Weber Rescue Systems RSU 200-107 PLUS E-FORCE 2, Operating Manual

Page 1: ...ccordance with EN 13204 NFPA 1936 SPS 270 E FORCE 2 SPS 360 L E FORCE 2 SPS 370 E FORCE 2 RSX 160 50 E FORCE 2 RSX 180 80 PLUS E FORCE 2 RSU 200 107 PLUS E FORCE 2 SP 35 AS E FORCE 2 SP 53 BS E FORCE 2 RZ 1 910 E FORCE 2 RZT 2 1360 E FORCE 2 1060298 www weber rescue com ...

Page 2: ...ecific hazards 13 2 6 How to respond in the event of danger or accidents 15 2 7 Signage 16 3 Technical data 17 3 1 Combi tools 17 3 2 Cutters 18 3 3 Spreader 19 3 4 Rescue ram 20 3 5 Operating conditions 20 3 6 Type plate 20 4 Design and function 21 4 1 Overview of E FORCE 2 devices 21 4 2 Hydraulic supply 25 4 3 Electrical supply using a combi device as an example 26 4 4 Operating E FORCE 2 devic...

Page 3: ... 40 6 3 Intended use 42 6 4 Power line connection 42 6 5 Li ion battery 42 6 6 Charging process 43 6 7 Maintenance 44 6 8 Charging cycles 44 7 Transport packaging and storage 45 7 1 Safety information 45 7 2 Transport inspection 45 7 3 Symbols on the packaging 46 7 4 Disposal of packaging 46 7 5 Storage 46 8 Installation and commissioning 47 8 1 Safety information 47 8 2 Checking 47 8 3 Shut down ...

Page 4: ...inherent part of the product and must be kept in a place that is known and accessible to personnel at all times This documentation contains information for operating your equipment However you may also find information which may not directly apply to your specific equipment All information technical data graphics and diagrams contained in these operating instructions are based on the latest data a...

Page 5: ...ent accidents injuries and damage to property DANGER indicates an imminently dangerous situation that can result in death or serious injury if not avoided WARNING indicates a potentially dangerous situation that can result in death or serious injury if not avoided CAUTION indicates a potentially dangerous situation that can result in minor or light injuries if not avoided ATTENTION indicates a pot...

Page 6: ...ience The manufacturer assumes no liability for damage due to Failure to comply with the operating manual Unintended use Assignment of untrained personnel Unauthorised modifications Technical changes Use of non approved replacement parts Use of non original replacement parts The actual scope of delivery can vary from the explanations and graphic representations provided in this manual in the case ...

Page 7: ...vice is available to you for technical information Germany Name Ms Corina Schulz Telephone 49 0 7135 71 10235 Fax 49 0 7135 71 10396 E mail corina schulz weber rescue com Austria Name Mr Robert Hack Telephone 43 0 7255 6237 12473 Fax 43 0 7255 6237 12461 E mail robert hack weber rescue com NOTE When contacting our customer service department please state your equipment s designation type and produ...

Page 8: ...FORCE 2 The battery powered cutting devices are used exclusively for cutting doors and roof beams pillars and door sills the ring and the spokes of the steering wheel If possible for cutting solid material always position the material at the base of the cutter blades closest to the pivot point as it is equipped with special edges for cutting round material In industrial application the devices can...

Page 9: ...E FORCE 2 These devices are exclusively for pushing up steering columns vehicle roofs and other obstacles and for pushing away vehicle body parts They can also be used for supporting and bracing loads WARNING Improper use can be dangerous Any improper or unintended use of the devices can be hazardous Therefore make absolutely sure that The devices are used only for the applications stated above Al...

Page 10: ...n maintenance and cleaning The customer must ensure that all personnel who handle the equipment have fully read and understood the operating manual In addition at regular intervals the operator must train personnel and inform them of the hazards of working with the equipment Moreover the customer is responsible for ensuring that the equipment is always in technically faultless condition Consequent...

