HURST KL-32 User manual

362R522-85 US
Spreaders
Operating instructions for rescue equipment
Edition 11.2012
(Original operating instructions)
Ersetzt 08.2011

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Content Page
1.Hazard classes 4
2.Product safety 5
3.Intended use 8
4.Description of the functions 9
4.1 Description 9
4.2 Unit in detail 10
4.3 Circuit diagram 11
4.4 Control of the operating movements 11
4.5 Hydraulic supply 11
4.6 Hoses 11
5.Connecting the equipment 12
5.1 General information 12
5.2 Coupling the mono-couplings 12
5.3 Coupling the quick-disconnect-couplings 13
6.Operation 14
6.1 Preparations 14
6.2 Operating the star grip 14
7.Spreading, pulling, peeling and squeezing 15
7.1 Safety notes 15
7.2 Spreading 15
7.3 Pulling 17
7.4 Peeling 17
8.Dismantling the equipment / deactivation following operation 18
8.1 Spreader 18
8.2 Hydraulic unit 18
8.3 Hoses 18
7.5 Squeezing 18
9.Maintenance and service 19
9.1 Spreader, overall 19
10.Repairs 20
10.1 General information 20
9.2 Protective equipment 20
10.2 Preventative service 21
10.3 Repairs 22

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11.Troubleshooting 28
12.Technical data 30
12.1 Peeling 32
12.2 Recommended hydraulic fluid 32
12.3 Operating and storage temperature Ranges 32
12.6 Conversions 32
13.CE - Declaration of Conformity 33
14.Notes 34

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1. Hazard classes
Wear helmet with face protection
Wear safety gloves
Wear safety shoes
Proper recycling
Observe principles of environmental protection
Read and observe operating instructions
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.
Pictogram Damage /
injury to Key word Definition Consequences
human
DANGER! Immediate danger Death or major
injury
WARNING! Potentially dangerous
situation Potential death or
major injury
CAUTION! Less dangerous
situation Minor or slight injury
device
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

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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. spreader arms).
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.
Wear protective clothing,
safety helmet with visor,
protective gloves
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!
Inspect all cables, hoses
and screwed connections for
leaks and externally visible
damage! If necessary, repair
immediately! Squirting oil can
result in injuries and fires.

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In the event of malfunctions,
immediately deactivate the
equipment and secure it. The
malfunction is to be repaired
immediately.
Do not carry out any changes
(additions or conversions)
to the equipment without
obtaining the prior approval of
HURST.
Observe all safety and danger
notes on the equipment and
in the operating instructions.
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.
When working close to live
components and cables,
suitable measures must
be taken to avoid current
transfers or high-voltage
transfers to the equipment.
Please note that, when
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.
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 wearing protective
gloves, since the torn edges
can be very sharp.

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The generally applicable, legal and other binding national and international regulations
pertaining to the prevention of accidents and protection of the environment apply and are to
be implemented in addition to the operating instructions.
WARNING / CAUTION!
The equipment is to be used exclusively for the purpose stated in the operating
instructions (see chapter “Intended Use”). Any other or further use is not considered
intended use. The manufacturer / supplier is not liable for any damages resulting from
unintended use. The user bears sole responsibility for such.
Observanceoftheoperatinginstructionsandcompliancewiththeinspectionandmaintenance
conditions are part of the intended use.
Never work when you are overtired or intoxicated!
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.
When working with or storing
the equipment, ensure that
the function and the safety
of the equipment are not
impaired by the effects of
stark external temperatures
or that the equipment is
damaged in any way. Please
note that the equipment can
also heat up over a long
period of use.
Ensure adequate lighting
when you are working. Before transporting the equipment, always ensure
that the accessories are
positioned such that they
cannot cause an accident.
Always keep these operating
instructions within reach
where the equipment is used.
Ensure the proper disposal
of all removed parts, left-over
oil, left-over hydraulic fluid
and packaging materials!
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.

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3. Intended use
HURST spreaders 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.
fig. 1 fig. 2
JAWS OF LIFE spreaders are designed especially for rescue services. They are used to
release persons trapped as a result of a road accident e.g. by forcing open the car doors
(see below fig. 1) or by squashing other parts of the vehicle. In other catastrophic situations
they are used to lift (by spreading) or to displace objects in order to rescue buried or trapped
persons, e.g. by concrete components in collapsed houses (see below fig. 2), and to squash
constructional components, e.g. pipes.
In principle, objects can be pulled, spread, squashed or compressed in length.
All objects to be worked on are to be secured using stable supports or substructures.
When lifting loads, additional risks to the operator and/or persons not involved may be
posed if the load moves in an uncontrolled manner or if the spreader slips or tips over.
When applying the tool and lifting, make sure that there is no danger, if necessary by using
additional supports or safety devices.

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WARNING / CAUTION!
The following may not be squeezed:
- live cables
- hardened parts such as springs, spring steels, steering columns
and rollers
- 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.
JAWS OF LIFE rescue spreaders 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.
Spare parts and accessories for the rescue tool can be ordered from your authorized
HURST-dealer!
4. Description of the functions
4.1 Description
Theequipmentisdesignedsuchthat,viaahydraulicallyactivatedpiston,twoequal,opposite
spreader arms are symmetrically opened by mechanical joints, thereby spreading objects.
Closing the spreader arms is also carried out hydraulically and mechanically by reverse
order of the piston.
All spreaders ensure full load-holding function when disconnected from the hydraulic supply
(e. g. when being accidentally decoupled; defective hose, etc.).

