Amkus Super Simo 240SS Programming manual

©Copyright AMKUS Rescue Systems 2020-2021 1 LAP-012 October 7, 2021 Rev02
AMKUS RESCUE SYSTEMS
AMKUS.com
4201 Montdale Drive, Valparaiso, IN 46383-4098 USA
800-592-6587 · 219-548-5000
G-Force
INSTRUCTIONS FOR INSTALLATION, OPERATION, AND MAINTENANCE
240SS
Super Simo Power Unit
WARNING
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. Obtain safety information at amkus.com
This instruction manual is intended to familiarize operators and maintenance personnel with the
operation, basic maintenance, and safety procedures associated with this product. This manual
should be kept available to all operating and maintenance personnel.
This manual does NOT address servicing of AMKUS Rescue Systems. Only competent rescue tool
repair technicians are qualified to repair AMKUS equipment.
This manual is intended for use with manuals published by manufacturers of the prime movers
(motor and pump) used in this power unit.

©Copyright Task Force Tips LLC 2020-2021 2 LAP-012 October 7, 2021 Rev02
The member companies of FEMSA that provide emergency
response equipment and services want responders to know and
understand the following:
1. Firefighting 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 on
to use.
3. IT IS YOUR RESPONSIBILITY to know that you have been
properly trained in Firefighting 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.
Fire and Emergency Manufacturers and Service Association, Inc.
PO Box 147, Lynnfield, MA 01940 • www.FEMSA.org
© 2020 FEMSA. All Rights Reserved.
PERSONAL RESPONSIBILITY CODE
DANGER

©Copyright AMKUS Rescue Systems 2020-2021 3 LAP-012 October 7, 2021 Rev02
This Safety Manual is not intended as a substitute for proper training in the use of rescue systems as
taught from credible sources such as the National Fire Protection Association (NFPA), The
International Fire Service Training Association (IFSTA), or sources approved by the Authority Having
Jurisdiction (AHJ).
Examples of recent publications:
SUPPORTING MATERIALS
The following document contains supporting safety and operating information
pertaining to the equipment described in this manual.
Safety Data Sheet (SDS)
AMKUS MV1 HYDRAULIC FLUID
©Copyright Amkus Rescue Systems, Inc. 2014-2016 LAA-004 December 8, 2016 Rev04
SAFETY DATA SHEET
According to OSHA Hazard Communication
Standard, 29 CFR 1910.1200
AMKUS RESCUE SYSTEMS
www.amkus.com
4201 Montdale Drive, Valparaiso, IN 46383-4098 USA
800-592-6587 • 219-548-5000 • Fax [phone]
SECTION 1. IDENTIFICATION
DIULFCILUARDYH1VMSUKMAemaNtcudorP
Manufacturers of suppliers details
AMKUS RESCUE SYSTEMS, INC.
4201 Montdale Drive
Valparaiso, IN 46383-4098 USA
0005-845-912tseuqeRSDS
Customer Service
Emergency telephone number
CERTMEHC0039-424-008noitamrofnIl
lipS
Health Information
Recommend use of the chemical and restrictions on use
liociluardyHesUdednemmoceR
SECTION 2. HAZARDS IDENTIFICATION
*+6&ODVVL¿cation
Not a hazardous substance or mixture
GHS Label element
deriuqerlobmysdrazahoNsmargotcipdrazaH
drowlangisoNdrowlangiS
:SDRAZAHLACISYHPstnemetatSdrazaH
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.
2WKHUKD]DUGVZKLFKGRQRWUHVXOWLQFODVVL¿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 Àammable 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
1910.1200.