Page 11: ...ledge of the applicable stipulations by the manufacturer is capable of executing the tasks assigned to him or her and of independently recognising possible hazards WARNING Inadequate training can result in injuries Improper handling of the equipment can lead to serious injury or material damage Therefore make absolutely sure to allow particular tasks to be carried out only by the persons stated in...

Page 12: ...l toed safety shoes must always be worn as protection against heavy falling parts and from slipping on slick surfaces Work gloves Work gloves must be worn when working with the equipment to provide protection from sharp edges and shards of glass Helmet with face shield A helmet with face shield must be worn for protection against flying or falling parts and shards of glass Protective goggles Prote...

Page 13: ...n pose a fatal hazard Therefore If the insulation is damaged immediately disconnect the power supply and arrange for repairs Allow only qualified electricians to work on the electrical equipment For all work on the electrical equipment it must be disconnected from the power source and it must be checked that the device is de energised Prior to maintenance cleaning and repair work the power supply ...

Page 14: ...longer than necessary Hydraulic power WARNING Hydraulic power hazard Serious injury can result due to the released hydraulic forces and escaping hydraulic oil Therefore Constantly monitor the device during the work procedure and set down if necessary Inspect the hose lines and devices for damage after every use Avoid skin contact with the hydraulic oil wear protective gloves Immediately remove the...

Page 15: ...iliarise personnel with accident alarms first aid gear and emergency equipment Keep entryways clear for emergency vehicles In the event of an accident Shut down equipment immediately Initiate first aid measures Get people out of the danger zone Inform the responsible parties at the site of the incident Notify a doctor and or the fire brigade Clear entryways for emergency vehicles ...

Page 16: ... the operating manual Hand injury warning When working with the equipment take care to avoid hand injuries through trapping or sharp edges WARNING Danger of injury due to illegible symbols Over time stickers and symbols on the equipment can become soiled or otherwise illegible Therefore make absolutely sure to Keep all safety warning and operating information on the device easily legible Replace d...

Page 17: ...x cutting capacity with round material Ø 25 mm Ø 30 mm Ø 30 mm Max cutting force 324 kN 491 kN 491 kN Spreading force in working range 34 591 kN 45 783 kN 45 783 kN Pulling force in working range 31 39 kN 45 54 kN 54 62 kN Nominal pressure 700 bar 700 bar 700 bar EN class BK 30 265 F 14 CK 37 360 H 19 CK 37 370 H 20 NFPA class A6 B5 C6 D6 E7 A6 B8 C6 D8 E7 A6 B8 C6 D8 E7 ID No 1075250 1074458 1077...

Page 18: ...mm 180 mm 200 mm Max cutting capacity with round material Ø 32 mm Ø 35 mm Ø 43 mm Max cutting force 493 kN 903 kN 1050 kN Nominal pressure 700 bar 700 bar 700 bar EN class BC 160 H 18 BC 180 H 21 CC200 H 24 NFPA class A6 B7 C6 D7 E8 A7 B9 C7 D9 E9 A8 B9 C8 D9 E9 ID No 1077690 1075255 1075262 per EN 13204 according to EN 13204 18 Technical data RSX 160 50 E FORCE 2 RSX 180 80 PLUS E FORCE 2 RSU 200...

Page 19: ...600 mm 800 mm Pulling path 515 mm 697 mm Spreading force in working range 38 171 kN 56 421 kN Spreading force in working range 32 49 kN 42 72 kN Max crushing force 76 kN 100 kN Nominal pressure 700 bar 700 bar EN class AS 35 600 18 BS 53 800 24 ID No 1075263 1077791 per EN 13204 according to EN 13204 Technical data 19 SP 35 AS E FORCE 2 SP 53 BS E FORCE 2 ...