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4.2 Unit in detail
1 Star grip
2 Control valve
3 Spreader body
4 Handle
5 Hand guard
6 Spreading arm
7 Tip with borehole for chain set
8 Interlock bolt
9 Pressure hose
10 Return hose
11 Handhold
12 Mono-coupling male
13 Quick-disconnect coupling (male)
14 Quick-disconnect coupling (female)
1
14 13
quick-disconnect coupling
system:
2
3
4
5
6
7
8
9
10
11
12
6
8

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4.3 Circuit diagram
4.4 Control of the operating movements
4.5 Hydraulic supply
4.6 Hoses
AB
spreading
pulling /
squeezing
star grip
To enable comprehension of the function, a simplified hydraulic cylinder of the rescue
equipment (A) + hand valve (B) are depicted here.
The spreading arms movement is controlled via the star grip on the mounted valve.
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.
The pump unit and the rescue tool are connected by hoses.

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5.1 General information
5. Connecting the equipment
5.2 Coupling the mono-couplings
The equipment is connected to the hydraulic pump via mono-coupling halves (male and
female).
mono-coupling
half (male) mono-coupling
half (female)
dust protection caps
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.
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!

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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).
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.
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!
To protect them from dust, the accompanying dust protection caps must be put back on.
REMARK:
Coupling of the devices is only possible, when the hoses are depressurized.
CAUTION!
Always connect the return line first and afterwards the supply line!
X

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6.1 Preparations 6. Operation
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.
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 spreader arms facing upwards.
2.) open and close fully with the spreader arms facing downwards.
3.) open and close fully with the spreader arms facing upwards.
4.) open and close fully with the spreader arms facing downwards.
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 spreader arms of the equipment without any load at least twice (see
chapter “Operation of the star grip”).
6.1.2Inspection 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.
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!

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7.2 Spreading
Use the front area of the tips for increasing the gap only. Full spreading capacity can be
achieved when approximately half of the grooved area of the tips is used. The greatest force
is created in the rear area of the spreading range of the tip.
WARNING / CAUTION!
The arms – made from a light metal alloy – may not be damaged.
7.1 Safety notes
7. Spreading, pulling, peeling and squeezing
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.
Intheeventofapotentiallyexplosivesituation,itisnotpermittedtousemotorpumps(danger
of the formation of sparks). In such cases, hand pumps are to be used.
The following are to be worn when working with the rescue equipment:
- protective clothing and protective shoes,
- safety helmet with visor or protective goggles,
- protective gloves
- 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 spreader 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.

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spreading Increasing
a gap
Working surface is too
small, tips slip off. Only
for increasing the size
of a gap (not suitable
for spreading)
Tips get a safe grip. Work with the tips only.
Do not damage the
arms.

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7.3 Pulling
7.4 Peeling
- JAWS OF LIFE chain sets are to be used for pulling purposes.
- Before the pulling process can be performed, ensure that the bolt and hook fit correctly to
prevent the chain from slipping.
- Only chain sets in perfect condition may be used.
- The pull chains are to be inspected at least once per year by an expert.
- See separate operating instructions for the relevant chain set!
Mounting bore for
chain set
Peeling zone
With the integrated peeling zone in the tool
tips of the spreader sheet steels can be peeled
open (for maximum sheet steel thickness t, see
chapter “Technical data”).
WARNING / CAUTION!
Splinters can fly uncontrollably from particularly hard materials.
Keep a safe distance!

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7.5 Squeezing
Basically, squeezing may only be carried in the area of the tips.
8. Dismantling the equipment / deactivation following
operation
8.1 Spreader
8.2 Hydraulic unit
8.3 Hoses
Once work has been completed, the spreader 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.
Upon completion of work, the unit must be deactivated.
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.
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.
REMARK:
Never store the spreader with fully closed spreader arms! The complete closure
of the spreader arms can cause hydraulic and mechanical stress to build up
again.
Squeezing zone

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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 the wearing parts prevents breakages from occurring. A function
test is also to be carried out every three years or should there be any doubt regarding the
safety or reliability of the equipment.
(Please also observe the relevant valid national and international regulations pertaining to
service intervals of rescue equipment)
CAUTION!
Clean off any dirt before actuating the equipment!
WARNING / CAUTION!
In order to carry out maintenance and repair works, tools appropriate for the job
and personal protective equipment are essential.
9.1 Spreader, overall
Inspections to be carried out:
Visual inspection
Spreader
• Opening width of the spreader arms on the tips (see chapter “Technical data”),
• General tightness (leaks),
• Operability of the star grip,
• Existence and stability of handle,
• Labels completely existent and legible,
• Covers in perfect condition,
• Couplings must be easy to couple,
• Dust protection caps must be available.
Spreader arms
• Spreader arms free of cracks and without any chipped spots or deformations on the surfaces,
• Bolts and retaining rings of the spreader arms must be present and in correct working order,
• Grooving of the tips must be clean and squared, and not have any tears
• Tips existent and locked
Hoses (also refer to separate manual for the hydraulic hoses)
• Visual check for visible damage,
• Check for leaks.

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• Control of the protective equipment on / around the rescue equipment, especially the
hand guard of the moveable parts (they must be free of tears!).
9.2 Protective equipment
10.1 General information 10. Repairs
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.
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, an examination for the distribution of permission is being carried out.An
examination in each individual case is necessary!)
Spare parts and accessories for the rescue tool can be ordered from your authorized
JAWS OF LIFE dealer!
Function test
• Opening and closing function flawlessly upon activation of the star grip,
• no suspicious noises.
• no further movement of the spreader arms upon interruption of the valve activation during
the process (“dead-man’s” function)