©Copyright AMKUS Rescue Systems 2020-2021 4 LAP-012 October 7, 2021 Rev02
TABLE OF CONTENTS
1.0 MEANING OF SAFETY SIGNAL WORDS
2.0 SAFETY
3.0 GENERAL DESCRIPTION
4.0 SPECIFICATIONS
4.1 PART IDENTIFICATION
4.2 SCREEN IDENTIFICATION
4.3 WIRING IDENTIFICATION
5.0 OVERALL DIMENSIONS
6.0 SAFETY CONSIDERATIONS
6.1 PROTECTIVE CLOTHING
6.2 TRAINING
7.0 INSTALLATION
7.1 SITE SELECTION
7.2 INSTALLATION
7.2.2 MOUNTING THE UNIT
7.2.3 FILLING THE UNIT
7.2.4 CONNECTING THE PRESSURE AND RETURN HOSES
7.2.5 HEAT EXCHANGER
7.2.6 CONTROL PANEL
7.2.7 VFD PANEL
7.2.8 WIRELESS REMOTE CONTROLS (OPTIONAL)
8.0 INITIAL START-UP
9.0 OPERATION
9.1 GENERAL
9.2 OPTIONAL WIRELESS REMOTE CONTROL
9.2.1 FEATURES
9.2.2 OPERATING INSTRUCTIONS
10.0 TROUBLESHOOTING GUIDE
11.0 ROUTINE MAINTENANCE
11.1 HYDRAULIC PUMP
11.1.1 OIL CHANGE PROCEDURE
11.2 HYDRAULIC HOSES
11.3 COUPLINGS
11.4 2ND GENERATION 240SS BATTERY REPLACEMENT
12.0 PARTS, SERVICE, AND TECHNICAL INFORMATION
13.0 DECOMMISSIONING
14.0 INSPECTION, CLEANING, DECONTAMINATION, AND STORAGE

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1.0 MEANING OF SAFETY SIGNAL WORDS
A safety related message is identified by a safety alert symbol and a signal word to indicate the level of risk involved with a particular
hazard. Per ANSI Z535.6, the definitions of the four signal words are as follows:
2.0 SAFETY
DANGER
DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury.
WARNING
WARNING indicates a hazardous situation which, if not avoided, could result in death or serious
injury.
CAUTION CAUTION indicates a potentially hazardous situation which, if not avoided, could result in minor
or moderate injury.
NOTICE
NOTICE is used to address practices not related to physical injury.
WARNING
When using electric motorized equipment, basic safety precautions should always be followed
to reduce the risk of fire, electric shock, injury, or death.
• Circuit breakers matched to the motor capacity are required. Don’t operate electric motors
without circuit breaker protection.
• Always use a cord heavy enough to carry the current the tool will draw. Use of an undersized
cord will cause a drop in line voltage resulting in loss of power and overheating.
• Power cord type must be rated for outdoor use, such as SW, SOW, STW, STOW, SJW, SJOW,
SJTW, or SJTOW. (W service rating = outdoor and wet location).
• Ensure the power cord is in good condition before use. Never lift or pull the equipment by the
cord or yank it to disconnect from receptacle. Keep cord from heat, oil, crushing, and sharp
edges. Inspect cords for damage after each use. Replace damaged cords before placing
equipment in service.
• Disconnect the equipment from the power supply when not in use, before cleaning, inspecting,
or servicing electric motors and controls.
• Keep covers and guards in place and in working order.
WARNING
Using rescue tools can cause ignition or explosion resulting in injury or death. Ignition or explosion
can result from situations such as:
• Flammable hazards are created when fuel lines, refrigerant lines (atomized oil), or pressurized
hydraulic fluid lines are breached. Ignition sources can suddenly ignite these fuels.
• Flammable vapors can be released by careless refueling or operation of gasoline driven
engines. Refer to engine manufacturer’s manuals for specific details.
• Extrication tools can create sparks as metals are cut and deformed. Avoid unnecessary risk
when flammable vapors are present.
• Power units with electric motors or internal combustion engines are ignition sources.
Flammable vapors heavier than air can accumulate in low spots. Avoid selecting these locations
when setting up the power units. Use detectors to verify safe site selection.
WARNING
Hydraulic fluid (mineral oil) escaping under pressure can puncture the skin, infiltrate eyes, or lungs
resulting in serious injury. Seek medical attention immediately. Avoid the urge to contain leaks with
hands. Injection injuries require immediate medical attention. Safety Data Sheet (SDS) for AMKUS
MV1 and AMKUS MV0 Hydraulic Fluid is available at AMKUS.com and CHEMTREC.com
Hydraulic leaks can occur from situations such as:
• Leaks at hose crimps and connections can develop from constant use, over-pressurization,
side-loading, or mis-crimping.
• Hose damage from being driven over, stepped on, twisted, kinked, crushed, excessive vibration,
abuse, or neglect.
• Leaks and breaks in hydraulic components can occur from improper maintenance or exceeding
service life expectations. Establish sound practices.
• Connecting hydraulic tools in series can pressurize both sides of double acting cylinders. Each
tool must be separately connected to a power unit.
• Release stored pressure before servicing tools by moving off end stops. Refer to power unit
manuals for proper operation.

