hydraulic rescue equipment

hydraulic rescue equipment
Operating instructions
HYDRAULIC RESCUE EQUIPMENT
Battery powered devices
814.237.8
Mains adapter
Tested according
814.236.0
to EN 13204 and
NFPA 1936
Hydraulic rescue equipment (rechargeable devices):
S 180 A, SP 35 A, SPS 330 A
Energy pack, mains adapter
Page 1/40
Table of Contents
1
General
1.1 Information regarding the operating instructions
1.2 Explanation of symbols
1.3 Limitations of liability
1.4 Copyright
1.5 Guarantee conditions
1.6 Customer service
4
4
5
6
6
7
7
2
Safety
2.1 Appropriate use
2.2 Responsibility of the customer
2.3 Operating personnel
2.4 Personal protective gear
2.5 Specific hazards
2.6 Safety devices
2.7 Behaviour in the event of danger or accidents
2.8 Signage
8
8
10
11
12
13
15
16
17
3
Technical data
3.1 Operating conditions
3.2 Type plate
18
20
20
4
Structure and function
4.1 Overview
4.2 Brief description
4.3 Hydraulic supply
4.4 Connection to the energy pack
4.5 Use of the control handle
4.6 Changing the spreader jaws (SP 35 A and SPS 330 A)
4.7 Accessories (SP 35 A and SPS 330 A)
21
21
21
22
23
23
24
24
5
Energy pack
5.1 Safety information
5.2 General
5.3 Control and charging electronics
5.4 Hanging / wearing
5.5 Charging
5.5 Mains adapter
5.6 Accessories
25
25
25
26
27
27
28
28
6
Possible applications
6.1 Safety information
6.2 Cutting (S 180 A and SPS 330 A)
6.3 Spreading (SP 35 A and SPS 330 A)
6.4 Pulling (SP 35 A and SPS 330 A)
6.5 Crushing (SP 35 A and SPS 330 A)
6.6 Lifting (SP 35 A and SPS 330 A)
29
29
29
31
31
32
32
Hydraulic rescue equipment (rechargeable devices):
S 180 A, SP 35 A, SPS 330 A
Energy pack, mains adapter
Page 2/40
Table of Contents
7
Transport, packaging, and storage
7.1 Safety information
7.2 Transport inspection
7.3 Symbols on the packaging
7.4 Disposal of packaging
7.5 Storage
33
33
33
34
34
34
8
Installation and commissioning
8.1 Safety information
8.2 Checks
8.3 Installation
8.4 Shutting down (end of work)
35
35
35
36
36
9
Servicing
9.1 Safety information
9.2 Care and maintenance
9.3 Maintenance schedule
37
37
37
38
10 Faults
39
11 Decommissioning / recycling
40
Hydraulic rescue equipment (rechargeable devices):
S 180 A, SP 35 A, SPS 330 A
Energy pack, mains adapter
Page 3/40
General
1 General
1.1
Information regarding the operating instructions
These operating instructions provide information for using the rechargeable
battery-powered hydraulic rescue devices (one-man portable). Compliance
with all of the safety and handling instructions specified is a prerequisite for
safe work.
Furthermore, adhere to the local accident prevention guidelines and general
safety regulations for the region in which the devices are used.
Personnel must carefully read this manual prior to starting all work! It is an
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,
irrespective of the equipment type. For this reason you will also find
explanations which do not refer directly to your equipment.
All information, technical data, graphics and diagrams contained in these
operating instructions are based on the most up-to-date data available at the
time of writing.
Alongside the careful reading of the operating instructions we also recommend
that you be trained and instructed on handling the rescue equipment (possible
applications, application tactics etc.) by our qualified trainers.
Hydraulic rescue equipment (rechargeable devices):
S 180 A, SP 35 A, SPS 330 A
Energy pack, mains adapter
Page 4/40
General
1.2
Explanation of symbols
Warning instructions
Warning instructions are marked by symbols in this operating manual. The
individual instructions are introduced by signal words that express the extent of
the hazard.
It is essential to comply with the instructions in order to prevent accidents,
injuries and damage to property.
DANGER!
... indicates an immediate dangerous situation that can
result in death or serious injury if it is not avoided.
WARNING!
... indicates a potentially dangerous situation that can
result in death or serious injury if it is not avoided.
CAUTION!
... indicates a potentially dangerous situation that can
result in minor or light injuries if it is not avoided.
ATTENTION!
... indicates a potentially dangerous situation that can
result in material damage if it is not avoided.
Tips and recommendations
NOTE !
... indicates useful tips and recommendations as well as
information for efficient and trouble-free operation.
Hydraulic rescue equipment (rechargeable devices):
S 180 A, SP 35 A, SPS 330 A
Energy pack, mains adapter
Page 5/40
General
1.3
Limitations of liability
All information and instructions in this operating manual have been provided
under due consideration of applicable standards and guidelines, the current
state of technology, as well as our many years of knowledge and experience.
The manufacturer assumes no liability for damage due to:
•
Disregard of the operating instructions
•
Improper use
•
Deployment of untrained personnel
•
Unauthorized conversions
•
Technical changes
•
Use of non-approved spare parts
•
Use of non-original spare parts
The actual scope of delivery can vary from the explanations and graphic
representations provided in this manual in the case of special versions, or due
to technical changes.
