blade arms move
Are the hoses
slowly or jerkily when connected
activated
properly?
Does the pump
unit work?
Device doesn’t
Check the
perform at its given
hydraulic fluid level
power
in the supplying
pump
Following release,
Cover damaged
the star grip doesn’t
or star grip hard to
return to the central
move?
position
Hoses cannot be
coupled
only by use of monocoupling-system:
It is frequently not
possible to couple
hose assemblies
Hydraulic fluid leak
on the hoses or the
fixing-ins
Damages on the
surface of the
hydraulic hoses
Hydraulic fluid leaks
on the piston rod
Cause
Solution
Air in the hydraulic Deaerate pump
system
system
Insufficient
hydraulic fluid in
the pump
Damage to the
torsion spring for
reset
Soiled valve or
star grip
Defective valve
Other mechanical
damage (e. g. star
grip)
Is a mono-coupling Pressure too high
mounted?
(e.g. caused by
too-high ambient
temperature)
Pressurized
Top off hydraulic fluid,
deaerate
Repair by an
authorized dealer, by
personnel specially
trained by HURST, or
by HURST itself
Set hydraulic pump
to pressureless
circulation
Relieve pump
Coupling defective Coupling needs to be
replaced immediately
Hydraulic fluid
Hydraulic fluid
Control the
must be replaced
degree of viscosity not adapted to
the application
(see chapter
and application
situation
“Recommended
temperature of
Hydraulic fluids”)
the used hydraulic
fluid
Coupling defective Coupling needs to be
replaced immediately
Are the hoses
Leak, possible
Replace hoses
defective?
damage
Mechanical
damages or
contact with
aggressive agents
Defective rod seal
Damage to the
piston
25
Replace hoses
Repair by an
authorized dealer, by
personnel specially
trained by HURST, or
by HURST itself
Trouble
Check
Cause
Leak on the handhold Does the pressure Pressure release
in the Rescue tool.
set on the pump
comply with
the maximum
permissible
pressure on
the rescue
equipment?
Solution
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 authorized
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 monomono-coupling
mono-coupling
cooupling (female) in
(female)
(female) inverted the right way
Leak on the handhold Is the return
hose connected
correctly to the
quick-disconnect
coupling?
check the
connections
between monocoupling and
hoses
Return hose is not Re-connect the return
coupled correctly hose and secure it.
or not connected.
hose connection
to the couplings
interchanged
Returnline
disabled
reconnect the hoses
to the coupling in the
right way
disconnect the
returnline from the
coupling, clean it and
reconnect it.
coupling damaged Coupling must be
replaced immediately
Leak in the couplings Is the coupling
damaged?
If it isn’t possible to rectify the malfunctions, inform an authorized HURST dealer or the
HURST customer service department immediately!
The address for the HURST customer service 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:[email protected]
26
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!
The values may also differ because of reading inaccuracies and/or tolerances in the
measuring equipment used.
NOTE:
The following tables contain only the technical data required for standard
acceptance.
Additional data concerning your unit can be obtained from HURST on request.
12.1 Cutter
type
JL-500
ref.no.
dimensions l x w x h
(w/o connection hoses)
362R513
[mm]
362R528
775 x 290 x 215
[in.]
30.51x11.42x8.46
[mm]
194
[in.]
7.64
weight incl. hydraulic
fluid
[kg]
21,6
[lbs.]
47.6
max. operating
pressure
[MPa] *
[psi.]
5,000
min. needed volume
of hydraulic fluid
[l] **
0,2
max. cutting opening
35
[gal.-US]
coupling system
0.053
mono-coupling
classification (NFPA 1936)
*
**
quick-disconnectcoupling
A7/B9/C7/D8/E9
1 MPa = 10 bar
Necessary volume of hydraulic fluid in the hydraulic unit to operate the unit (differential volume on piston / rod side)
27
type
MOC
ref.no.
dimensions l x w x h
(w/o connection hoses)
362R486
362R386
[mm]
790 x 230 x 228
[in.]
31.11x9.06x8.98
[mm]
280
[in.]
11.0
weight incl. hydraulic
fluid
[kg]
20,5
[lbs.]
45.2
max. operating
pressure
[Mpa] *
[psi.]