Page 20: ...TR 108 429 63 372 19 ID No 1075272 1078342 per EN 13204 according to EN 13204 3 5 Operating conditions The permissible temperature range of the E FORCE 2 devices is between 20 C and 60 C Reliable operation cannot be guaranteed outside of this range 3 6 Type plate On all E FORCE 2 devices the type plate is located on the bottom of the drive unit It shows the serial number production date nominal pr...

Page 21: ... enclosed accident victims The combi device s uses include cutting door and roof beams columns and sills as well as opening doors lifting vehicle parts and loads and crushing pipes and beams Because the devices are equipped with internal electrohydraulic drive they are not linked to a power unit and can therefore be used in hard to reach locations The movement speed of the cutter blades arms is af...

Page 22: ... enclosed accident victims The cutter s uses include cutting door and roof beams columns and sills Because the devices are equipped with internal electrohydraulic drive they are not linked to a power unit and can therefore be used in hard to reach locations The movement speed of the cutter blades is affected by moving the control lever on the control handle with greater or lesser force The maximum...

Page 23: ...steering columns vehicle roofs and other obstacles Because the devices are equipped with internal electrohydraulic drive they are not linked to a power unit and can therefore be used in hard to reach locations The rescue cylinders are a supplement to the spreader and can be used for example if the spreading arm s spreading distance is no longer adequate The movement speed of the piston is affected...

Page 24: ...cident victims The spreaders are mainly suitable for opening doors and for lifting vehicles and other movable loads Because the devices are equipped with internal electrohydraulic drive they are not linked to a power unit and can therefore be used in hard to reach locations The movement speed of the spreading arms is affected by moving the control lever on the control handle with greater or lesser...

Page 25: ...his means the entire hydraulic system is completely closed and void of air Any possible volume expansion due to heat is balanced by the accumulator Hydraulic oil All battery powered devices should use a special hydraulic oil for rescue equipment in accordance with WN 4841751 Normally the oil does not have to be changed but if this becomes necessary it can be changed only by service engineers at WE...

Page 26: ... the battery along the rails 3 provided for this purpose until the battery clicks in The tool acknowledges that the battery has been inserted in the right direction with a short tone To release press the push buttons on both sides of the battery 4 Then pull the battery up and out Rails Push buttons 2 3 4 1 26 Design and function ...

Page 27: ...y through Closing the cutter Opening the spreaders Extending the rescue ram The tools main direction of movement is triggered by pressing the rocker switch to the left with your index finger grooved side of the rocker switch Opening the cutter Closing the spreaders Retracting the rescue ram The opposite direction is triggered by pressing the control rocker to the right with your thumb curved side ...

Page 28: ...FORCE 2 SPS 370 E FORCE 2 Shear blades 1819240 1068993 1063315 Pulling device with pins 2096617 2835746 2836033 Chain set 571407 2819139 2819139 RZM 740 1056478 Transport case 1058128 28 Design and function Transport case Shear blades Pulling device Chain set RZM 740 ...

Page 29: ...t insert 1059363 1072763 Blade insert 1061568 1075983 Blade complete 1059362 1078502 Blade inserts in pouch 1061567 1078501 Shear blade for RSX 160 50 1050557 Design and function 29 Blade without insert Blade insert Blade complete Blade inserts in pouch Shear blade for RSX 160 50 ...

Page 30: ...ccessories E FORCE 2 devices ID Nr Replacement battery 3 0 Ah 1053785 Replacement battery 5 0 Ah 1072893 Battery case 1056921 Strap for battery case 1056920 Plug in charger 230V 1054097 Plug in charger 110V 1054099 Onboard charger 1060423 Permanet power supply power adaptor 230V 1060422 Permanet power supply power adaptor 110V 1060426 30 Design and function Spreader tips Chain set Extension ...

Page 31: ...fixed in place A clamping device as shown in the illustrations is not obligatory When the blade insert is being changed the battery must be removed from the cutter and not under load This means that the shear is not completely open or closed The blade insert for the cutter blade with the smooth surface can now be replaced The roll pins are knocked out and downward from the punch see figure 1 Fig 1...

