WARNING. Service Procedure: ION OIL FILL PROCEDURE LEVEL 3 TOOL REPAIR. AMKUS RESCUE SYSTEMS

Transcription

1 Service Procedure: ION OIL FILL PROCEDURE LEVEL 3 TOOL REPAIR WARNING Understand manual before use. Servicing AMKUS Rescue Tools without understanding the manual, receiving proper training, and using appropriate personal protective equipment is a misuse of AMKUS equipment. This manual does not fully address safety. Additional safety information is published in the documents pictured below. Obtain safety information at www. amkus.com/resources/information An AMKUS Level 3 Certifi cation is required to complete the Level 3 repairs involved in this and other Level 3 Manuals. Only AMKUS Level 3 Certifi ed personnel are authorized to perform the complete contents of this and other manuals. AMKUS Level 3 certifi cation is only offered at AMKUS Rescue Systems Headquarters to authorized AMKUS Dealers. All certifi cations must be renewed every 3 years. If your certifi cation has expired, you are no longer authorized to perform Level 3 repairs and must be re-certifi ed at AMKUS Rescue Systems Headquarters. Failure to renew or maintain your AMKUS Level 3 Certifi cation could result in voiding any and all warranty coverage if AMKUS Level 3 maintenance is still performed Fax

2 Table Of Contents 1.0 ADDITIONAL MANUALS MEANING OF SAFETY SIGNAL WORDS BEFORE SERVICING ANY AMKUS RESCUE TOOL PURPOSE PROCEDURE MAJOR FLUID FILL 5.2 FLUID TOP OFF 6.0 INSPECTION, CLEANING, DECONTAMINATION, AND STORAGE...Back Cover 7.0 PARTS, SERVICE AND TECHNICAL INFORMATION...Back Cover DANGER PERSONAL RESPONSIBILITY CODE The member companies of FEMSA that provide emergency response equipment and services want responders to know and understand the following: 1. Firefi ghting and Emergency Response are inherently dangerous activities requiring proper training in their hazards and the use of extreme caution at all times. 2. It is your responsibility to read and understand any user s instructions, including purpose and limitations, provided with any piece of equipment you may be called upon to use. 3. It is your responsibility to know that you have been properly trained in Firefi ghting and /or Emergency Response and in the use, precautions, and care of any equipment you may be called upon to use. 4. It is your responsibility to be in proper physical condition and to maintain the personal skill level required to operate any equipment you may be called upon to use. 5. It is your responsibility to know that your equipment is in operable condition and has been maintained in accordance with the manufacturer s instructions. 6. Failure to follow these guidelines may result in death, burns or other severe injury. FEMSA Fire and Emergency Manufacturers and Service Association P.O. Box 147, Lynnfi eld, MA

