Amkus GH2S2-XL Guide

AMKUS, Inc.
2700 Wisconsin Ave.
Downers Grove, IL 60515-4226
Tel: [phone]
Toll Free: 1-800-59 AMKUS
Fax: [phone]
Website: www.amkus.com
E-mail: [email protected]
User Information Manual
AMKUS, Inc., 2700 Wisconsin Avenue, Downers Grove, IL 60515-4226
Website: www.amkus.com E-mail: [email protected]
Tel.[phone] Fax [phone]
Serial Number_______________________
Manufactured in the USA by
Thank you for choosing AMKUS Rescue Systems. Please read this User Information Manual
thoroughly. If you have any questions, please contact your local dealer or AMKUS, Inc.
Please complete the tool registration form included with your equipment and return it to
AMKUS, Inc. You may also register your equipment on-line at www.amkus.com.
The serial number for your power unit is identified on the product label which is located on the
yellow hydraulic fluid reservoir. For quick reference, record the serial number on the cover of
this manual. Please have the serial number available if you need to contact your local dealer or
AMKUS, Inc.
Troubleshooting Guide
Any problem not resolved by these suggestions may
require you to contact your local dealer or
AMKUS, Inc. for further guidance.
Problem Solution
Engine will not start
or poor engine per-
formance
Check owner’s manual
troubleshooting guide.
Rescue tools lack
power or speed
Check hydraulic fluid level
in power unit reservoir.
Fluid leaks at fittings
or hoses
Check tightness of hose
fittings.
Replace damaged hoses.
Parts, Service & Technical Information
Parts, service and technical information can be obtained
from your local AMKUS dealer or by contacting AMKUS, Inc.
Maintenance Records
It is the responsibility of the user to keep maintenance
records for each component of the rescue system.
Maintenance shall be performed in accordance with the
recommendations as outlined in this manual.
AMKUS, Inc. is an ISO 9001
registered company.
Routine Maintenance for Couplings
Couplings should be kept free of dirt and contaminants.
They may be most easily cleaned by immersing in,
or scrubbing with, a petroleum based solvent such as
SAFE-SOL® 140. Couplings should then be lubricated
with a non-water based lubricant such as WD-40®.
The rubber dust caps which are provided with the tools
should also be cleaned periodically. Be aware that
while the couplings may be clean, the dust caps will
accumulate dirt during use. Do not cover a clean cou-
pling with a dirty dust cap.
GH2S2-XL
7/2015
Rev. 4
GH2S2-XL Power Unit Specifications
Length: 23.0 in. (584 mm)
Width (with one hose loop standard): 19.0 in. (483 mm)
Height: 20.5 in. (521 mm)
Weight (Ready-to-use): 114.0 lbs. (51.7 kg)
(Includes gas, engine oil, hydraulic fluid and couplings)
Rated Output Pressure: 10,500 psi (724 bar)
Fluid Type: AMKUS MV-1 Mineral Base Hydraulic Fluid
(For equipment stored and operated in environments below
freezing use AMKUS MV-0 Mineral Base Hydraulic Fluid)
Hydraulic Fluid Reservoir Capacity: 2.0 gals. US (7.6 l.)
Usable Hydraulic Fluid Capacity: 1.45 gals. US (5.5 l.)
Maximum Angle of Inclination: 20 degrees from horizontal
General Maintenance and Storage
1. Always store the unit in a clean dry space.
2. Never store tools or power unit hoses under
pressure.
After each use:
1. Check to see that important markings are legible.
Contact your local dealer or AMKUS, Inc. for
replacement labels.
2. Wipe hoses, fittings and couplings clean (see
routine maintenance for hoses and couplings).
3. Inspect the power unit, hoses, fittings and
couplings after each use for damage, leakage
and excessive wear.
4. If damage or excessive wear is noticed, do not
use the power unit; contact your local dealer or
AMKUS, Inc.
Tools do not operate Check to see that the
power unit is running.
Check to see that the line is
charged.