1.4
Copyright
All text, diagrams, drawings and images in this operating manual may be
used without restriction and without any prior approval.
NOTE !
Further information, images and drawings can be found on
our homepage.
www.weber-hydraulik.com
Hydraulic rescue equipment (rechargeable devices):
S 180 A, SP 35 A, SPS 330 A
Energy pack, mains adapter
Page 6/40
General
1.5
Guarantee conditions
The guarantee conditions can be found as a separate document in the sales
documentation.
1.6
Customer service
Our customer service department is available to you for technical information.
Germany
Name:
Telephone:
Fax:
E-Mail:
Ms. Corina Schulz
+49 (0) 7135 / 71-235
+49 (0) 7135 / 71-396
corina.schulz@weber.de
Austria
Name:
Telephone:
Fax:
E-Mail:
Mr. Robert Niederhofer
+43 (0) 7255 / 6237-463
+43 (0) 7255 / 6237-461
robert.niederhofer@weber-hydraulik.at
NOTE!
When contacting our customer service department please
provide the designation, type and year of manufacture of
your equipment.
This information can be found on the equipment type
plate.
Hydraulic rescue equipment (rechargeable devices):
S 180 A, SP 35 A, SPS 330 A
Energy pack, mains adapter
Page 7/40
Safety
2 Safety
This section of the operating manual provides a comprehensive overview of all
the important safety aspects for optimal protection of operating personnel, as
well as for safe and trouble-free operation.
Significant hazards can occur if the handling and safety instructions in this
manual are not complied with.
2.1
Appropriate use
The rechargeable hydraulic devices are designed and tested exclusively for
the appropriate designated purposes described here. All other activities are
fundamentally prohibited.
Rechargeable devices (S 180 A, SP 35 A, SPS 330 A)
•
All of the rechargeable devices are designed as one-man devices
and may thus be operated by one person only.
•
The S 180 A serves exclusively for the cutting of doors and roof
pillars, posts and sills, the rims and spokes of steering wheels.
The rear cutter section should be used whenever possible for
separating solid material as this is equipped with special round
material cutters.
In industrial applications the equipment can also be used for cutting
pipes, construction steel, profiles, sheets and cables.
•
The SP 35 A serves exclusively for the opening of doors, the lifting
of vehicles or other moveable loads, the pushing away and moving
of vehicle parts and loads and the crushing of tubes and pillars.
The spreader jaws should be used whenever possible for crushing.
The spreader jaws can be used as a peeling tool.
The chain set is to be used exclusively for pulling.
•
The combination device SPS 330 A may be used for the same
purposes as those specified for the S 180 A and the SP 35 A.
Hydraulic rescue equipment (rechargeable devices):
S 180 A, SP 35 A, SPS 330 A
Energy pack, mains adapter
Page 8/40
Safety
Accessories (Energy pack, mains adapter, carrier)
•
The energy pack serves exclusively for operating the WEBERHYDRAULIK rechargeable devices and may only be charged with
the original mains adapter.
•
The mains adapter and the carrier are designed and approved only
for the WEBER-HYDRAULIK energy pack.
•
The RZM 700 may only be used in conjunction with SPS 330 A. It
serves exclusively to push steering columns, vehicle roofs and
other obstacles upwards and to push vehicle parts out of the way.
In addition, it can be used to brace, stiffen and pull.
WARNING!
Danger due to improper use!
Any use of the equipment that exceeds the intended use
or deviates from it can lead to dangerous situations!
Therefore it is imperative that:
- The equipment is used only for the purposes
listed above.
- Observe all other instructions in chapter 5 (possible
applications) regarding appropriate use of the
equipment.
Hydraulic rescue equipment (rechargeable devices):
S 180 A, SP 35 A, SPS 330 A
Energy pack, mains adapter
Page 9/40
Safety
2.2
Responsibility of the customer
In addition to the working safety instructions in this operating manual, observe
safety and accident protection guidelines and environmental protection
guidelines applicable to the area of application of the equipment. Particularly
applicable in this regard:
•
•
•
•
The customer must inform himself of applicable industrial safety
regulations, and in a hazard analysis identify other hazards that
may exist at the equipment's installation site due to the special
working conditions.
The customer must clearly regulate and specify responsibilities for
installation, operation, maintenance, and cleaning.
The customer must ensure that all personnel who handle the
equipment have fully read and understood the operating manual.
In addition, the operator must train personnel and inform them of
the dangers of working with the machinery at regular intervals.
Moreover, the customer is responsible for ensuring that the equipment is
always in technically faultless condition. Consequently the following applies:
•
•
After every usage, at least once per year, the device must undergo
a visual inspection by trained personnel (per GUV-G 9102 or
country-specific directive).
Every three years, or in the event of doubts about the safety or
reliability of the equipment, an additional functional and load test is
to be carried out (per GUV-G 9102 or country-specific directive).
Hydraulic rescue equipment (rechargeable devices):
S 180 A, SP 35 A, SPS 330 A
Energy pack, mains adapter
Page 10/40
Safety
2.3
Operating personnel
The following qualifications are cited in the operating manual for the various
activity areas:
•
Trained person
Is informed about the tasks assigned to them and the possible
dangers in the event of improper behaviour through customer
training.