Page 32: ...f the blade inserts cannot be inserted by hand use the soft head hammer see figure 3 Fig 3 The roll pins are located using a punch and light blows of a hammer from above into the position holes provided for this purpose Roll pins should be pushed into position until They are flush with the top surface of the blade see figure 4 Fig 4 32 Design and function ...

Page 33: ...tely pressed in Fitting the bracket for the chain set is identical The chain lock must be fitted with the lock facing upwards The collar studs on the SP 53 spreader tips can be pressed out of the spreader arms but have a safety system to prevent them being lost and so they cannot be separated from the tips The SP 35 AS spreader tips are not secured with removable collar studs but rather with a ten...

Page 34: ...way or stay in the danger zone only as long as necessary 5 2 Cutting Cutters combi devices The devices cutting capabilities can only be used optimally if they are placed as near as possible to the blades pivot point Figure 1 This means it may be necessary to readjust the device The device only achieves full cutting performance when the rocker lever is pressed all the way through In addition it can...

Page 35: ...ck absorbers hinges or steering columns the shear blades arms may cause severe damage 5 3 Lifting pressing rescue cylinder In its closed state the rescue cylinder is positioned for lifting or pushing away vehicle body parts Therefore make sure that the cylinder is placed as centrally as possible and at a right angle to the load For better positioning the pushing head can be turned on the piston ro...

Page 36: ...ng vehicle parts away and squashing tubes and beams For this the vehicle must be stably stabilized and supported To prevent any sliding during spreading the arms and tips are fluted inside and out Whenever possible the tips should be used only to enlarge a gap because repositioning the spreader prevents slipping 36 Possible applications ...

Page 37: ...ns with locks mounted about 10 20 cm from the end Check the chains prior to every use Check that the weight does not stress the tip of the hook but lies in the middle of the hook instead Do not make any repairs on your own Do not stress the chains beyond the permitted load carrying capacity Do not load with a jerking movement Do not galvanize or paint the chains Do not shorten the chain by knottin...

Page 38: ...ged by more than 2 The internal chain pitch over a measuring distance of 11 chain links has increased by more than 2 5 6 Crushing Spreaders combi devices Pipes and other hollow profiles are crushed by closing the spreader arms With combi devices however crushing is only to be performed in the tip area ATTENTION Material to be crushed can suddenly jump away Do not remain in the work area of the spr...

Page 39: ...r enough apart under the load to prevent slipping The load being lifted must be constantly monitored tipping rolling away or changing position Also the lifted load must immediately be propped up and supported in a suitable way 5 8 Peeling spreaders combi devices To create entry openings after bus and train accidents in silos etc both the spreader tips and the peeling tool can be used Possible appl...

Page 40: ...AC Australia 1054098 110V AC USA 1054099 6 2 Special safety instructions WARNING Do not throw used rechargeable batteries into a fire or into household waste Your dealer can dispose of batteries in an environmentally sound manner The following batteries can be charged with the charger Voltage Battery type Nominal capacity Number of cells 28 V M 28 BX 3 0 Ah 2 x 7 28 V Li 28 V 3 0 Ah 2 x 7 28 V Li ...

Page 41: ...evice with conductive objects Do not load a damaged battery replace it immediately instead Before every use check the device connection cable battery pack extension cable and plug for damage and ageing Allow only qualified personnel to repair damaged parts This device is not designed for use by persons including children with limited physical sensory or mental abilities or lacking experience and o...

Page 42: ...for a prolonged period of time the battery switches to standby mode To use again the battery must be reactivated recharged The charge status can be called up by pressing the button on the battery see Fig 1 To do this the battery can remain in the battery powered device but it must be switched off at least 1 minute beforehand otherwise the display will not be accurate The number of glowing LEDs ind...