Certified Model NFPA 1936, 2015 edition
GH2S2-XL Power Unit
EN13204 Designation: MTO
4735
DECLARED DUAL-NUMBER NOISE EMISSION VALUES in accordance with EN ISO 4871
Measured A-weighted emission sound pressure level, LpA (ref. 20µPa), in decibels: 88.6
Uncertainty, KpA, in decibels: 1.5
Measured A-weighted sound power level, LWA (ref. 1 pW), in decibels: 100.5
Uncertainty, KWA, in decibels: 1.5
Values determined according to Annex B of EN 13204 using the basic standards
EN ISO 3744 and EN ISO 11201.
Note: The sum of a measured noise emission value and its associated uncertainty represents an
upper bound of the range of values which can occur in measurements.

Routine Maintenance for Gasoline
Engine
Follow the maintenance guidelines in the engine
owner’s manual.
Routine Maintenance for
Hydraulic Pump
Normally, you will have a maintenance agreement
for your system with your local dealer. However, if
you have decided to service the equipment yourself,
please review the following instructions carefully.
Change hydraulic fluid after each 20 hours of tool
operation (approximately every 2 years). If you sus-
pect your hydraulic fluid has been contaminated in
any way, contact your local dealer or AMKUS, Inc.
To change the hydraulic fluid, remove the hydraulic
fluid reservoir fill plug/vent cap. Place the unit over
a drain pan; unscrew and remove the drain plug.
Be careful not to lose it! Allow the hydraulic fluid
to drain. Clean and replace the drain plug. Fill the
hydraulic fluid reservoir with new AMKUS mineral
base hydraulic fluid. Replace the fill plug/vent cap.
Connect the male and female couplings on each of
the hydraulic hose line sets, creating a loop. Follow
the operating instructions in the engine owner’s
manual for starting the engine. Then operate the
engine at full speed. To purge air from the hydraulic
hoses, charge each hose line by moving the knob
on the corresponding selector valve to the pressure
position (in line with the selected hose line) and
allow the fluid to circulate through each hose line
for at least one minute. Move each selector valve
back to the neutral position. Check the level of the
hydraulic fluid in the sight gauge. Add more fluid if
necessary. DO NOT OVERFILL.
Uncouple the male and female couplings on each
hydraulic hose line set to open the loop that was cre-
ated earlier.
Check the pressure output of the power unit at
each hose line by connecting a pressure gauge
to the pressure line (the male coupling). Move
the selector valve to charge the line to which the
gauge is connected. The nominal pressure of the
system is 10,500 psi. The pressure reading you
receive should be between 10,000 psi and 11,000
psi. If you have a reading outside of that range,
contact your local dealer or AMKUS, Inc. DO NOT
ATTEMPT TO ADJUST THE PRESSURE RELIEF
SETTING!
Routine Maintenance for Hoses
After each use, hoses should be wiped clean with
a light cleaning solvent such as Simple Green®.
Inspect hoses for damage to the rubber outer cover.
Damage which exposes the wire braided reinforce-
ment subjects the wire to corrosion and may weaken
the hose. Damaged hoses should be replaced.
Do not use this product until you have read this manual and understand all
safety and operating instructions! Failure to comply with these warnings and
instructions may result in serious injury, disease, illness or death.
Important Safety Instructions
Safety
It is the responsibility of the user to insure that appropriate
protective clothing and equipment are used to provide pro-
tection from those hazards to which personnel are exposed
or could be exposed while working with this product.
Always wear appropriate apparel!
AMKUS equipment is manufactured with superior crafts-
manship and quality that is backed by a factory warranty.
AMKUS cannot control how other manufacturers of rescue
tools rate, test and warranty their equipment. Therefore,
we do not recommend that tools other than AMKUS be
connected to our equipment. Mixing AMKUS equipment
with another manufacturer’s equipment may cause opera-
tional problems, equipment failure or warranty claims to be
denied.
Caution: Use only AMKUS supplied
mineral base hydraulic fluid in all
AMKUS equipment.
Training
This product is designed to be used by emergency services
personnel to facilitate the extrication of victims from entrap-
ment. Its use should be limited to trained personnel only.
