Weber Rescue Systems E-FORCE2 User manual

E
Operating manual
Battery-powered rescue device

tested in accordance with











    
1.1 Abouttheoperangmanual  4
1.2 Explanaonofsymbols  5
1.3 Limitaonsofliability  6
1.4 Copyright  6
1.5 Warrantycondions  7
1.6 Customerservice  7
    
2.1 Intended use 8
2.2 Responsibilityofthecustomer  10
2.3 Operangpersonnel  11
2.4 Personalprotecveequipment  12
2.5 Specichazards  13
2.6 Howtorespondintheeventofdangeroraccidents 15
2.7 Signage  16
    
3.1 Combitools  17
3.2 Cuers  18
3.3 Spreader  19
3.4 Rescueram  20
3.5 Operangcondions  20
3.6 Typeplate  20
   
4.1 OverviewofE-FORCE2devices  21
4.2 Hydraulicsupply  25
4.3 Electricalsupply,usingacombideviceasanexample 26
4.4 OperangE-FORCE2devices  27
4.5 Accessories  28
4.6 Replacingbladeinserts(PLUS)  31
4.7 Changingthespreaderps(spreaders,combitools) 33


    
5.1 Safetyinformaon  34
5.2 Cung(cuers,combidevices)  34
5.3 Liing/pressing(rescuecylinder)  35
5.4 Spreading(spreaders,combidevices)  36
5.5 Pulling(spreaders,combidevices)  37
5.6 Crushing(spreaders,combidevices)  38
5.7 Liing(spreaders,combidevices)  39
5.8 Peeling(spreaders,combidevices)  39
    
6.1 Chargertechnicaldata  40
6.2 Specialsafetyinstrucons  40
6.3 Intendeduse  42
6.4 Powerlineconnecon  42
6.5 Li-ionbaery  42
6.6 Chargingprocess  43
6.7 Maintenance  44
6.8 Chargingcycles  44
    
7.1 Safetyinformaon  45
7.2 Transportinspecon  45
7.3 Symbolsonthepackaging  46
7.4 Disposalofpackaging  46
7.5 Storage  46
    
8.1 Safetyinformaon  47
8.2 Checking  47
8.3 Shut-down(endofwork)  48
    
9.1 Safetyinformaon  49
9.2 Careandmaintenance  49
9.3 Maintenanceschedule  50
   
   
   



1.1Abouttheoperangmanual
ThisoperangmanualprovidesimportantinformaononusingE-FORCE2devices.Proper
compliancewithallspeciedsafetyinstruconsandguidelinesisaprerequisiteforsafework.
Furthermore,adheretothelocalaccidentprevenonguidelinesandgeneralsafetyregulaons
fortheregioninwhichthedevicesareused.
Theseoperanginstruconsmustbecarefullyreadpriortostarnganywork!Theyarean
inherentpartoftheproductandmustbekeptinaplacethatisknownandaccessibleto
personnelatallmes.
Thisdocumentaoncontainsinformaonforoperangyourequipment.However,
youmayalsondinformaonwhichmaynotdirectlyapplytoyourspecicequipment.
Allinformaon,technicaldata,graphicsanddiagramscontainedintheseoperanginstrucons
arebasedonthelatestdataavailableatthemeofthedocument'screaon.
Werecommendthat,inaddiontocarefullyreadingthroughtheoperangmanual,yoube
trainedonhandlingtherescueequipment(possibleapplicaons,applicaontaccs,etc.)by
ourqualiedtrainers.



1.2Explanaonofsymbols

Warningsaremarkedbysymbolsinthisoperangmanual.
Theindividualinstruconsareintroducedbysignalwordsthatexpresstheseverityofthe
hazard.
Itisessenaltocomplywiththeinstruconsinordertopreventaccidents,injuriesanddamage
to property.
  
  …indicatesanimminentlydangeroussituaonthatcanresult
  indeathorseriousinjuryifnotavoided.
 
