American ART-258 User manual

1.0 IMPORTANT RECEIVING INSTRUCTIONS
Visually inspect all components for shipping damage. Please
contact American Rescue Technology products if damage has
occurred.
SAFETY FIRST
2.0 SAFETY ISSUES
American Rescue Technology products are designed and
manufactured to provide excellent service when used for their
intended purpose. Operator safety is a major consideration in the
product design and operator manuals are provided to promote
their safe use.The company urges all users to read the instruction
manual and to seek operating instructions from qualified
instructors before attempting to use the products.
Although most safety precautions are addressed in factory
authorized training programs as well as throughout this manual,
pay particular attention to the following:
• Power units and tools should be operated by qualified
personnel only.
• Be sure to follow all maintenance procedures and to use only
factory authorized service parts.
Instruction Manual
5.5 HP Honda Gas Power Unit
ART-258
L2514 Rev. O 09/01
Specifications ART-258
Operating Pressure 350 bar (5,000 psi maximum)
Valve Type (2) Dump
Motor Honda GXV 160 5.5 HP (4,1 kW), 4 cycle
See Honda GXV 160 Owner’s Manual supplied with pump.
Sound Level 80 dBA at 1 m (3 ft) at no load
Flow Rate 7,5 1/min (460 in3/min) at 0 bar (0 psi)
1,6 1/min (100 in3/min) at 350 bar (5,000 psi)
Unloading Pressure 110 bar (1,600 psi)
Reservoir Capacity 8 Liter (2.1 gallons)
Dry Weight 44 kg (97 lbs)
Recommended Hydraulic Fluid American Rescue Technology Fire Resistant Phosphate Ester Fluid

2
WARNING:
• These power units have factory-adjusted internal relief
valves which must not be repaired or adjusted except by
factory trained service personnel.
• Do not use gasoline power units in an explosive
atmosphere.
• Operate and refuel the pump in well ventilated areas
only. Avoid inhaling exhaust gasses.
• Inspect equipment for broken or missing parts or
damaged hoses before and after use.
• Keep clear of all moving parts.
• Always use cribbing to shore and stabilize objects being
lifted.
• Wear proper protective gear; including bunker gear,
gloves, helmets, face shields, etc. Ear protection should
be worn when operating gasoline or diesel power units.
CAUTION:
• Check hydraulic fluid level before operating power unit.
Add fluid when necessary.
• Use only American Rescue Technology hydraulic fluid.
Do not substitute other brands because characteristics
may differ. Brake or automatic transmission fluid will not
work in the American Rescue Technology system and
will damage the equipment.
• American Rescue Technology hydraulic fluid is a
custom blended fluid. In case of contact with the skin,
wash off with soap and water. In case of eye contact,
flush generously with water. If discomfort persists, see
a physician.
DO NOT OPERATE THIS EQUIPMENT
WHEN TIRED. STAY ALERT.
3.0 INSTALLATION
3.1 Install Fluid Level Gauge
For shipping purposes, a plug is installed in the fill port on the top
of the reservoir. See illustration below.
1. Remove shipping plug (1).
2. Install the fluid level gauge that was shipped with the power
unit (2).
Figure 1
CAUTION:
• The fluid level gauge acts as the vent for the reservoir
and must be installed whenever you run the power unit.
Never run the power unit with the shipping plug installed.
This will cause damage to the pumping mechanism.
3.2 Check Fluid Level
Check the fluid level prior to start-up (see Figure 2).The fluid level
should be above the “2” band on the gauge as pictured below.Add
hydraulic fluid if necessary. To add fluid, remove the fluid level
gauge and pour fluid through the opening in the top of the
reservoir.
IMPORTANT: Add fluid only when all system components are
fully in the retracted position. If fluid is added when plungers
are advanced, there will be more fluid in the system than the
reservoir can hold.
Figure 2
3.3 Install Hydraulic Hoses and Rescue Tools
The valves operate independently, and their connections are made
separately. Follow the steps below to connect each tool to a single
valve on the power unit.
1. Remove caps from flare fittings on valve.
2. Match tank and pressure hoses with appropriate valve ports
and hand-tighten fittings. (See Figure 3)
3. Tighten connections using an open end wrench.
CAUTION: Over tightening may damage connections.
4. Refer to appropriate Rescue Tool instruction manual for
information on connecting power unit hoses to the RescueTool.
Figure 3
Pressure Port
Tank Port
1
2
3
4
2
1
FLUID LEVEL GAUGE MARKINGS:
1. Empty
2. Add Oil
3. In Use
4. Full