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WARNING
Electric shock can result in injury or death. Rescue tools are made from metal which is a conductor
of electricity. Electric current can flow from the hazard through the rescue tool to shock nearby
people. Maintain awareness of potential hazards. Examples include:
• Never operate electric power units with damaged power cords.
• Do not drive over or crush power cords.
• Use care to avoid cutting power cords on sharp objects.
• Do not strain cords during storage. Hidden cord damage can remain undetected until wet
conditions create an electrocution hazard.
• Power sources and electronics are not waterproof. Do not submerge or douse the power units
or controls. Refer to manuals from battery, charger, and motor manufacturers for specific
details.
• Cutting into concealed spaces can be hazardous. Power cables and battery packs may be
hidden from view in structures and electric vehicles.
• Never operate near damaged electric power lines before power is verified as OFF.
WARNING
Misuse of AMKUS Rescue Systems can result in a wide variety of hazards and consequences.
Remain aware of and avoid misuse situations. Examples of misuse include:
• Using low pressure (5000 psi) tools on high pressure (10,500 psi) hydraulic power units creates
high risk of hydraulic cylinder rupture. Ensure compatibility before use.
• Failure to inspect and properly maintain rescue equipment. Inspect all rescue equipment after
each use. Any equipment found damaged or inoperable should be removed from service.
• Storage of rescue equipment in adverse conditions. Always store rescue equipment in clean,
dry, and secure conditions.
• Operation of rescue equipment with missing or illegible safety markings
• Modification of tools and power units inconsistent with manufacturer’s specifications
• Repairs attempted by unqualified technicians.
• Use of rescue tools for non-rescue purposes such as construction, production use, demolition,
or as a jack for vehicle service.
• Pressure relief valve set over +5% above the Rated Output Pressure 10,500 psi (724 bar)
• Using tools which have been heat damaged. Heating beyond 212°F (100°C) will compromise the
strength.
CAUTION Lifting or moving rescue tools and power units can result in falling or spine injury. Rescue tools and
power units are heavy. Risk of injury increases in unfavorable conditions such as poor lighting,
inclines, loose, wet, or icy surfaces. Follow accepted safe lifting practices.
NOTICE
Use of hydraulic fluids other than AMKUS MV1 or MV0 (see Specifications for fluid for specific tool
lines) can result in equipment damage and loss of function. Some examples include:
• Phosphate ester hydraulic fluids and blends are incompatible with Buna-N seal and hose
materials used in AMKUS Rescue Systems
• Mixing glycol with mineral oils can result in gelling and plugging of pump inlet screens
• Using fluids with wrong viscosity or wear properties. Always use AMKUS MV1 or MV0 as
specified for your tools.