  …indicatesapotenallydangeroussituaonthatcanresultindeath
  orseriousinjuryifnotavoided.
 
  …indicatesapotenallydangeroussituaonthatcanresultinminor
  orlightinjuriesifnotavoided.
 
  …indicatesapotenallydangeroussituaonthatcanresultin
  materialdamageifnotavoided.



 
  ...highlightsusefulpsandrecommendaons,aswellasinformaon
  forecient,trouble-freeoperaon.
1.3Limitaonsofliability
Allinformaonandinstruconsinthisoperangmanualhavebeencompiledinkeepingwith
applicablestandardsandguidelines,thecurrentstateoftechnology,andourmanyyearsof
knowledgeandexperience.
Themanufacturerassumesnoliabilityfordamagedueto:
• Failuretocomplywiththeoperangmanual
• Unintendeduse
• Assignmentofuntrainedpersonnel
• Unauthorisedmodicaons
• Technicalchanges
• Useofnon-approvedreplacementparts
• Useofnon-originalreplacementparts
Theactualscopeofdeliverycanvaryfromtheexplanaonsandgraphicrepresentaons
providedinthismanualinthecaseofspecialversions,orduetotechnicalchanges.
1.4Copyright
Alltexts,diagrams,drawingsandimagesinthisoperangmanualmaybeusedwithout
restriconandwithoutanypriorapproval.



  Furtherinformaon,imagesanddrawingscanbefoundonour
website www.weber-rescue.com
1.5Warrantycondions
Thewarrantycondionscanbefoundasaseparatedocumentinthesalesdocumentaon.
1.6Customerservice
Ourcustomerserviceisavailabletoyoufortechnicalinformaon.

Name: MrBerndDürr
Telephone: + 49(0)7135/71-10530
Fax: + 49(0)7135/71-10396
E-mail: [e-mail]

Name: MrMahiasSchmid
Telephone: + 43(0)7255/6237-12473
Fax: + 43(0)7255/6237-12461
E-mail: a[e-mail]
 
  Whencontacngourcustomerservicedepartmentpleasestateyour
  equipment'sdesignaon,typeandproduconyear.
  Thesedetailscanbefoundontheequipmenttypeplate.



Thisseconoftheoperangmanualprovidesacomprehensiveoverviewofallimportantsafety
aspectsforopmalprotecngoperangpersonnelandforsafe,trouble-freeoperaon.
Signicanthazardsmayoccurifthehandlingandsafetyinstruconsinthismanualarenot
complied with.
2.1 Intended use
Thehydraulicbaery-powereddevicesaredesignedandtestedexclusivelyfortheintended
applicaonsdescribedhere.Allotheracviesarestrictlyforbidden.
Allbaery-powereddevicesaredesignedasone-mandevicesandare
thereforetobeoperatedbyonlyoneperson.
(RSX160-50E-FORCE2,RSX165-65E-FORCE2,RSU180PLUSE-FORCE2,
RSX185E-FORCE2,RSU210PLUSE-FORCE2,C100E-FORCE2)
• Thebaery-poweredcungdevicesareusedexclusivelyforcungdoors
 androofbeams,pillarsanddoorsills,theringandthespokesofthesteering
wheel.
• Ifpossible,forcungsolidmaterial,alwaysposionthematerialatthebase
 ofthecuerbladesclosesttothepivotpoint,asitisequippedwithspecial
 edgesforcungroundmaterial.
• Inindustrialapplicaon,thedevicescanalsobeusedtocutpipes,structural
 steels,proles,sheetsandcables.
(SP40CE-FORCE2,SP44ASE-FORCE2,SP53BSE-FORCE2)
• Thebaery-poweredspreadingdevicescanbeusedforopeningdoors,
 liingvehiclesorothermoveableloads,pushingawayandmovingvehicle
 partsandloads,andcrushingpipesandebars.
• Ifpossible,alwaysusethepsofthespreaderforcrushing.
• Thepsofthespreadercanalsobeusedasapeelingtool.
• Thechainsetissolelytobeusedforpulling.