•
Specialist
Is an individual who, due to their specialized training, skills, and
experience, as well as knowledge of the applicable manufacturer's
regulations is capable of executing the tasks assigned to them and
of recognizing possible hazards on their own.
WARNING!
Danger of injury due to insufficient training!
Improper handling of the equipment can lead to serious
injury or material damage.
Therefore it is imperative that:
- Particular tasks are only carried out by the personnel
listed in the appropriate chapter of this instruction
manual.
- In case of doubt call in specialists immediately.
NOTE !
The equipment may not be used by personnel who have
consumed alcohol, taken medication or drugs!
Hydraulic rescue equipment (rechargeable devices):
S 180 A, SP 35 A, SPS 330 A
Energy pack, mains adapter
Page 11/40
Safety
2.4
Personal protective gear
Wearing personal protective equipment (PPE) is essential to minimize the risks
to operating personnel when working with the rechargeable hydraulic devices.
It is essential to wear the following protective clothing for all work:
Protective work clothing
Tight-fitting work clothing with tight sleeves and without
projecting parts should be worn for work. It is primarily used
to protect against entanglement by moving equipment parts.
Safety footwear
Safety footwear with steel toecaps must always be worn as
protection against heavy falling parts and from slipping on
slippery ground.
Work gloves
Work gloves must be worn when working with the equipment
for protection against sharp edges and glass fragments.
Helmet with face shield
A helmet with face shield must be worn for protection against
flying or falling parts and glass fragments.
Protective goggles
Protective goggles must also be worn in addition to the face
shield in order to protect the eyes from slivers.
With certain work the following must also be worn in addition:
Ear protectors
In addition to the basic protective equipment, ear protectors
should also be worn for protection against hearing damage.
Hydraulic rescue equipment (rechargeable devices):
S 180 A, SP 35 A, SPS 330 A
Energy pack, mains adapter
Page 12/40
Safety
2.5
Specific hazards
The hazards that arose within the framework of the risk evaluation are listed in
the following section.
Follow the safety instructions listed here and the warning instructions in the
other sections of this manual to minimise potential health hazards and avoid
dangerous situations.
Electric shock
DANGER!
Life-threatening danger due to electric shock!
There is an imminent life-threatening danger if live parts
are touched. Damage to insulation or to specific
components can pose a life-threatening danger.
Therefore:
-
Disconnect the power supply immediately if there is
damage to the insulation and have it repaired.
-
Only a qualified electrician should perform work on
the electrical equipment.
-
All electrical work on the system must be carried out
with the system disconnected from the mains power
supply and the system must be check to confirm
that it is de-energised.
-
Prior to any maintenance, cleaning or repair works
the power supply must be switched off and secured
against being unintentionally switched back on.
-
Do not bypass fuses or render them inoperable.
Always use the correct amperage when changing
fuses.
-
Keep moisture away from live parts. Moisture can
lead to a short circuit.
Hydraulic rescue equipment (rechargeable devices):
S 180 A, SP 35 A, SPS 330 A
Energy pack, mains adapter
Page 13/40
Safety
Noise
WARNING!
Hearing damage due to noise!
The noise occurring in the work area can cause severe
hearing damage.
Therefore:
-
Also wear ear protectors when carrying out
particularly noise-intensive works.
-
Do not stay in the hazardous area longer than
necessary.
Hydraulic energy
WARNING!
Danger due to hydraulic energy!
Serious injuries can be caused by discharged hydraulic
force and the emergence of hydraulic oil.
Therefore:
-
Always keep your eyes on the hydraulic equipment
throughout the working process and set down if
necessary.
-
Check the hose lines and the equipment for damage
after every usage.
-
Avoid skin contact with the hydraulic oil (wear
protective gloves).
-
Remove hydraulic oil from wounds without delay
and seek medical attention immediately.
Hydraulic rescue equipment (rechargeable devices):
S 180 A, SP 35 A, SPS 330 A
Energy pack, mains adapter
Page 14/40
Safety
2.7
Behaviour in the event of danger or accidents
Preventative measures
•
Always be prepared for accidents
•
Keep first aid equipment (first-aid box, blankets etc.)
to hand
•
Familiarize personnel with accident alarms, first-aid kits,
and rescue equipment
•
Keep entry ways clear for rescue vehicles
In the event of an accident
•
Shut down the equipment immediately
•
Initiate first-aid measures
•
Get people out of the danger zone
•
Inform the responsible parties at the implementation site
•
Notify a physician and/or the fire department
•
Keep entry ways clear for rescue vehicles
Hydraulic rescue equipment (rechargeable devices):
S 180 A, SP 35 A, SPS 330 A
Energy pack, mains adapter
Page 15/40
Safety
2.8
Signage
The following symbols and instruction signs are found on the equipment. These
symbols and instructions refer to the immediate vicinity in which they are affixed.
Comply with the instructions in the operating manual
Do not use the marked equipment until after you have
read the operating manual.
Warning of injury to hands
When working with the equipment care should be taken to
avoid hand injuries through clamping or sharp edges.