Page 43: ...r the 5 0 Ah rechargeable battery lies between 1 min and 90 min If the battery is fully charged the LED on the charger switches from red to green The battery does not need to be removed from the charger after charging The battery can continue to stay in the charger This cannot overload the battery and it keeps the battery ready to use If both LEDs flash alternately the battery is either not correc...

Page 44: ...y an authorised customer service centre 6 8 Charging cycles Information Explanation Charging cycles approx 1000 Partial discharge No effect because the battery always retains its capacity until discharge Partial discharge and subsequent recharge Each recharge counts as a full charging cycle Therefore the battery should be used until completely drained Deep discharge protection is provided 44 Batte...

Page 45: ... location 7 2 Transport inspection Upon receipt the delivery should be checked immediately for completeness and damage during transport so that a quick remedy can be performed if necessary If there is visible external damage please proceed as follows Do not accept the delivery or only accept it with reservation Note the extent of the transport damage on the transport documents or on the transport ...

Page 46: ...posal of packaging All packaging materials and disassembled parts transport protection must be disposed of properly in accordance with local regulations 7 5 Storage The equipment must be stored in a dry and dust free environment where possible Avoid direct UV radiation to the hoses CAUTION The equipment must be stowed securely in the mountings provided in order to avoid damage during transit etc 4...

Page 47: ...tective devices are installed and in proper working order prior to starting work Personal protective equipment Wear the protective equipment detailed in Chapter 2 4 for all work NOTE Special reference is made where it is necessary to wear additional protective equipment for certain work with or on the device 8 2 Checking Inspect the E FORCE 2 device for damage If the cutting device is not in prist...

Page 48: ...ge Check the guide piece for damage 8 3 Shut down end of work Cutters After work is over the blade tips must be placed one above the other to prevent injury The blades of the cutting device must not be completely closed as otherwise tension will build up in the device Rescue cylinder After work is over the cylinder s piston rod must be completely retracted so as to relieve the hydraulic load on th...

Page 49: ...enance In the interest of permanent operational readiness the following measures are essential Each time the device is subjected to a load but at least once a year the equipment and the accessories must be visually inspected Special attention must be paid to spreader tips joints blades hoses and coupling halves Every three years or if there are doubts about the safety or reliability of the equipme...

Page 50: ...carried out using a conventional citrus cleaner 9 3 Maintenance schedule A precise maintenance plan with testing intervals regulations and results can be found in the GUV G 9102 Point 18 hydraulically operated rescue equipment NOTE If there are any problems with the maintenance of the devices our customer service is available see Chapter 1 6 50 Service ...

Page 51: ... settings altered Have repaired by an authorized workshop Combi device s opening width below target value Cutter head settings altered Have repaired by an authorized workshop Pressure build up despite movement open closed without load Hex nut central bolt too tight Have repaired by an authorized workshop Blade chipping Blades damaged e g from cutting high strength materials Regrindable to about 2 ...

Page 52: ...he charger The displays on the battery and charger give information about the battery charge status Spreader Malfunction Possible cause Remedy Device does not reach full performance Rocker levers not completely pressed to the side Press the rocker lever completely to the side Spreader moves in opposite direction under load Check valve defective Have the device checked by an authorized service cent...

Page 53: ...ic oil is disposed of separately For disposal of all device components and packaging materials the disposal conditions of the specific location apply Do not discard electric tools with household waste According to European directive 2002 96 EC for used electric and electronic devices and its implementation in national regulations used electric tools must be collected separately and recycled in an ...

Page 54: ...12 EC Declaration of Conformity 54 EC Declaration of Conformity ...

Page 55: ...Notes 55 13 Notes ...

Page 56: ...efon 49 0 7135 71 10270 Telefax 49 0 7135 71 10396 info weber rescue com www weber rescue com Industriegebiet 3 4 4460 Losenstein Austria Telefon 43 0 7255 6237 120 Telefax 43 0 7255 6237 12461 info weber rescue com www weber rescue com Edition 2015 A www weber rescue com ...