3
4.0 OPERATION
1. Check all system fittings and connections to be sure they are
tight and leak free.
2. Check gasoline engine gas and oil levels.See Honda GXV160
Owner’s Manual for recommended fluids.
3. Before starting gasoline engine, be sure that the control valve is
in the dump (2) position to prevent accidental movement of tool.
NOTE: When the pump is new or after fluid has been
changed, it may be necessary to prime the pump.To do this,
pull the engine starter grip slowly a few times to get the
engine to turn, but not start. This slow rotation should pull
fluid up into the pump pistons.
4. Start the gasoline engine using procedure in Honda GXV160
Owner’s Manual.
5. Operate the pump control valve to direct pressure to the tool
(1) or return to tank (2). Control valve handle positions are
shown below. (See Figure 4.)
NOTE: The control valves operate independently from one another.
Figure 4
NOTE: When the hydraulic system is connected for the first time,
air will be trapped in the components. To ensure smooth
operations, purge air from the system by opening and closing the
rescue tool several times.
WARNING:
• To ensure proper operation, avoid kinking or tightly
bending hoses. If a hose becomes kinked or otherwise
damaged, it must be replaced. Damaged hoses may
rupture at high pressure causing personal injury.
5.0 MAINTENANCE
5.1 Check Fluid
IMPORTANT: Observe local ordinances when disposing of used
fluid.
Completely drain the reservoir after every 100 hours of
operations. Refill with new hydraulic fluid. If power unit is used
infrequently, change the fluid once a year.
Procedure: (see Figure 5)
1. Position drain plug above a pan to catch the used fluid.
2. Remove the drain plug (A).
3. Tilt the power unit to allow fluid to drain completely out of
reservoir.
Figure 5
4. Reinstall drain plug (A).
5. Fill the reservoir through the fluid level gauge opening (B) with
new hydraulic fluid. (See page one for recommended fluid
specification.) It may be necessary to prime the pump after
filling (see Section 4.0, OPERATION for priming instructions).
5.2 Check Engine Operation
See the Honda GXV160 Owner’s Manual that was supplied with
your power unit. Follow the Maintenance Schedule to keep the
engine in operating condition.
5.3 Check Power Unit Operation
Operate the pump and observe its performance. Refer to the
TROUBLESHOOTING on page 4 to isolate problems. If the power
unit fails to perform as it should, the seals may need to be
replaced.The life of the seals will depend upon usage, cleanliness,
and environmental conditions.
For repair service, contact your dealer or factory trained service
personnel.
A
B
12

6.0 TROUBLESHOOTING
A system failure may or may not be the result of a power unit
malfunction.To determine the cause of the problem, the complete
system must be included in any diagnostic procedure. Refer to
Honda GXV160 Owner’s Manual for engine information.
Only factory trained personnel should service the power unit or
system components. For repair service, contact your dealer or
factory trained service personnel.
Symptom Possible Cause Solution
Power unit fails to Pump not primed. Pull the engine starter grip slowly a few times
build pressure to get the engine to turn but not start. This slow
rotation should pull oil up into the pump pistons.
External leak in system. Trace circuit checking all connections and
components.
Internal leak in pump or valve. Contact your dealer or factory trained service
personnel.
Internal leak in system component. Repair or replace leaking system component.
Rescue tool will not Valve not in the pressure position. Move valve lever firmly into pressure position.
open or close.
Flow to tool blocked by loose Release pressure and turn off unit. Check that
coupler connection. all couplers are completely connected and
hand tightened.
Fluid level too low. Fill reservoir to proper level.
Filter screens clogged. Remove the reservoir. Clean or replace filter
screens.
Pump or valve failure. Contact your dealer or factory trained service
personnel.
Rescue tool opens Air in fluid. Tighten all hydraulic connections. Fill the
and closes erratically reservoir to the proper level. Open and close the
rescue tool several times to purge the system.
External hydraulic leak. Replace any damaged valves, hose, or fittings.
Tighten leaky connections. Purge air from
system by opening and closing the rescue tool
several times.
Relief valve failure Contact your dealer or factory trained service
personnel.
Pump worn or damaged Contact your dealer or factory trained service
personnel.
Sequencing valve failure. Contact your dealer or factory trained service
personnel.