WARNING!
Danger of injury due to illegible symbols!
Over time, stickers and symbols on the equipment can be
become fouled or can become illegible in some other
manner.
Therefore it is imperative that:
- Keep all safety, warning, and operating instructions that
are affixed to the device in good, legible condition.
- Replace damaged signs and stickers immediately.
Hydraulic rescue equipment (rechargeable devices):
S 180 A, SP 35 A, SPS 330 A
Energy pack, mains adapter
Page 16/40
Technical data
3 Technical data
S 180 A
SP 35 A
SPS 330 A
Mains adapter (M-M 230
V)
Energy pack
S 180 A
SP 35 A
SPS 330 A
Length
791 mm
886 mm
840 mm
Width
222 mm
215 mm
222 mm
Height
192 mm
208 mm
191 mm
Weight
18.7 kg
23.0 kg
17.4 kg
Opening width
180 mm
620 mm
330 mm
Max. cutting force
42 t
-
24 t
Max. cutting capacity
with round material
Ø 30 mm
-
Ø 25 mm
Spreading force in
working range
-
38 – 132 kN
42 – 148 kN
Clamping force
-
99 kN
35 kN
Spreading distance
-
620 mm
330 mm
Pulling distance
-
545 mm
400 mm
Pressure
700 bar
700 bar
700 bar
DIN class
C150-G-E
S30-E
K25-F-E
Part no.
593.115.0
593.047.2
593.002.2
Hydraulic rescue equipment (rechargeable devices):
S 180 A, SP 35 A, SPS 330 A
Energy pack, mains adapter
Page 17/40
Technical data
Energy pack
Length
219 mm
Width
85 mm
Height
279 mm
Weight
8.5 kg
Rated voltage
12V – DC (direct current)
Nominal capacity
20 Ah
Type of protection
IP 54
Input voltage range
12 – 32 V DC (direct current)
Max. input current
17 A at 12V; 8.5 A at 24V
Nominal charging current
7A
Charging voltage /
Nominal output voltage
14 V-DC (direct current )
Charging as per
DIN 41722
Temperature range when
charging
+ 5° to + 35° C
Operating temperature
- 20° C to + 60° C
Part no.
386.868.0
Mains adapter
Length
158 mm
Width
110 mm
Height
40 mm
Weight
0.9 kg
Input voltage
230 V AC (alternating current),
50 Hz max. 200 VA
Nominal output voltage
14 V-DC (direct current )
Nominal charging current
7 A-DC (direct current )
Charging as per
DIN 41722
Temperature range (operating)
- 20° C to + 50° C
Relative humidity
up to 80%
Type of protection
SKI / IP 20
Part no.
386.868.0
Hydraulic rescue equipment (rechargeable devices):
S 180 A, SP 35 A, SPS 330 A
Energy pack, mains adapter
Page 18/40
Technical data
3.1
Operating conditions
The permissible operating temperature range for the rechargeable equipment
is - 20° C to + 60° C. Reliable functioning of the equipment cannot be
guaranteed outside this range.
3.2
Type plate
The type plate can be found on the device body of all cutting devices. Here
you can find the serial number, manufacturing date, nominal pressure,
equipment designation and the EN standard.
Hydraulic rescue equipment (rechargeable devices):
S 180 A, SP 35 A, SPS 330 A
Energy pack, mains adapter
Page 19/40
Design and Function
4 Structure and function of the equipment
4.1
Overview
1
2
3
4
5
6
7
8
4.2
Cutter (arms)
Protective cover
Handle
Bayonet connector
Rocker lever
Device body
Pump unit
Electrical power cable
Brief description
Rechargeable hydraulic devices are specially designed rescue equipment for
cutting or spreading bodywork parts. They are used for rescuing trapped or
enclosed accident victims.
They are not tied to a vehicle because they have their own internal electrohydraulic drive, and so can also be used in inaccessible places.
The speed of movement of the shearing blades is controlled by the greater or
lesser degree of force applied to the rocker lever on the handle. The maximum
force is only applied when the rocker lever is actuated to its fullest extent.
Hydraulic rescue equipment (rechargeable devices):
S 180 A, SP 35 A, SPS 330 A
Energy pack, mains adapter
Page 20/40
Design and Function
4.3
Hydraulic supply
Drive
The drive of the rechargeable device is created through a permanently exited
12V DC motor with a nominal power of 400 Watts. The drive motor runs only
as long as the rocker switch is being actuated.
Pump
The hydraulic pressure is created by a high pressure hydraulic pump (in the
pump unit). The pump is a swashplate axial piston pump with four pistons.
The pressure acts directly on the working cylinder and so there is no need for
connection lines in the equipment.
Oil tank
The volume of oil for operation is taken from a spring-loaded piston-type
accumulator. The complete hydraulic system is therefore completely closed
and void of air. The system pressure (accumulator pressure) is 0.5 bar. Any
possible reduction in volume as a result of heat will be balanced out by the
accumulator.
Hydraulic oil
All rechargeable devices are designed and tested for AERO Shell Fluid 41
hydraulic oil. This oil possesses a particularly high purity level and also works
flawlessly at temperatures below zero, down to -20° C.