©Copyright AMKUS Rescue Systems 2020-2021 7 LAP-012 October 7, 2021 Rev02
3.0 GENERAL DESCRIPTION
For two-tool simultaneous operations, the 240SS Super Simo is a true “on board” 2 circuit hydraulic rescue tool power unit. This high
performance unit provides the power and tool speed needed to be used with longer length hoses such as 100, 150, and even 200 foot
length hoses. The performance of the 240SS virtually eliminates long tool reaction times created by the expansion of long lengths of
hydraulic hoses.
AMKUS uses another industry first, Variable Frequency Drives to regulate electrical requirements. This infinitely customizable control
system is set up to require only 5 amps of current at start up. Unlike other electric power units, the 240SS increases electrical power as
the pressure increases through the use of a Programmable Logic Controller (PLC). Maximum electrical requirement of less than 15kW is
needed only when both circuits reach 10,500 psi simultaneously.
The Programmable Logic Control Module puts the controls in one location providing master on/off switch, circuit controls, low oil, high
temperature indicator lights. The Human Machine Interface (HMI) display provides system operational information as well as input and
output indicators to quickly troubleshoot the system. An Ethernet interface provides a programming and troubleshooting connection for
factory assistance should the need occur to interface to the power unit.
4.0 SPECIFICATIONS
Table 4.0
Length 33 in 838 mm
Width 10.25 in 260 mm
Height 21 in 533 mm
Weight 217 lbs (wet) 98.4 kg (wet)
177 lbs (dry) 80.3 kg (dry)
Motor Input Voltage 208/240 VAC Single Phase
Current Draw Amps (maximum) 70 Amps @ 208VAC (input)
Number of Pumps 2
Rated Flow of Pump Per Port (Stage 1) 1 gpm 3.9 L/min
Rated Output Pressure (Stage 1) 6450 psi 445 bar
Rated Flow of Pump Per Port (Stage 2) 0.68 gpm 2.6 L/min
Rated Output Pressure (Stage 2) 10,500 psi 724 bar
Fluid Type AMKUS MV1 Mineral Base Hydraulic FluidSafety Data Sheet
(SDS) for AMKUS MV1 Hydraulic Fluid is available at
AMKUS.com and CHEMTREC.com
(For equipment stored and operated in environments below 32
deg. F (0 deg C) contact Amkus Rescue Systems for
recommendation.
Hydraulic Fluid Reservoir Capacity 7 gal (US) 26.5 L
Hydraulic Filter Replacement AMKUS Part # KSS010

©Copyright AMKUS Rescue Systems 2020-2021 8 LAP-012 October 7, 2021 Rev02
4.1 PART IDENTIFICATION
Figure 4.1
Power Unit
Wireless Remote Controls
Receiver
Reel ReturnReel Pressure
Reel Return Reel Pressure
Sight Gauge
Drain Plug
Vent Cap Reservoir Fill Cap
Oil Filter
Heat Exchanger Inlet
Power Plug
Heat Exchanger Outlet

©Copyright AMKUS Rescue Systems 2020-2021 9 LAP-012 October 7, 2021 Rev02
4.2 SCREEN IDENTIFICATION
Figure 4.2
Main Screen
The main touch screen is used to operate the unit.
Using the touchscreen or the button switches below,
the user may:
• Start the system
• Operate either pump motor
• Open or close the pump valves
See Section 9.0 on page 17 for detailed operating
instructions.
I/O Screen
The I/O screen shows the states of each input and
output in real time. This screen is most helpful for
troubleshooting a system.
Runtime Screen
The runtime screen shows total hours of use on each
motor.

