Amkus Super Simo 240SS User manual

©Copyright AMKUS Rescue Systems, Inc. 2018 LAP-012 July 16, 2018 Rev01
Instructions for safe operation, installation, and maintenance.
DANGER 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. This manual does not fully address safety. Additional
safety information is published in AMKUS Safety Manual LAA-001. Obtain manual at
amkus.com/resources/information.
Manual: 240SS
Super Simo Power Unit
AMKUS RESCUE SYSTEMS
amkus.com
4201 Montdale Drive, Valparaiso, IN 46383-4098 USA
800-592-6587 • 219-548-5000 • Fax [phone]
Electrically driven, truck mounted, 10,500 PSI (720 bar) twin pump
hydraulic power unit for simultaneous operation of two rescue tools.
©Copyright Amkus Rescue Systems, Inc. 2016 LAA-001 April 15, 2016 Rev00
DANGER 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 www.amkus.com/
This Safety Manual is intended to familiarize rescue workers and maintenance personnel with the safety messages of AMKUS
Rescue Systems, including powered rescue tools (rams, cutters, spreaders, combination tools), power units (electric or gasoline
driven), and powered rescue tool components (cable assemblies, hose assemblies, hose reels, etc.). The safety messages in this
publication supersede safety information appearing in AMKUS publications prior to April 2016.
This manual is intended for use with manuals published by manufacturers of prime movers (engines, electric motors, and pumps)
used in AMKUS power units.
This manual does NOT address operation or servicing of AMKUS Rescue Systems. Only competent rescue tool repair technicians
are quali¿ ed to repair AMKUS equipment. This manual should be available to all personnel involved with AMKUS equipment.
SAFETY MANUAL for AMKUS
RESCUE SYSTEMS
AMKUS RESCUE SYSTEMS
www.amkus.com
4201 Montdale Drive, Valparaiso, IN 46383-4098 USA
800-592-6587 • 219-548-5000 • Fax [phone]
©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
MADE IN USA • www.amkus.com
4201 Montdale Drive, Valparaiso, IN 46383-4098 USA
800-592-6587 • 219-548-5000 • Fax [phone]
SECTION 1. IDENTIFICATION
DIULF CILUARDYH 1VM SUKMAemaN tcudorP
Manufacturers of suppliers details
AMKUS RESCUE SYSTEMS, INC.
4201 Montdale Drive
Valparaiso, IN 46383-4098 USA
0005-845-912tseuqeR SDS
Customer Service
Emergency telephone number
CERTMEHC 0039-424-008noitamrofnI
llipS
Health Information
Recommend use of the chemical and restrictions on use
lio ciluardyHesU dednemmoceR
SECTION 2. HAZARDS IDENTIFICATION
GHS Classi¿ cation
Not a hazardous substance or mixture
GHS Label element
deriuqer lobmys drazah oNsmargotcip drazaH
drow langis oNdrow langiS
:SDRAZAH LACISYHPstnemetatS drazaH
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.
Other hazards which do not result in classi¿ 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 À ammable 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.
LAA-001
SAFETY MANUAL
FOR AMKUS RESCUE SYSTEMS
LAA-004
SAFETY DATA SHEET
AMKUS MV1 HYDRAULIC FLUID
This manual is intended for use with manuals published by manufacturers of the prime movers
(motor and pump) used in this power unit.