The oil does not usually require changing, however if this should become
necessary then an oil change must be performed by WEBER HYDRAULIK
service personnel only.
Hydraulic rescue equipment (rechargeable devices):
S 180 A, SP 35 A, SPS 330 A
Energy pack, mains adapter
Page 21/40
Design and Function
4.4
Connections to the energy pack
To connect the equipment to the energy pack, the bayonet connector must first
be gently inserted into the coupling half on the energy pack. Fasten the
bayonet connection by tightening clockwise. Ensure that the lock engages
correctly at this time.
4.5
Use of the control handle
The rechargeable device can be operated by the rocker lever on the control
handle. The speed of movement of the shearing blades/arms is controlled
precisely by the greater or lesser degree of force applied.
The maximum cutting or spreading force is only applied when the rocker lever
is actuated to its fullest extent.
Close cutters / open spreaders
The primary motion of the device is triggered by moving the rocker lever to the
left.
Open cutters / close spreaders
The cutters are opened or the spreaders closed by moving the rocker lever to
the right.
Dead-man's switching
If the rocker lever is released then it returns to the neutral position
automatically. With this, the device stops still in any position (including under
load).
Symbol to close:
Hydraulic rescue equipment (rechargeable devices):
S 180 A, SP 35 A, SPS 330 A
Energy pack, mains adapter
Symbol to open:
Page 22/40
Design and Function
4.6
Changing the spreader jaws (SP 35 A and SPS 330 A)
The spreader jaws are secured with collar studs in the spreader arms. In order
to change, press out the studs secured by a spring-loaded ball.
After
changing the jaws, push the collar studs back in again. When doing this
ensure that the studs are correctly seated (completely pressed in).
Fitting the bracket for the chain set is identical. The chain master link must be
fitted with the lock facing upwards.
NOTE !
In order to fit the chain master link onto the SPS 330 A,
two additional pulling adapters are necessary - they must
be fitted first (same system as for the spreader jaws).
4.7
Accessories (SP 35 A and SPS 330 A)
Chain set
A chain set is required in order to be able to pull with the SP 35 A or the SPS 330
A. The two chain master links and the hooks are included.
Order number: 057.140.7
Pulling adapter
To attach the chain set to the SPS 330 A, two pulling adapters are required in
addition to the chain master link.
Order number: 209.661.7
Rescue cylinder RZM 700
A rescue cylinder attachment is available with which to increase the spreading
distance of the SPS 330 A to 700 mm. This is attached to the jaws by means
of ball studs.
Order number: 282.526.0
Hydraulic rescue equipment (rechargeable devices):
S 180 A, SP 35 A, SPS 330 A
Energy pack, mains adapter
Page 23/40
Energy pack
5 Energy pack
5.1
Safety information
CAUTION!
Once the equipment connector is inserted the rechargeable
device is immediately ready for operation. Therefore, always
pull out the connector when not in use in order to prevent
accidents.
5.2
General
The energy pack comprises a rechargeable, leak-proof and storage-tolerant
lead acid battery (12V / 20A), a control unit with acoustic warning device and
an integrated charging device for 12V – 32V DC.
The battery comprises an encapsulated, maintenance-free, lead acid storage
battery with highly absorbent separators (webbing inserts). This can be
charged either by the integrated charger or via a separate mains charger
(230V AC).
The service life of the battery is specified by the manufacturer as five years or
1,000 charging cycles.
A test and reset button, four LEDs, a screw locking device, the charging socket
(switchable to consumer) and an interconnection terminal for remote operation
of the Hydro-Pac are located on the top side.
A consumer such as a hand-held spotlight up to 100 W can be connected to
the charging socket (changeover via the rocker switch).
Attention! The deep discharge protection (chapter 5.3) is disabled by this!
NOTE !
The energy pack battery is approved for transport in
aircraft by the IATA (International Air Transport
Association).
Hydraulic rescue equipment (rechargeable devices):
S 180 A, SP 35 A, SPS 330 A
Energy pack, mains adapter
Page 24/40
Energy pack
5.3
Control and charging electronics
The control electronics have the task of ensuring that the rescue device is
always ready for use through switching functions and monitoring functions.
The monitoring is carried out by a microprocessor that is integrated in the
splash-proof glued plastic housing of the energy pack together with the control
and charging electronics.
Monitoring electronics
The monitoring electronics enable a check of the charge status of the energy
pack whilst in idle state using the "Test" pushbutton and with a test resistor.
The result is displayed via a row of LEDs (red, yellow, green).
GREEN: Battery fully charged
GREEN/YELLOW: Battery slightly discharged
YELLOW: Battery is half discharged
YELLOW/RED: Battery is substantially discharged
RED: Battery is almost completely discharged!
Deep discharge protection (DDP)
When starting up a device, permanent voltage monitoring starts automatically.
If due to use, the factory set threshold voltage of 10.5V is undercut, an
acoustic signal (peeping) sounds after a three second delay and the red
"ALARM" LED illuminates.
If the threshold voltage of 8.5V is also undercut through further use then after
another three second delay the battery will be disconnected from the device in
order to avoid the battery being damaged. This forced shut-down is signalled
by a constant tone and also this remains intact (self-latching) after the device is
switched off.