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4.3 WIRING IDENTIFICATION
Figure 4.3
Connection Callouts
1 - Radio (TR)
2 - HMI Ethernet (C5)
3 - HMI POWER/CONTROL (HMI)
4 - OIL/TEMP SENSORS (LVTEMP)
5 - 12VDC IN (12 IN)
6 - 12VDC OUT (12 OUT)
7 - MOTOR 1 (M1)
8 - MOTOR 2 (M2)
9 - 208/240VAC IN (POWER)
1
2
3
4
5
6
7
8
9

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5.0 OVERALL DIMENSIONS
Figure 5.0

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6.0 SAFETY CONSIDERATIONS
6.1 PROTECTIVE CLOTHING
6.2 TRAINING
7.0 INSTALLATION
7.1 SITE SELECTION
When selecting a location to mount the 240SS system it is important to install it inside a compartment away from the elements. For more
information contact your local AMKUS dealer.
AMKUS equipment is manufactured with superior craftsmanship and quality that is backed by the standard warranty which is published
on the AMKUS website.
7.2 INSTALLATION
Normally, AMKUS equipment is prepared and serviced a dealer prior to delivery. If, however, you decide to place the equipment into
service yourself, please review the following instructions carefully.
Remove equipment from the packing cartons and carefully inspect for damage. Damage that occurs during shipment should be reported
immediately to the carrier.
There are 4 major components included in the 240SS Super Simo Power Unit and an optional remote control system.
A. VFD (Variable Frequency Drive) Panel
B. Control Panel
C. Heat Exchanger
D. Power Unit
Figure 7.2A
WARNING
Tool operators bear responsibility for ensuring use of appropriate protective clothing and
equipment. The chosen protective clothing and equipment must provide protection from potential
hazards users may encounter while operating AMKUS rescue tools. Requirements for protective
clothing and equipment are determined by the Authority Having Jurisdiction (AHJ).
WARNING
AMKUS tools facilitate the extrication of entrapment victims. Only trained emergency services
personnel should attempt victim extrication. All personnel using Amkus rescue tools are assumed
to have completed a training course covering safe extrication of entrapment victims. The training
must be acknowledged as educationally sound by the local Authority Having Jurisdiction (AHJ)
over such training.
NOTICE
Only use AMKUS tools with AMKUS equipment. Mixing AMKUS tools with another manufacturer’s
equipment may cause operational problems, equipment failure, or denial of warranty claims.
Optional
Wireless Receiver
VFD Panel
Control Panel
Heat Exchanger
Power Unit

©Copyright AMKUS Rescue Systems 2020-2021 13 LAP-012 October 7, 2021 Rev02
7.2.2 MOUNTING THE UNIT
1. Remove the black cover from the power unit by removing
the bolts on either end of the unit.
2. Determine the location for the power unit. To allow for
easier service, make sure the black cover can be
removed and the sight gauge is visible.
3. The power unit has been shipped with the kinetic
bushings and mounting brackets installed.
4. Install and tighten the 4 mounting bolts.
7.2.3 FILLING THE UNIT
1. Remove the black vent cap with a 12mm Hex Key.
2. Unscrew the red reservoir fill cap and fill the hydraulic
fluid reservoir until the sight gauge is completely full.
3. Replace the black vent cap and the red reservoir fill cap.
7.2.4 CONNECTING THE PRESSURE AND RETURN HOSES
Connect the pressure and return hoses as follows:
If AMKUS standard couplers are being used, be sure the pressure line has a male coupler at the end of the reel. The return line will
have a female coupler at the end of the reel.
If AMKUS Mono Couplers are being used, be sure the pressure line is connected to the pressure port (P) of the female Mono Coupler
and the return line is connected to the tank port (T) of the female Mono Coupler.
Figure 7.2.4
NOTICE
Use of hydraulic fluids other than AMKUS MV1 or MV0 (see Specifications for fluid for specific tool
lines) can result in equipment damage and loss of function. Some examples include:
• Phosphate ester hydraulic fluids and blends are incompatible with Buna-N seal and hose
materials used in AMKUS Rescue Systems
• Mixing glycol with mineral oils can result in gelling and plugging of pump inlet screens
• Using fluids with wrong viscosity or wear properties. Always use AMKUS MV1 or MV0 as
specified for your tools.
Remove Bolt
Remove Bolt
Sight Gauge
Mounting Bracket
Figure 7.2.2
Vent Cap Reservoir Fill Cap
Figure 7.2.3
Return Port
Pressure Port
Return Port
Pressure Port
Pump 2
Pump 1