(SPS270MK2E-FORCE2,SPS360LE-FORCE2,SPS370E-FORCE2,
SPS400E-FORCE2,RIT-TOOLE-FORCE2)
• Thecombidevicescanbeusedforboththeapplicaonsindicatedforthe
 cuersandthoseforthespreader.Thepsofthespreadercanalso
be used as a peeling tool.
(RZ1-910E-FORCE2,RZT2-1360E-FORCE2,RZT2-1500E-FORCE2)
• Thesedevicesareexclusivelyforpushingupsteeringcolumns,vehicleroofs
 andotherobstaclesandforpushingawayvehiclebodyparts.
• Theycanalsobeusedforsupporngandbracingloads.
 
 
  Anyimproperorunintendeduseofthedevicescanbehazardous!
  Therefore,makeabsolutelysurethat:
» Thedevicesareusedonlyfortheapplicaonsstatedabove.
» AllotherinformaononproperuseofthedevicesinChapter5
 (Possibleapplicaons)isobserved.


2.2Responsibilityofthecustomer
Inaddiontothehealthandsafetyinstruconsinthisoperangmanual,onemustadhereto
thesafety,accidentprevenon,andenvironmentalproteconguidelinesfortheregioninwhich
theequipmentisused.Parcularlyapplicableinthisregard:
• Thecustomermustbefamiliarwiththeapplicablehealthandsafety
 provisionsandinahazardanalysisidenfyotherhazardsthatmay
 existattheequipment'sinstallaonsiteduetothespecialworking
 condions.
• Thecustomermustclearlyregulateandspecifyresponsibilies
 forinstallaon,operaon,maintenanceandcleaning.
• Thecustomermustensurethatallpersonnelwhohandletheequipment
 havefullyreadandunderstoodtheoperangmanual.
• Inaddion,atregularintervals,theoperatormusttrainpersonnelandinform
 themofthehazardsofworkingwiththeequipment.
Moreover,thecustomerisresponsibleforensuringthattheequipmentisalwaysintechnically
faultlesscondion.Consequently,thefollowingapplies:
• Aereachuse,andatleastonceayear,avisualinspeconoftheequipment
 mustbecarriedoutbyatrainedindividual(accordingtoDGUVGrundsatz305-002
 orcountry-specicguidelines).
• Everythreeyears,orifyouhavedoubtsaboutthesafetyorreliability
 oftheequipment,funconaltesngandstresstesngmustbecarriedout
 (accordingtoDGUVGrundsatz305-002orcountry-specicguidelines).


2.3Operangpersonnel
Thefollowingqualicaonsarecitedintheoperanginstruconsforthevariousacvityareas:
• 
 isinformedthroughtrainingoeredbythecustomeraboutthetasks
 assignedtohimandthepossibledangersofimproperconduct.
• 
issomeonewho,duetospecialisedtraining,skillsandexperience,aswell
 asknowledgeoftheapplicablespulaonsbythemanufacturer,iscapable
 ofexecungthetasksassignedtohimorherandofindependently
 recognisingpossiblehazards.
  
  
  Improperhandlingoftheequipmentcanleadtoserious
  injuryormaterialdamage.
  Therefore,makeabsolutelysureto:
» allowparculartaskstobecarriedoutonlybythepersonsstated
 intherelevantchapterofthismanual.
» Whenindoubt,callinspecialistsimmediately.
  
  Theequipmentmaynotbeusedbypersonnelwhohaveconsumed
  alcohol,medicaonordrugs!


2.4Personalprotecveequipment
Wearingpersonalprotecveequipment(PPE)isessenaltominimisetheriskstooperang
personnelwhenworkingwiththehydraulicrescuedevices.