The forced shut-down can be alleviated briefly by pressing the RESET button
in order to be able to drive the device back to its default position, or if
necessary to carry out a few final actions.
ATTENTION!
The energy pack may be reset a maximum of three times!
If it used more frequently without the device being recharged
in the meantime, this can lead to serious damage to the
battery and the motor of the rescue device.
Hydraulic rescue equipment (rechargeable devices):
S 180 A, SP 35 A, SPS 330 A
Energy pack, mains adapter
Page 25/40
Energy pack
Charging electronics
The battery is charged by an integrated electronically-controlled charging
device. The charge status of the battery is irrelevant to this. It is also
unnecessary to completely discharge the battery before recharging because
lead acid batteries do not exhibit a memory effect. Overcharging the battery is
prevented by a voltage limiter in the charger.
5.4
Hanging / wearing
The energy pack should be worn on the left side with the upper edge at belt
height if possible. Worn in this way, the receptacle for the equipment
connector points rearwards and the connection cable runs behind the feet,
meaning that it does not hang as an obstruction.
The shoulder strap is drawn over the head and placed on the right shoulder so
that it can not slide off the shoulder whilst working.
The harness is equipped with a quick-release fastener in the middle. It is
pulled at tight at both loose ends so that the energy pack rests close to the
body.
Alternatively, the energy pack can also be worn on the back. Two shoulder
straps are used for this, each of which is hooked through the eyelet. Thus, the
energy pack can be worn like a rucksack. (Order number for a second
shoulder strap: 810.846.3)
5.5
Charging
The energy pack is charged via the charging cable (484.777.6) directly
connected to a 12-24V socket, or via the mains adapter (812.182.6) connected
to 230V / 50 Hz AC.
When connecting, ensure that the connector is plugged into the energy pack
before the charging cable is connected to a power source. In addition, make
sure that the connector is well seated.
When disconnecting, always disconnect the connector from the power source
first and only then disconnect the energy pack. Otherwise there is a risk of a
short-circuit.
When charging correctly, the LEDs corresponding to the charge status of the
battery flash. The green LED is continuously illuminated when the battery is
fully charged or when it is being trickle-charged.
The battery will only be deep discharged when the deep discharge protection
(DDP) is switched off repeatedly by pressing of the RESET button. (Charging
with reduced charge current - trickle charging)
Hydraulic rescue equipment (rechargeable devices):
S 180 A, SP 35 A, SPS 330 A
Energy pack, mains adapter
Page 26/40
Energy pack
5.6
Mains adapter
The following safety instructions must be followed when using the mains
adapter to charge the energy pack:
•
The mains adapter may not be used if there is known to be damage to
the mains adapter or to the connection cable.
•
Only run the mains adapter from earthed mains sockets.
•
Do not expose the device to rain or water (use only in closed
buildings).
•
Ensure that liquid ingress to the mains adapter is prevented in all
instances. CAUTION! Life-threatening voltage!
•
Only plug and unplug the connection cable by the plug itself.
•
Do not place objects on the mains adapter.
•
Never cover or modify the device.
WARNING!
Improper charging can cause the formation of combustible
gases in the energy pack batteries.
Therefore:
5.7
-
Avoid flames and sparks when charging.
-
Only charge in well ventilated spaces.
-
Switch the mains adaptor off before unplugging
the charging cable from the energy pack.
Accessories
Mounting
A mounting bracket is available for secure installation in a vehicle. This also
enables charging from the vehicle power supply.
Order number: 387.390.0
Shoulder strap
A second shoulder strap is required in order to wear the energy pack as a
rucksack (chapter 5.4).
Order number: 810.846.3
Hydraulic rescue equipment (rechargeable devices):
S 180 A, SP 35 A, SPS 330 A
Energy pack, mains adapter
Page 27/40
Possible fields of application
6 Possible applications
6.1
Safety information
WARNING!
Never reach between the cutter arms!
WARNING!
During all work with the rechargeable devices, parts which
are tensioned can break off or be blown off and thus
endanger personnel.
Therefore, personnel who are not directly involved must
maintain a safe distance or only stay in the hazardous
area as long as is strictly necessary.
6.2
Cutting (S 180 A and SPS 330 A)
The cutting capacity of the equipment can only be optimally utilised if it is
applied as close to the pivot point of the cutter as possible (Fig.1).
Some readjustment of the equipment may be necessary here.
The full cutting capacity of the device is only attained when the operating lever
is fully depressed. In addition, there can be a delay of a few seconds before
the unit has full working pressure available.
Fig. 1
Hydraulic rescue equipment (rechargeable devices):
S 180 A, SP 35 A, SPS 330 A
Energy pack, mains adapter
Page 28/40
Possible applications
In order to avoid the cutter being damaged, it must always be applied at right
angles to the cutting material.
In addition, the shearing blades must not be more than 5 mm apart at the tips
during the cutting process. If this value is exceeded then the cutting process
must be aborted and the cutter reapplied.
CAUTION!
Do not cut parts with free ends as this poses a danger of
personnel being injured by flying parts.
ATTENTION!
Cutting high strength body parts such as shock absorbers,
hinges or steering columns must be avoided as this can
cause serious damage to the shearing blades (arms).