3 1.0 ADDITIONAL MANUALS DANGER Manual: Battery Powered Electro-hydraulic Rescue Tools Understand manual before use. Operating AMKUS Rescue Systems without understanding the manual, receiving proper training, and using appropriate personal protective equipment is a misuse of AMKUS equipment. This manual does not fully address safety. Additional safety information is published in AMKUS Safety Manual LAA-001 and Safety Data Sheet LAA-028 for hydraulic uid. Instructions for safe operation of DeWALT lithium ion batteries and chargers are included with DeWALT packaging. Obtain safety information at CUTTER Model: AMK-iC550 SPREADER Model: AMK-iS240 COMBI TOOL Model: AMK-iCT516 RAM Model: AMK-iTR230 BATTERY 36 VDC 4Ah LITHIUM ION, DeWALT DCB360 Part#: AMK-IBATT CHARGER DeWALT DC Hour Charger, 110 VAC Part#: AMK-ICHRG HYDRAULIC SYSTEM Self-contained, 10,150 PSI (700 bar) high-speed single stage pump HYDRAULIC FLUID AMKUS MV2 (Mineral Oil base) part#: KF0006 Safety Data Sheet (SDS) for AMKUS MV2 Hydraulic Fluid is available at AMKUS.com and CHEMTREC.com Copyright Amkus Rescue Systems, Inc Fax LAI-001 January 23, 2017 Rev00 MANUAL: ION Electro-Hydraulic Battery Operated Rescue Tools LAI-001 SECTION 1. IDENTIFICATION Product Name Manufacturers of suppliers details SDS Request Customer Service Emergency telephone number Spill Information SAFETY DATA SHEET According to OSHA Hazard Communication Standard, 29 CFR AMKUS MV2 HYDRAULIC FLUID, INC Montdale Drive Valparaiso, IN USA Health Information Recommend use of the chemical and restrictions on use Recommended Use Hydraulic oil CHEMTREC SAFETY MANUAL for AMKUS RESCUE SYSTEMS Understand manual before use. Operating AMKUS Rescue Systems without understanding the DANGER manual, receiving proper training, and using appropriate personal protective equipment is a misuse of AMKUS equipment. Obtain safety information at This Safety Manual is intended to familiarize rescue workers and maintenance personnel with the safety messages of AMKUS Rescue Systems, including powered rescue tools (rams, cutters, spreaders, combination tools), power units (electric or gasoline driven), and powered rescue tool components (cable assemblies, hose assemblies, hose reels, etc.). The safety messages in this publication supersede safety information appearing in AMKUS publications prior to April This manual is intended for use with manuals published by manufacturers of prime movers (engines, electric motors, and pumps) used in AMKUS power units. This manual does NOT address operation or servicing of AMKUS Rescue Systems. Only competent rescue tool repair technicians are quali ed to repair AMKUS equipment. This manual should be available to all personnel involved with AMKUS equipment. SECTION 2. HAZARDS IDENTIFICATION cation Not a hazardous substance or mixture GHS Label element Hazard pictograms No hazard symbol required Signal word No signal word Hazard Statements PHYSICAL HAZARDS: Not classi ed as a physical hazard under GHS criteria. HEALTH HAZARDS: Not classi ed as a health hazard under GHS criteria. ENVIRONMENTAL HAZARDS: Not classi ed as an environmental hazard under GHS criteria. Precautionary statements Prevention: No precautionary phrases. Response: No precautionary phrases. Storage: No precautionary phrases. Disposal: No precautionary phrases. cation Prolonged or repeated skin contact without proper cleaning can clog the pores of the skin resulting in disorders such as oil acne/folliculitis. Used oil may contain harmful impurities. High-pressure injection under the skin may cause serious damage including local necrosis. Not classi ed as ammable but will burn. The classi cation of this material is based on OSHA HCS 2012 criteria. Under normal conditions of use or in a foreseeable emergency, this product does not meet the de nition of a hazardous chemical when evaluated according to the OSHA Hazard Communication Standard, 29 CFR Fax Copyright Amkus Rescue Systems, Inc LAA-028 December 15, 2016 Rev01 MADE IN USA Copyright Amkus Rescue Systems, Inc Fax LAA-001 April 15, 2016 Rev00 Safety Data Sheet AMKUS MV2 Hydraulic Fluid LAA-028 Safety Manual For AMKUS Rescue Systems LAA-001 3

4 2.0 MEANING OF SAFETY SIGNAL WORDS A safety related message is identifi ed by a safety alert symbol and a signal word to indicate the level of risk involved with a particular hazard. Per ANSI standard Z , the defi nitions of the four signal words are as follows: DANGER DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury. WARNING CAUTION NOTICE WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury. CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. NOTICE is used to address practices not related to physical injury. 3.0 BEFORE SERVICING ANY AMKUS RESCUE TOOL WARNING Servicing rescue equipment creates injury risk not found during normal product use; Guards removed for service create pinch points. Avoid injury during service by keeping hands and fingers away from movable mechanisms when cycling the tool under pressure. Replace guards before returning tools to service. Pressure stored within a hydraulic cylinder against an end stop can be suddenly released during service by disassembly of hydraulic components. Release pressure by moving piston slightly from the end stop before service. Release pressure by turning the control valve in which the piston moves slightly away from the end stop before servicing any components. Energizing electrical connections and wiring exposed during service creates ignition and shock hazards. Do not attempt to open a battery case. There are no user serviceable components inside the battery. Always wear safety glasses when servicing, or testing Amkus rescue equipment. Obtain Level 3 service technician training before servicing Amkus rescue equipment. 4