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7.2.5 HEAT EXCHANGER
The heat exchanger supply utilizes a check valve. The flow direction can be
determined by the arrow stamped on the check valve.
1. Connect the hose to an installer provided #8 SAE 100 R2 hose.
2. Connect the other end to the inlet side of the heat exchanger. The inlet
side is the port closest to the power plug.
3. Mount the heat exchanger in a location that allows the intake of fresh air.
7.2.6 CONTROL PANEL
The 240SS Control Panel houses a display and 5 buttons used to operate the
unit. The green button is used to start/stop the entire system. Each reel circuit
has a motor button and valve control button. Refer to the operating section of
this manual for further explanation of button functions.
Mount the 240SS Control Panel in a compartment accessible to operators.
7.2.7 VFD PANEL
Mount the 240SS VFD Panel in a compartment. Ensure the VFD can be
accessed and the cover can be easily removed by maintenance technicians.
7.2.8 WIRELESS REMOTE CONTROLS (OPTIONAL)
1. Mount the reciever in a compartment that is out of the elements.
2. Plug the reciever cable into the matching plug from the VFD panel.
(see Figure 4.3)
Figure 7.2.8
NOTICE
To prevent recirculation of the heated air, the air intake side of the heat exchanger should have a
minimum of 3 inches from any obstruction. The exhaust (fan) side of the heat exchanger should
exhaust into free air (no back pressure).
Heat Exchanger Inlet
Power Plug
Heat Exchanger Outlet
Figure 7.2.5
Figure 7.2.6
Wireless Remote Controls
Receiver

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8.0 INITIAL START-UP
1. Connect the hose reel hoses together
before starting the system.
2. Using a hex-key wrench, remove
4 corner screws to remove the VFD cover.
3. The VFD is shipped with the circuit breakers
in the OFF position.
Place the VFD circuit breakers in the ON position
by flipping each switch up.
4. The upper section of the Control Panel houses the
touch screen display and the touch display.
The green button is used to enable/disable the
entire unit. Press the physical or digital green
button to start the system. The screen should
indicate the system has started.
ON
5. Press the physical or digital blue M1 button to start
Motor No. 1.
The screen should indicate Motor No.1 is running.
ON
6. Press the physical or digital red M2 button to start
Motor No. 2.
The screen should indicate Motor No. 2 is running.

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16. Check the sight gauge and add fluid until the sight gauge is completely full again.
17. Put the black cover on the power unit back in place and tighten the bolts on both ends to 25 in-lb (2.8 Nm).
ON
7. Press the physical or digital blue V1 button to activate
Valve No. 1.
The screen should indicate Valve No. 1 is open.
ON
8. Press the physical or digital blue V2 button to activate
Valve No. 2.
The screen should indicate Valve No. 2 is open.
FULL
LOW
9. With both motors running and valves open, allow the
power unit to flow through the reels for several minutes
while monitoring the fluid sight gauge level.
If the fluid level continues to drop after several minutes
check for fluid leaks.
10. When finished, shut the power unit off.
11. Replenish hydraulic fluid until the
sight gauge is completely full.
Pressure
Line
Fluid Flowing
From The
Pressure Line
Return
Line
12. To verify the pressure and return hoses, remove both
couplings from the end of the hoses and place the
hose ends in a bucket.
13. Charge the appropriate valve. Fluid will flow from the
pressure line.
14. Turn off the valve once the pressure line is identified.
If AMKUS standard couplers are being used,
place the male coupler on the pressure line
and the female coupler on the return line.
Repeat for the other reel.
If AMKUS Mono Couplers are being used,
be sure the pressure line is connected to the
pressure port (P) of the female Mono Coupler
and the return line is connected to the tank port (T)
of the female Mono Coupler.
15. Install Couplings