©Copyright AMKUS Rescue Systems, Inc. 2018 LAP-012 July 16, 2018 Rev01
2
DANGER
PERSONAL RESPONSIBILITY CODE
The member companies of FEMSA that provide emergency response
equipment and services want responders to know and understand the
following:
1. Firefi ghting 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 upon to use.
3. It is your responsibility to know that you have been properly trained in
Firefi ghting 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.
FEM S A
Fire and Emergency Manufacturers and Service Association
P.O. Box 147, Lynnfi eld, MA 01940 • www.FEMSA.org
TABLE OF CONTENTS
1.0 MEANING OF SAFETY SIGNAL WORDS................................................................................................................................. 3
1.1 GENERAL WARNINGS ....................................................................................................................................................... 3
2.0 SPECIFICATIONS...................................................................................................................................................................... 4
2.1 GENERAL............................................................................................................................................................................ 4
2.2 OVERALL DIMENSIONS..................................................................................................................................................... 5
2.3 PART IDENTIFICATION....................................................................................................................................................... 6
2.4 SCREEN IDENTIFICATION................................................................................................................................................. 7
2.5 WIRING IDENTIFICATION .................................................................................................................................................. 8
3.0 PROTECTIVE CLOTHING......................................................................................................................................................... 9
4.0 TRAINING .................................................................................................................................................................................. 9
5.0 INSTALLATION .......................................................................................................................................................................... 9
5.1 SITE SELECTION ............................................................................................................................................................... 9
6.0 GETTING STARTED ................................................................................................................................................................ 12
6.1 INITIAL START-UP............................................................................................................................................................. 12
7.0 OPERATING INSTRUCTIONS................................................................................................................................................. 15
7.1 GENERAL.......................................................................................................................................................................... 15
7.2 OPTIONAL WIRELESS REMOTE CONTROL OPERATING INSTRUCTIONS................................................................. 15
8.0 TROUBLESHOOTING GUIDE ................................................................................................................................................. 15
9.0 ROUTINE MAINTENANCE ...................................................................................................................................................... 16
9.1 ROUTINE MAINTENANCE FOR HYDRAULIC PUMP...................................................................................................... 16
9.2 ROUTINE MAINTENANCE FOR HOSES.......................................................................................................................... 16
9.3 ROUTINE MAINTENANCE FOR COUPLINGS................................................................................................................. 16
9.4 MAINTENANCE RECORDS.............................................................................................................................................. 16
10.0 PARTS, SERVICE AND TECHNICAL INFORMATION........................................................................................................... 16
11.0 DECOMMISIONING ............................................................................................................................................................... 16
12.0 INSPECTION, CLEANING, DECONTAMINATION, AND STORAGE..................................................................................... 16

©Copyright AMKUS Rescue Systems, Inc. 2018 LAP-012 July 16, 2018 Rev01
3
1.0 MEANING OF SAFETY SIGNAL WORDS
A safety related message is identifi ed by a safety alert symbol and a signal word to indicate the level of risk involved with a particular
hazard. Per ANSI standard Z535.6-2011, the defi nitions of the four signal words are as follows:
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.
1.1 GENERAL WARNINGS
WARNING Servicing tools creates injury risk not found during normal product use;
• Guards removed for service create pinch points. Avoid injury during service by keeping hands
and fi ngers away from movable mechanisms when cycling the tool under pressure. Replace
guards before returning tools to service.
• Pressure stored within a hydraulic cylinder against an end stop can be suddenly released
during service by disassembly of hydraulic components. Release pressure by moving
cylinder slightly from the end stop before service.
• Energizing electrical connections and wiring exposed during service creates ignition and
shock hazards.
• Always wear safety glasses when servicing, or testing Amkus rescue equipment.
Obtain Level 3 service technician training before servicing Amkus rescue equipment.
WARNING Do not touch electrical connections before you fi rst ensure that power has been disconnected.
Electrical shock can cause serious or fatal injury. Only qualifi ed personnel should attempt the
installation, operation and maintenance of this equipment.
WARNING Be sure the system is properly grounded before applying power. Do not apply AC power before
you ensure that all grounding instructions have been followed. Electrical shock can cause serious
or fatal injury.
WARNING Use proper care and procedures that are safe during handling, lifting, installing, operating and
maintaining operations. Improper methods may cause muscle strain or other harm.
WARNING When using electric motorized equipment, basic safety precautions should always be followed to
reduce the risk of fi re, electric shock, injury, or death.
WARNING When using electric motorized equipment, basic safety precautions should always be followed
to reduce the risk of fi re, electric shock, injury, or death. The following are some basic safety
precautions:
Electric motor and controls are ignition sources. Flammable vapors heavier than air can accumulate
in low spots. Avoid selecting these locations when setting up the equipment. Use detectors to verify safe
site selection.
Electric motor and wiring are not waterproof. Don’t submerge or douse electric motors or their
controls. Refer to manuals from motor manufacturer for specifi c details.
Installation by qualifi ed person – Power componentry properly, sized and installed, to run the equipment
are the responsibility of the purchaser. Qualifi ed electricians should install the equipment per applicable
regulations (NEC, NFPA, OSHA, etc.) before the equipment can be used.
Circuit breakers matched to the motor capacity are required. Don’t operate electric motors without
circuit breaker protection.
Type of power cord - cord type should be rated for outdoor use, such as SW, SOW, STW, STOW, SJW,
SJOW, SJTW, or SJTOW. (W service rating = outdoor and wet location)
Use of power cords - 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.
Don’t abuse the cord – Make sure 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 power –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