5 4.0 PURPOSE 4.1 This service procedure outlines the process of fi lling and topping off the ION tools with hydraulic fl uid. 5.0 PROCEDURE 5.1 MAJOR FLUID FILL Position the tool so that the fl uid reservoir is at its highest point while also ensuring that the tool is level Ensure the piston is all the way extended but not under pressure Remove the (6) screws from the reservoir cover and remove cover Gently pry under the lip of the bladder, with your fi ngers, to remove it. Sharp tools may damage the bladder Once removed, inspect the bladder for any damage (cracks, holes or splits). Replace if damaged Clean the bladder and the reservoir cover s mating surfaces of all debris. 5

6 5.1.7 Slowly add oil to the reservoir, allowing air to escape Place the cover over reservoir and cycle the tool to fi ll the cylinder s chamber without building pressure. Add oil as needed With the piston fully extended, there should only be a fi lm of fl uid covering the bottom of the reservoir Retract the piston allowing the fl uid to fi ll the reservoir, allow time for air bubbles to dissipate Once the air bubbles have dissipated from the fl uid, cycle the tool to ensure there is no air in the tool. If air bubbles appear again repeat steps With the piston fully extended reinstall the bladder and reservoir cover. (The fl uid will overfl ow from the reservoir and force air from the system.) 6

7 5.2 FLUID TOP OFF Position the tool so that the oil bolt is at its highest point, while ensuring that the tool is level With piston fully extended, but not under pressure, remove the oil bolt using a 5mm hex key. NOTICE DO NOT OPERATE THE TOOL WITH THIS BOLT OUT! Using a syringe, slowly add AMKUS MV2 Hydraulic Oil to the tool. Be sure to allow air in the unit time to escape during top off. This may take some patience Reinstall the oil bolt into the tool. Cycle tool 3-5 times from full open to full close Repeat steps as necessary until the tool will not take any more oil After the tool is full, cycle the tool to ensure that pressure builds in both directions of operation. 7

8 6.0 INSPECTION, CLEANING, DECONTAMINATION, AND STORAGE 1. Always store the tool securely in a clean, dry space. 2. Relieve the pressure on the tools after use by backing off the end stop. 3. Charge the battery. BEFORE BEING PLACED BACK IN SERVICE, the rescue tool must be inspected to this list: 1. Check to see that all rescue tool markings are legible. Contact your local dealer or AMKUS Rescue Systems for replacement labels. 2. Wipe the tool clean. 3. If the rescue tool becomes contaminated, determine the nature of the contamination. IE: biological, chemical, radioactive. The authority having jurisdiction may follow internal decontamination guidelines or request technical advice from AMKUS Rescue Systems. 4. Inspect the tool, controls and battery after each use for damage, leakage and excessive wear. 5. If rescue tool damage or excessive wear is noticed, remove the rescue tool from service immediately; contact your local dealer or AMKUS Rescue Systems for service. 6. Install battery and verify tool operation. Any rescue tool failing any part of the checklist is unsafe for use and must have the problem WARNING corrected before use or being placed back into service. Operating a rescue tool that has failed the checklist is a misuse of this equipment. Contact your local dealer or Amkus Rescue Systems. 7.0 PARTS, SERVICE AND TECHNICAL INFORMATION Parts, service and technical information may be obtained from your local AMKUS dealer, or by contacting AMKUS Rescue Systems Fax