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9.0 OPERATION
9.1 GENERAL
The 240SS is a simultaneous operation power unit. Two tools can be connected to a single power unit and operated either
independently or simultaneously. To operate the 240SS. Ensure there is power to the unit. Begin operation by pressing the system start
button. Then, press the motor button to begin building pressure. Once pressure builds, press the corresponding valve button to charge
the rescue tool for operation.
After completing operations, pressing the green start button turns the entire system off.
9.2 OPTIONAL WIRELESS REMOTE CONTROL
9.2.1 FEATURES
1. Emergency Stop (Red) - Closes both valves and powers down both motors. Press to active Emergency Stop. Rotate thumb
wheel clockwise to resume normal operation.
2. Start Buttons (Green) - Synchronizes the remote to the receiver and activates the system.
3. M1 Motor Switch (Blue left side) - Depress to activate motor for M1 circuit. Depress again to turn motor off.
4. M2 Motor Switch (Red left side) - Press to activate motor for M2 circuit. Press again to turn motor off.
5. V1 Valve 1 Switch (Blue right side) - Press to activate control valve for V1 circuit. Press again to turn control valve off.
6. V2 Valve 2 Switch (Blue right side) - Press to activate control valve for V2 circuit. Press again to turn control valve off.
9.2.2 OPERATING INSTRUCTIONS
1. Rotate the Emergency Stop (1) (Red) thumb wheel clockwise and
release to ensure the remote is in the operation mode.
2. Press and hold both start buttons at the bottom of the remote. While
holding the start buttons the remote is linking up to the receiver
mounted in the apparatus. Hold the start buttons pressed firmly to
ensure a good signal.
3. Push the M1 and/or M2 motor buttons (The motors are programmed
to reach full operating speed in 5 seconds).
4. Push the V1 and/or V2 valve button(s) to activate the appropriate reel
circuits.
5. To shut off a circuit, push the appropriate valve (5) and/or (6) button.
To quickly shut down the entire system including the power, motors and reel
circuits, push the Emergency Stop.
To re-activate the system, repeat these instructions starting at number 1.
10.0 TROUBLESHOOTING GUIDE
Table 10.0
PROBLEM POSSIBLE REMEDY
Tool lacks 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.
Tools do not operate Check to that the power unit is running.
Check that the line is charged.
Check hydraulic fluid level in power unit reservoir.
System turns on but screen is dark Change the PLC battery (see section 11.4)
NOTICE
Immediately remove malfunctioning or damaged tools from service. Consult your dealer or AMKUS
Rescue Systems.
ALL SERVICE MUST BE PERFORMED BY QUALIFIED SERVICE TECNICIANS IN OBSERVANCE OF
SAFETY REGULATIONS.
1
5
6
2
3
4
Figure 9.2.2