Hydraulic rescue equipment (rechargeable devices):
S 180 A, SP 35 A, SPS 330 A
Energy pack, mains adapter
Page 29/40
Possible applications
6.3
Spreading (SP 35 A and SPS 330 A)
With the help of the rechargeable device's spreader function, possible
applications include doors being opened or vehicle parts being pushed out of
the way.
A stable positioning and support of the vehicle is essential with this.
In order to avoid slipping off when spreading, the arms and jaws are serrated
on the inner and outer sides.
It is best to spread using this area because the spreading force is highest here.
In addition, slipping of can be avoided by readjusting the spreaders. If possible
the tips should only be used to enlarge a gap.
6.4
Pulling (SP 35 A and SPS 330 A)
After the chain set is attached to the spreader jaws (as explained in chapter
4.6), the rechargeable device can also be used for pulling.
The chains must always be stretched taught during this application, and must
only be loaded in the direction of pulling. To tension the chain, it is possible to
press one lock in respectively so that the chain can be pulled through the
bracket.
If the pulling distance is insufficient then it must be secured with tensioning
chains or alternative means so that the equipment can be opened again and
the chain re-tensioned.
ATTENTION!
Please observe the separate operating instructions for the
WEBER-HYDRAULIK chain set (ID 281.913.9), so that the
chain set is properly employed.
Hydraulic rescue equipment (rechargeable devices):
S 180 A, SP 35 A, SPS 330 A
Energy pack, mains adapter
Page 30/40
Possible applications
6.5
Crushing (SP 35 A and SPS 330 A)
The crushing of pipes and other hollow profiles is performed by closing the
spreader arms.
However, in the case of the SPS 330 A only the area of the tips can be used
for crushing (fig. 2)!
Fig. 1
Fig. 2
ATTENTION!
Items being crushed can jump out suddenly.
Do not remain in the working area of the spreader!
6.6
Lifting (SP 35 A and SPS 330 A)
The rechargeable device can also be employed for lifting vehicles or other
moveable loads.
It is necessary to ensure that the load is secured against sliding away and that
the spreader jaws are applied far enough under the load to prevent slippage.
The lifting load must be observed constantly (for tilting, rolling away or changes
in altitude) throughout the lifting process. In addition, the lifting load must be
immediately supported and braced in an appropriate manner.
Hydraulic rescue equipment (rechargeable devices):
S 180 A, SP 35 A, SPS 330 A
Energy pack, mains adapter
Page 31/40
Transport, packaging, and storage
7 Transport, packaging, and storage
7.1
Safety information
CAUTION!
Incorrect transportation can cause damage!
Significant material damage can occur due to incorrect
transportation.
Therefore:
- Proceed with caution when unloading packages and
observe the symbols on the packaging.
- Do not open fully or dispose of packaging until at the
intended storage location.
7.2
Transport inspection
The delivery should be checked immediately upon receipt for completeness
and any possible transportation damage, so that a quick remedy can be
instigated if necessary.
In the event of visible external damage proceed as follows:
•
•
•
Do not accept the delivery, or only accept it with reservation.
Note the extent of transport damage on the transport documents or on
the transport company's delivery note.
Submit a complaint.
NOTE !
Report any defect as soon as it is detected.
Claims for damages can be directed to our customer
service department (see chapter 1.6).
Hydraulic rescue equipment (rechargeable devices):
S 180 A, SP 35 A, SPS 330 A
Energy pack, mains adapter
Page 32/40
Transport, packaging, and storage
7.3
Symbols on the packaging
Caution fragile!
Handle the package carefully, do not drop, throw, strike or tie up.
This way up!
The package must be transported and stored strictly such that
the arrows point upwards. Do not roll or tilt.
7.4
Disposal of packaging
All packaging materials and disassembled parts (transportation
protection) must be disposed of properly in accordance with
applicable local regulations.
7.5
Storage
The work equipment and the energy pack should be stored in a dry and dustfree environment where possible. In addition, the storage location should be
cool but free of frost. It is possible to set the energy pack down outside whilst
in use - even in the rain, but not in puddles.
CAUTION!
The equipment must be stowed securely in the mountings
intended for this, in order to avoid it being damaged whilst
in transit etc.
Hydraulic rescue equipment (rechargeable devices):
S 180 A, SP 35 A, SPS 330 A
Energy pack, mains adapter
Page 33/40
Installation and commissioning
8 Installation and commissioning
8.1
Safety information
WARNING!
Danger of injury due to improper operation!
Improper operation can cause serious injury or
material damage.
Therefore it is imperative that:
- Execute all operating steps in accordance with the
information in this operating manual.
- Prior to starting work ensure that all covers and
protective devices are installed and functioning properly.
Personal protective gear
Wear the protective gear detailed in chapter 2.4 with all work!
NOTE !
Special reference has been made where it is necessary to
wear additional protective equipment for certain work with
or on the device.
8.2
Checks
Check the rechargeable device or the energy pack for damage. If the
equipment should be found not to be in flawless condition then it must not be
used! In this event, inform your supplier immediately.