All personnel using this equipment are assumed to have
completed a course of instruction that is acknowledged
as being educationally sound by the local authority hav-
ing jurisdiction over such training. This document contains
basic operating and maintenance instructions only.
Getting Started
1. Connect the tool connection hoses to the hose lines
from the AMKUS hydraulic power unit. Please note
that the male and female couplings on the hose lines
leading from the power unit should be connected to
the corresponding male and female couplings on the
tool connection hoses. To connect the couplings, twist
the sleeve on the female coupling so that the notch in
the sleeve lines up with the pin. Push the sleeve back
so the pin fits into the notch. While holding the sleeve
back, push the male coupling into the female coupling.
Release the sleeve; it will spring forward into place.
Twist the sleeve ¼ turn so that the pin no longer lines
up with the notch. Pull on the couplings to check that
they are securely connected.
2. Check the engine oil, engine fuel and hydraulic fluid
levels. Add as appropriate.
Read and understand the engine owner’s
manual before operating the engine!
Failure to do so could result in personal
injury or equipment damage!
Set-Up Procedures
Normally, AMKUS equipment is prepared and serviced by
your dealer prior to delivery. If, however, you have decided
to place the equipment into service yourself, please review
the following instructions carefully.
1. Remove equipment from the packing cartons and care-
fully inspect for damage. Damage that occurs during ship-
ment should be reported immediately to the carrier.
2. The Honda®engine that powers your unit is shipped
without engine oil. Fill the engine crankcase with the proper
oil as specified in the engine owner’s manual.
3. Next, remove the hydraulic fluid reservoir fill plug/vent
cap. Fill the hydraulic fluid reservoir with approximately 2.0
gallons U.S. (7.6 liters) of AMKUS mineral base hydraulic
fluid. The fluid should reach a level that fills approximately
1/2of the sight gauge window. Replace the fill plug/vent
cap.
4. Following the instructions in the engine owner’s
manual, fill the engine fuel tank with the specified fuel.
Avoid getting dirt or water in the fuel tank. Never use
stale or contaminated gasoline or an oil/gasoline
mixture.
5. This power unit may be supplied either with hydrau-
lic hoses attached (pump hoses) or with couplings that
require extension hoses. If your unit is equipped with
couplings, attach the extension hoses to the couplings
on the power unit. In either case, connect the male
and female couplings on each of the hydraulic hose line
sets, creating a loop.
6. Follow the operating instructions in the engine own-
er’s manual for starting the engine. Then operate the
engine at full speed.
7. To purge air from the hydraulic hoses, charge each
hose line by moving the knob on the corresponding
selector valve to the pressure position (in line with
the selected hose line) and allow the fluid to circulate
through each hose line for at least one minute. Move
each selector valve back to the neutral position.
8. Check the level of the hydraulic fluid in the sight
gauge. Add more fluid if necessary. DO NOT
OVERFILL.
9. Uncouple the male and female couplings on each
hydraulic hose line set to open the loop that was cre-
ated earlier. The power unit is now ready to use.
Fill Plug/Vent Cap
Fuel Cap
Selector Valve
Knobs
Hydraulic Fluid Reservoir Sight Gauge
Drain Plug
Engine Oil Fill Cap
Operating Instructions
Following the instructions in the engine owner’s manual, start
the engine. Operate the engine at full speed for maximum
rescue tool speed and performance. Use the idle position only
when the rescue tools are not being operated.
The GH2S2-XL is a simultaneous operation power unit. This
means that two tools can be connected simultaneously and
operated either independently or simultaneously.
In order to operate a tool that is connected to the power unit,
the appropriate hose line must be charged by moving the knob
on the corresponding selector valve to the pressure position
(in line with the hose line to which the tool is connected). The
selected tool is now operational.
To stop the flow of hydraulic fluid to each hose line, move the
knob of the corresponding selector valve to the neutral position
(perpendicular to the hose line). The selector valve should be
in the neutral position when you are finished with an operation
or anytime you wish to stop the flow of hydraulic fluid.
Please note that the minimum safe bend radius of the hoses is
4 inches (101.6 mm).
When you have finished operations, follow the instructions in
the engine owner’s manual to stop the engine.