  
  Tight-ngworkclothingwithghtsleevesandnoprotrudingparts
  mustbewornwhenworking.Itmostlyservestoprotectagainst
  entanglementbymovingequipmentparts.
  
  Steel-toedsafetyshoesmustalwaysbewornasproteconagainst
  heavyfallingpartsandfromslippingonslicksurfaces.
  
  Workglovesmustbewornwhenworkingwiththeequipment
  toprovideproteconfromsharpedgesandshardsofglass.
  
  Ahelmetwithfaceshieldmustbewornforproteconagainstying
  orfallingpartsandshardsofglass.
  
  Protecvegogglesmustalsobeworninaddiontotheface
  shieldinordertoprotecttheeyesfromyingobjects.

  
  Inaddiontothebasicprotecveequipment,earprotectors
must also be worn to protect your hearing.


2.5Specichazards
Thehazardsarisingfromtheriskanalysisarelistedinthefollowingsecon.
Followthesafetyinstruconslistedhereandthewarningsintheotherseconsofthismanual
tominimisepotenalhealthhazardsandavoiddangeroussituaons.

   
   
   Thereisanimminentlife-threateningdangeriflivepartsaretouched.
   Damagetoinsulaonortospeciccomponentscanposeafatal
   hazard.
   Therefore:
» Iftheinsulaonisdamaged,immediatelydisconnectthepower
 supplyandarrangeforrepairs.
» Allowonlyqualiedelectricianstoworkontheelectrical
 equipment.
» Forallworkontheelectricalequipment,itmustbedisconnected
 fromthepowersource,anditmustbecheckedthatthedevice
is de-energised.
» Priortomaintenance,cleaningandrepairwork,thepowersupply
 mustbeswitchedoandsecuredtopreventitfrombeing
 switchedbackonagain.
» Donotbypassordisablefuses.
 Whenchangingthefuses,ensurethattheyhavethecorrect
amperage.
» Keepmoistureawayfromliveparts.
 Thiscanleadtoashort-circuit.


Noise


Thenoiseoccurringintheworkareacancauseseverehearingdamage.
Therefore:
» You should also wear ear protectors when carrying out
 certainnoise-producingtasks.
» Donotstayinthehazardousarealongerthannecessary.



Seriousinjurycanresultduetothereleasedhydraulicforcesandescaping
hydraulic oil.
Therefore:
» Constantlymonitorthedeviceduringtheworkprocedureandset
 downifnecessary.
» Inspectthehoselinesanddevicesfordamageaereveryuse.
» Avoidskincontactwiththehydraulicoil(wearprotecvegloves).
» Immediatelyremovethehydraulicoilfromwoundsandconsult
a doctor.


2.6Howtorespondintheeventofdangeroraccidents

• Alwaysbepreparedforaccidents
• Keeprstaidequipment(rstaidkit,blankets,etc.)
at hand
• Familiarisepersonnelwithaccidentalarms,rstaidgear,and
 emergencyequipment
• Keepentrywaysclearforemergencyvehicles

• Shutdownequipmentimmediately
• Iniaterstaidmeasures
• Getpeopleoutofthedangerzone
• Informtheresponsibleparesatthesiteoftheincident
• Nofyadoctorand/ortherebrigade
• Clearentrywaysforemergencyvehicles


2.7Signage
Theequipmentbearsthefollowingsymbolsandinstruconalsigns.
Theyrefertotheimmediatevicinityinwhichtheyareaxed.

Donotusethemarkedequipmentunlyouhavereadtheoperang
manual.

Whenworkingwiththeequipment,takecaretoavoidhandinjuriesthrough
trapping or sharp edges.


Overme,sckersandsymbolsontheequipmentcanbecomesoiledor
otherwise illegible.
Therefore,makeabsolutelysureto:
» Keepallsafety,warningandoperanginformaononthedevice
easily legible.
» Replacedamagedsignsandsckersimmediately.