5,000
min. needed volume
of hydraulic fluid
[l] **
0.14
[gal.-US]
8.8
max. cutting opening
coupling system
35
mono-coupling
classification (NFPA 1936)
A7/B7/C7/D7/E8
type
MOC II
ref.no.
dimensions l x w x h
(w/o connection hoses)
quick-disconnectcoupling
362R487
362R392
[mm]
787 x 230 x 228
[in.]
30.99x9.06x8.98
[mm]
180
[in.]
7.1
weight incl. hydraulic
fluid
[kg]
21,4
[lbs.]
47.2
max. operating
pressure
[Mpa] *
[psi.]
5,000
min. needed volume
of hydraulic fluid
[l] **
0.14
[gal.-US]
8.8
max. cutting opening
coupling system
35
mono-coupling
classification (NFPA 1936)
*
**
quick-disconnectcoupling
A7/B9/C6/D7/E8
1 MPa = 10 bar
Necessary volume of hydraulic fluid in the hydraulic unit to operate the unit (differential volume on piston / rod side)
28
type
MOC Ultra
ref.no.
dimensions l x w x h
(w/o connection hoses)
362R488
362R428
[mm]
751 x 240 x 228
[in.]
29.57x9.45x8.98
[mm]
145
[in.]
5.7
weight incl. hydraulic
fluid
[kg]
21,0
[lbs.]
46.3
max. operating
pressure
[Mpa] *
[psi.]
5,000
min. needed volume
of hydraulic fluid
[l] **
0.14
[gal.-US]
8.8
max. cutting opening
coupling system
35
mono-coupling
classification (NFPA 1936)
A8/B8/C6/D8/E8
type
X-Tractor II
ref.no.
dimensions l x w x h
(w/o connection hoses)
quick-disconnectcoupling
362R485
[mm]
362R402
732 x 278 x 185
[in.]
28.81x10.94x7.28
[mm]
148
[in.]
5.83
weight incl. hydraulic
fluid
[kg]
17,9
[lbs.]
39.4
max. operating
pressure
[Mpa] *
[psi.]
5,000
min. needed volume
of hydraulic fluid
[l] **
0,08
[gal.-US]
0.02
max. cutting opening
coupling system
35
mono-coupling
classification (NFPA 1936)
*
**
quick-disconnectcoupling
A6/B7/C6/D7/E7
1 MPa = 10 bar
Necessary volume of hydraulic fluid in the hydraulic unit to operate the unit (differential volume on piston / rod side)
29
12.2 Torque of the pivot bolt
type
JL-500
MOC
MOC II
150 + 10
130 + 10
130 + 10
130 + 10
117 + 10
110.6 + 7.4 96.0 + 7.4
96.0 + 7.4
96.0 + 7.4
86.0 + 7.4
[Nm]
torque
[ft.lbs]
MOC Ultra X-Tractor II
12.3 Recommended hydraulic fluid
CAUTION!
Use only the hydraulic fluid ‘HURST BLUE’! Other fluids could cause damages
to the rescue tool.
Fluid temperature range
-20 .... +55°C
A
-4.0 .... +131°F
Chemical name
CAS number
Polyether Polyol
9003-13-8
Remarks
12.4 Operating and storage temperature Ranges
Operating temperature
Ambient temperature
(device in operation)
Storage temperature
(device not in operation)
[°C] / [°F]
-20 … +55
-4 …
+131
[°C] / [°F]
-25 … +45
-13 …
+113
[°C] / [°F]
-30 … +60
-22 …
+140
12.5 Conversions
1 MPa
=
145.04
1 Nm
=
0.7376 ft.lbf
1 mm
=
0.0394
1
l
=
0.2641 gal. (US)
1
kg
=
2.2045 lbs.
psi
in.
30
13. Notes
31
Please dispose all packaging materials and
dismantled parts properly.
HURST
JAWS OF LIFE
HALE PRODUCTS, INC.
A Unit of IDEX Corporation
subject to revision
711 N. Post Road
Shelby, NC 28150 USA
Phone: (704) 487-6961
Fax:
(704) 487-7271
e-mail:[email protected]
Made in USA
Cutter_BA_US_159R195_0312.indd
© Copyright 2012 Hale Products, Inc