•
•
•
•
•
•
•
•
Check the cutter or arms (damage)
Check the control handle including rocker lever (function)
Check the bayonet coupling (damage, dirt)
Check the hand grip (securely fastened)
Check the protective cover (damage)
Check the operating controls (function)
Check the cable (damage)
Hydraulic rescue equipment (rechargeable devices):
S 180 A, SP 35 A, SPS 330 A
Energy pack, mains adapter
Page 34/40
Installation and commissioning
8.3
Installation
Prior to the first use it is necessary to completely charge the energy pack once.
Following this, the work equipment can be connected.
Once plugged in, the work equipment is immediately ready for operation. The
energy pack does not need to be switched on first.
8.4
Shutting down (end of work)
After the work is finished the cutter blades must be placed over each other or
the spreader arms placed together, in order to preclude any risk of injury.
The rechargeable device blades/arms must never be fully closed as this will
cause hydraulic stress to be built up in the equipment.
NOTE !
With combination devices, drive the spreader arms to
within a few millimetres of each other in order to relieve
the hydraulics.
Then the equipment can be disconnected from the energy pack.
Hydraulic rescue equipment (rechargeable devices):
S 180 A, SP 35 A, SPS 330 A
Energy pack, mains adapter
Page 35/40
Servicing
9 Servicing
9.1
Safety information
WARNING!
Injury hazard due to improperly executed maintenance
tasks!
Improper maintenance can cause serious injury or
material damage.
Therefore it is imperative that:
- Maintenance work is carried out only by specialist
personnel.
- Order and cleanliness are assured at the installation site!
Parts and tools that are lying loose are a source of
hazards.
- Protective gloves are worn during all work!
9.2
Care and maintenance
The following measures are imperative in the interest of maintaining a state of
constant operational readiness:
•
After each use and at least once per year, the device and the
accessory parts must undergo a visual inspection. The spreader jaws,
joints, blades, connection cable, housing and couplings in particular
should be checked at this time.
•
Recharge the energy pack immediately after every use.
•
Every three years, or in the event of doubts about the safety or
reliability of the equipment, an additional functional and load test is to
be carried out (per GUV-G 9102 or country-specific directive).
•
Fin grease OG must be injected into the moving parts and bolts from
time to time.
Hydraulic rescue equipment (rechargeable devices):
S 180 A, SP 35 A, SPS 330 A
Energy pack, mains adapter
Page 36/40
Servicing
ATTENTION!
The equipment must be cleaned of all contaminants before
any maintenance work so that no dirt can enter the
hydraulic system.
The cleaning can be carried out with a standard citrus
cleaning agent or with WD-40.
9.3
Maintenance schedule
A more precise maintenance plan with test intervals, test regulations and test
results can be taken from GUV - G 9102 item 17 (hydraulically actuated
rescue equipment).
NOTE !
Our customer service department is available for you if
there should be problems with the maintenance of the
equipment (see chapter 1.6).
Hydraulic rescue equipment (rechargeable devices):
S 180 A, SP 35 A, SPS 330 A
Energy pack, mains adapter
Page 37/40
Faults
10 Faults
Fault
LEDs indicate a partial
discharge although the
energy pack is connected
to a power supply.
LEDs do not illuminate
Possible cause
• Mains adapter faulty
• Energy pack fuse (10A)
faulty
Remedial measures
• Check mains adapter
and replace if
necessary.
• Change fuse
Equipment is not receiving
power or is receiving too
• Check connection cable
little power
or mains adapter and
replace if necessary
• Check power supply for
sufficient voltage
Damage to the housing of
the mains adapter.
-
Send mains adapter to
specialist dealer or
manufacturer
Damage to the housing of
the energy pack.
-
Send energy pack to
specialist dealer or
manufacturer
Work equipment does not
move
• Connection cable not
correctly coupled
• Energy pack not charged
Hydraulic rescue equipment (rechargeable devices):
S 180 A, SP 35 A, SPS 330 A
Energy pack, mains adapter
• Couple connection cable
properly.
• Charge energy pack
Page 38/40
Decommissioning / recycling
11 Decommissioning / recycling
After the service life has expired the equipment must be disposed of correctly.
Individual parts can however certainly be reused.
The hydraulic oil must be completely drained off and collected. Please note
that the hydraulic oil must be disposed of separately!
The local disposal regulations apply to the disposal of all equipment parts and
packaging materials.
NOTE !
Please consult your supplier regarding the disposal of the
equipment.
Hydraulic rescue equipment (rechargeable devices):
S 180 A, SP 35 A, SPS 330 A
Energy pack, mains adapter
Page 39/40
2009 edition, 2nd issue
WEBER-HYDRAULIK GmbH
Heilbronner Straße 30
Industriegebiet 3 + 4
74363 Güglingen/Germany
4460 Losenstein/Austria
Tel.: +49 (0) 7135/71-270
Tel.: +43 (0) 7255/6237-0
Fax:
+49 rescue
(0) 7135/71-396
Fax: +43 (0) 7255/6237-461
Hydraulic
equipment (rechargeable devices):
S 180 A, SP 35 A, SPS 330 A
info@weber.de
office@weber-hydraulik.at
Energy pack, mains adapter
www.weber-hydraulik.com
www.weber-hydraulik.at
Page 40/40
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