3.1 Combitools  










 798mm 914mm 920mm 956mm 761mm
Width 192mm 236mm 236mm 236mm 192mm
 241mm 241mm 241mm 241mm 241mm
 13,6kg 18,9kg 19,9kg 21,9kg 13,3kg
 270mm 360mm 370mm 420mm 215mm
 380mm 440mm 390mm 450mm 320mm
 324kN 491kN 491kN 822kN 324kN
 35–591kN 45–783kN 45–783kN 36-1.071kN 30-1.305kN
 30–37kN 39–49kN 49–59kN 59-98kN 35-47kN
 700 bar 700bar 700bar 700bar 700bar
 BK31/270-G-13,6
1H-2G-3G-4H-5G
CK37/360-H-18,9
1I-2J-3H-4K-5I
CK37/370-H-19,9
1I-2J-3H-4J-5I
CK36/420-I-21,9
1I-2K-3I-4K-5K
AC140H-13,3
1H-2H-3H-4H-5H
 A6/B7/C6/D7/E7 A7/B8/C7/D8/E8 A7/B8/C7/D8/E8 A7/B9/C7/D9/E9 A6/B7/C6/D7/E7
 1087085 1074458 1077676 1079181 1082900
*perEN13204**accordingtoEN13204
 
 

3.2 Cutters












 864mm 865mm 885mm 982mm 1017mm 743mm
Width 236mm 236mm 236mm 260mm 298mm 205mm
 241mm 241mm 241mm 241mm 241mm 241mm
 18,6kg 20,2kg 20,4kg 23,5kg 26,1kg
 160mm 165mm 180mm 210mm 180mm 120mm
 493kN 642kN - - - -
 700bar 700bar 700bar 700bar 700bar 700bar
 BC160-H-18,6
1I-2K-3H-4J-5H
BC165-F-20,2
1J-2F-3G-4J-5G
BC180-J-20,4
1J-2K-3K-4K-5K
CC200-K-23,5
1K-2K-3J-4K-5K
CC240-K-26,1
1K-2K-3J-4K-5K
AC120-D-23,5
1D-2D-3E-4F-5F
 A7/B8/C6/D7/E8 A8/B6/C6/D7/E9 A8/B9/C7/D9/E9 A8/B9/C8/D9/E9 A9/B9/C9/D9/E9 A4/B3/C5/D6/E6
 1077690 1079182 1082343 1087781 1088805 1091040
*perEN13204**accordingtoEN13204








3.3 Spreader
  
 807mm 867mm 993mm
Width 250mm 250mm 298mm
 241mm 241mm 241mm
 13,7kg 17,2kg 24,2kg
 515mm 610mm 800mm
 370mm(545mm) 460mm(640mm) 697mm

 40-173kN 44-857kN 53-421kN

 46-70kN 44-75kN 42-72kN
 55kN 90kN 100kN
 700bar 700bar 700bar
 -AS44/610-17,2 BS53/800-24,2
 1089500 1087404 1077791
*perEN13204**accordingtoEN13204






3.4 Rescue ram
  
 540mm 586mm 700mm
Width 134mm 134mm 134mm
 325mm 349mm 349mm
 15,7kg 20,1kg 21,4kg
 111,3kN 108,0kN/62,0kN 108,0kN/62,0kN
 540mm 586mm 700mm
 908mm 1386mm 1500mm
 700bar 550bar 550bar
 R111/368-15,7 TR108/428-62/372-20,1 TR108/428-62/372-21,4
 1075272 1078342 1081519
*perEN13204**accordingtoEN13204
3.5Operangcondions
ThepermissibletemperaturerangeoftheE-FORCE2devicesisbetween-20°Cand+55°C.
Reliableoperaoncannotbeguaranteedoutsideofthisrange.
3.6Typeplate
OnallE-FORCE2devices,thetypeplateislocatedontheboomofthedriveunit.Itshowsthe
serialnumber,producondate,nominalpressureanddevicedesignaon.