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11.0 ROUTINE MAINTENANCE
Obtain appropriate level service technician training before servicing AMKUS Rescue Systems equipment. For more information contact
your local AMKUS Rescue Systems dealer about service levels and training courses.
11.1 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.
Check the hydraulic fluid level sight gage after every use. Fluid should be “clear-gold”. Cloudy, milky, brownish, or smelly fluid indicates
contamination. Contact your local dealer or AMKUS Rescue Systems. A noticeable drop in fluid level indicates fluid loss. Investigate and
correct the cause of loss, add MV1 hydraulic fluid as needed. Change oil filter after every 100 hours of pump operation. Change
hydraulic fluid after every 300 hours of pump operation.
The rated hydraulic pressure at maximum output is 10,500 psi +- 500 psi (724 bar+-34 bar). Verify performance by periodic testing using
a pressure gauge. If performance falls outside of this range, contact your local dealer or AMKUS Rescue Systems.
11.1.1 OIL CHANGE PROCEDURE
1. Remove the fill plug/vent cap.
2. Place a drain pan under the drain plug.
3. Unscrew the drain plug being careful not to lose it.
4. Allow the hydraulic fluid to drain completely.
5. Clean and reinstall the drain plug.
6. Replace the filter.
7. Fill the hydraulic fluid reservoir with new AMKUS MV1 fluid.
8. Reinstall the fill plug/vent cap.
9. Cycle rescue tools several times to purge air from the hydraulic hoses.
11.2 HYDRAULIC HOSES
After each use, hoses should be wiped clean with a light cleaner such as Simple Green®. Inspect hoses for damage to the rubber outer
cover. Damage which exposes the wire braided reinforcement subjects the wire to corrosion and may weaken the hose.
11.3 COUPLINGS
Use care when making hydraulic connections by avoiding dirt, sand, and water puddles at the scene. Even with care, residual oils on the
moving parts will gradually accumulate dirt and grit making connections difficult. Couplings and dust caps can be periodically cleaned
using an automotive type aerosol solvent de-greaser. Avoid water-based cleaning products. Apply a light spray lube (automotive, lock, or
gun type) to keep the collars moving easily. Avoid covering a clean coupling with a dirty dust cap.
WARNING
Service technicians bear responsibility for ensuring use of appropriate protective clothing and
equipment. The chosen protective clothing and equipment must provide protection from potential
hazards users may encounter while servicing or operating AMKUS rescue tools. Requirements for
protective clothing and equipment are determined by the Authority Having Jurisdiction (AHJ).
NOTICE
DO NOT ATTEMPT TO ADJUST THE INTERNAL PRESSURE RELIEF SETTING! Pressure relief valves
are NOT user serviceable. User adjustment is a misuse of this equipment.

©Copyright AMKUS Rescue Systems 2020-2021 19 LAP-012 October 7, 2021 Rev02
11.4 2ND GENERATION 240SS BATTERY REPLACEMENT
240SS units manufactured after June, 2018 (models with a touch screen) contain a coin cell battery. Need for a battery change is rare
and indicated by the touch screen remaining dark after the unit is powered on and running.
Figure 11.4
1. Flip the PLC Run/Stop switch to the Stop position.
2. Power down the PLC completely.
3. Use an insulated screw driver to pull
out the battery holder from the PLC.
4. Remove and replace battery with a quality BR2032
coin battery or equivalent.
Be sure the battery polarity is correct
(positive is indicated).
5. Slide the battery holder into
the PLC.
6. Power the PLC back on.
7. Flip the Run/Stop switch to
the Run position.

©Copyright AMKUS Rescue Systems 2020-2021 20 LAP-012 October 7, 2021 Rev02
AMKUS RESCUE SYSTEMS
AMKUS.com
4201 Montdale Drive, Valparaiso, IN 46383-4098 USA
800-592-6587 · 219-548-5000
12.0 PARTS, SERVICE, AND TECHNICAL INFORMATION
Parts, service, and technical information may be obtained from your local AMKUS dealer, or at amkus.com
13.0 DECOMMISSIONING
When decommissioning any AMKUS Rescue Systems Tool or power supply, follow local regulations. For proper disposal information,
contact your local AMKUS Rescue Systems dealer.
14.0 INSPECTION, CLEANING, DECONTAMINATION, AND STORAGE
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 tool, hoses, fittings and couplings clean (see routine maintenance for hoses and couplings).
3. If the power unit becomes contaminated, determine the nature of the contamination. Follow the decontamination guidelines
provided by the Authority Having Jurisdiction. Technical advice may be requested from AMKUS Rescue Systems.
4. Inspect the power unit, hoses, fittings and couplings 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. Check the hydraulic fluid levels after each use. Replenish as necessary with AMKUS MV1 mineral based hydraulic fluid.
WARNING
Any equipment failing any part of this checklist is unsafe for use and must have the problem
corrected before use or being placed back in service. Operating equipment that has failed the
checklist is a misuse of this equipment. Contact your local AMKUS dealer or AMKUS Rescue
Systems.