©Copyright AMKUS Rescue Systems, Inc. 2018 LAP-012 July 16, 2018 Rev01
4
2.0 SPECIFICATIONS
AMKUS 240SS Specifi cations
Length 33 in 838 mm
Width 10.25 in 260 mm
Height 21 in 533 mm
Weight 217 lbs (wet) 98.4 kg
177 lbs (dry) 80.3 kg
Motor Input Voltage 208/240 | VAC Single Phase
Current Draw Amps (maximum) 70 Amps at 208VAC (Input)
Number of Pumps 2
Rated Flow Of The Pump per Port, First Stage 1 gpm 3.9 l/min
Rated Output Pressure, First Stage 6450 psi 445 bar
Rated Flow Of The Pump per Port, Second Stage 0.68 gpm 2.6 l/min
Rated Output Pressure, Second Stage 10,500 psi 724 bar
Fluid Type: AMKUS MV1 Mineral Base Hydraulic Fluid
Safety 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 gals. US 26.5 liters
Hydraulic Filter AMKUS Part # KSS010
2.1 GENERAL
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 fi rst Variable Frequency Drives to regulate electrical requirements. This infi nitely 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 only needed 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.

©Copyright AMKUS Rescue Systems, Inc. 2018 LAP-012 July 16, 2018 Rev01
5
2.2 OVERALL DIMENSIONS

©Copyright AMKUS Rescue Systems, Inc. 2018 LAP-012 July 16, 2018 Rev01
6
2.3 PART IDENTIFICATION
Power Unit
Wireless Remote Control
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, Inc. 2018 LAP-012 July 16, 2018 Rev01
7
2.4 SCREEN IDENTIFICATION
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 6.0 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.

©Copyright AMKUS Rescue Systems, Inc. 2018 LAP-012 July 16, 2018 Rev01
8
2.5 WIRING IDENTIFICATION
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

©Copyright AMKUS Rescue Systems, Inc. 2018 LAP-012 July 16, 2018 Rev01
9
3.0 PROTECTIVE CLOTHING
It is the responsibility of the user to ensure that appropriate protective clothing are worn and equipment are used to provide
protection from those hazards to which personnel are exposed or could be exposed while working with this product.
4.0 TRAINING
This product is designed to be used by emergency services personnel to facilitate the extrication of victims from entrapment. 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 having jurisdiction over such training. This
document contains basic operating and maintenance instructions only.
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 carefully inspect for damage. Damage that occurs during shipment should be
reported immediately to the carrier.
2. 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
Optional
Wireless Receiver
VFD Panel
Control Panel
Heat Exchanger
Power Unit
5.0 INSTALLATION
5.1 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.
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.
NOTICE Only use AMKUS mineral-base hydraulic fluid in AMKUS equipment. Using another manufacturer’s
hydraulic fluid in AMKUS equipment may cause operational problems, equipment failure, or
denial of warranty claims.

©Copyright AMKUS Rescue Systems, Inc. 2018 LAP-012 July 16, 2018 Rev01
10
Remove Bolt
Remove Bolt
Sight Gauge
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.
Vent Cap Reservoir Fill Cap
4. Install and tighten the 4 mounting bolts. 5. Remove the black vent cap with a 12mm Hex Key. Unscrew
the red reservoir fi ll cap and fi ll the hydraulic fl uid reservoir
until the sight gauge is completely full. Replace the black
vent cap and the red reservoir fi ll cap.