Weber Rescue Systems BC 250 MK2 User manual

E
BC 250 MK2, BC 250 MK2 E-FORCE3, DOOR OPENER SETS, DO 140 MK2 E-FORCE3,
SPK 250 MK2, SPK 250 MK2 E-FORCE3, S25-20, S25-20 E-FORCE2, C120 MK2, C 120 MK2
E-FORCE3, C45-9, DO 120 (SET), DO 105 (SET), DPH 0705, EPH 0203
www.weber-rescue.com
Operang instrucons
Specialised rescue appliances
TACTICAL
checked in accordance with
EN 13204 and NFPA 1936
1060619

Content
1 General 4
1.1 Informaon on the operang instrucons 4
1.2 Explanaon of symbols 5
1.3 Limitaon of liability 6
1.4 Copyright 6
1.5 Warranty condions 7
1.6 Customer service 7
2 Safety 8
2.1 Intended use 8
2.2 Operator responsibility 10
2.3 Operang personnel 11
2.4 Personal protecve equipment (PPE) 12
2.5 Parcular hazards 13
2.6 Conduct in dangerous situaons and accidents 15
2.7 Signage 16
 
3.1 S 25-20 Cuer 17
3.2 C 45-9 Cuer, C120 17
3.3 BC 250 MK2 Concrete crusher 17
3.4 SPK 250 MK2 Expansion wedge 18
3.5 DO 140 MK2 E-FORCE3 Door opener 18
3.6 Door opener set DO 120 19
3.8 Operang condions 19
3.7 Door opener set DO 105 20
3.9 Type plate 21
 
4.1 S 25-20 Cuer 22
4.2 C 120 MK2 Cuer 22
4.2 Cuer C 45-9 23
4.3 BC 250 MK2 Concrete crusher 24
4.4 SPK 250 MK2 Expansion wedge 25
4.5 Door Opener Sets 26
4.6 DO 140 MK2 E-FORCE3 Door opener 27
4.7 Manual pump 28
4.8 E-FORCE2 and E-FORCE3 appliances 29
 
5.1 Hydraulic supply 30
5.2 Hydraulic supply for hose-connected appliances 31
5.3 Connecon for hose-connected appliances 33

TABLE OF CONTENTS | 3
5.4 Electricity supply for E-FORCE appliances 35
5.5 Operaon 36
5.6 Spare parts
6 Possible uses 41
6.1 Safety instrucons 41
6.2 Cung hard metal (S25-20 / S25-20 E-FORCE2, C45-9) 41
6.3 Breaking open doors (DO 140 MK2 E-FORCE3, door opener sets) 42
6.4 Liing loads (SPK 250 MK2, SPK 250 MK2 E-FORCE3) 44
6.5 Breaking concrete (SPK 250 MK2, SPK 250 MK2 E-FORCE3) 44
6.6 Follow-up cut (C 120 MK2, C120 MK2 E-FORCE3) 44
 
7.1 Charger technical specicaons 45
7.2 Special safety instrucons 45
7.3 Intended use 47
7.4 Mains connecon 47
7.5 Li-Ion-baery 47
7.6 Charging process 48
7.7 Maintenance 49
7.8 Charging cycles 49
 
8.1 Safety instrucons 50
8.2 Transport inspecon 50
8.3 Symbols on the packaging 51
8.4 Disposing of the packaging 51
8.5 Storage 51
 
9.1 Safety instrucons 52
9.2 Checking 52
9.3 Installaon 53
9.4 Shutdown (end of work) 54
10 Maintenance 55
10.1 Safety instrucons 55
10.2 Upkeep and maintenance 55
10.3 Maintenance schedule 56
 
 

1 General
1.1 Informaon on the operang instrucons
These operang instrucons provide important instrucons on handling the hydraulic
rescue equipment. To assure safety at the workplace, always observe all safety and handling
instrucons contained in this document.
Furthermore, the local accident prevenon regulaons and general safety determinaons
applicable to the operaon site of the equipment must also be observed.
Before starng any work, read these operang instrucons thoroughly! They are a component
of the product and must be stored in a known locaon that is accessible to personnel at all
mes.
This documentaon contains informaon about the operaon of your appliance, regardless of
which type of appliance it is. For this reason, you will also nd explanaons that do not relate
directly to your appliance.
All informaon, technical specicaons, graphics and illustraons contained in these operang
instrucons are based on the most up-to-date data available at the me these instrucons
were created.
In addion to thoroughly reading the operang instrucons, we also recommend that you
undergo training and instrucon in handling (possible uses, operaonal taccs, etc.) the rescue
equipment from one of our qualied trainers.
NOTE!
The current version of the operang instruc-
ons can be found on our website
hps://www.weber-rescue.com/
or by scanning the QR code.

GENERAL | 5
1.2 Explanaon of symbols

In these operang instrucons, warnings are idened by symbols.
The individual warnings are introduced by signal words expressing the degree of danger.
These warnings must be heeded to prevent accidents, injury and property damage.
DANGER!
… points out an immediately dangerous situaon which can cause death
or severe injury if it is not avoided.
WARNING!
…points out a potenally dangerous situaon which can cause death
or severe injury if it is not avoided.
CAUTION!
…points out a potenally dangerous situaon which can cause minor
or slight injury if it is not avoided.
ATTENTION!
…points out a potenally dangerous situaon which can cause property
damage if it is not avoided.


NOTE!
…emphasises useful ps and informaon for ecient, trouble-free
operaon.
1.3 Limitaon of liability
All informaon and instrucons in these operang instrucons were compiled under
consideraon of the applicable standards and regulaons, the current state of technology
and our long-standing knowledge and experience.
The manufacturer assumes no liability for damages due to:
• non-observance of the operang instrucons
• improper use
• assigning untrained personnel
• unauthorised modicaons
• technical changes
• use of impermissible replacement parts
• use of non-original accessories
For special designs or due to technical changes, the actual scope of delivery for may dier from
the explanaons and representaons described
1.4 Copyright
All texts, illustraons, drawings and images in these operang instrucons may be used freely
without prior authorisaon.

GENERAL | 7
NOTE!
Addional informaon, images and diagrams are available on our home
page: 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.
Germany
DEG Service Center
Phone: [phone]
E-mail: [e-mail]
International:
For quesons regarding spare parts, service and repair, please contact
our cered local service partners. Scan this QR code for an overview
of our worldwide service and sales network.
NOTE!NOTE!
When contacng our Customer Service, please provide the idencaon,
type and year of manufacture of the appliance. This informaon can be
found on the type plate.
For further processing, please complete
the RMA document in full:
Austria
Service Center Losenstein
Phone: [phone]
E-Mail: [e-mail]

2 Safety
This secon of the operang instrucons provides a comprehensive overview of all important
safety aspects to protect the operang personnel, as well as for safe, trouble-free operaon.
Failure to observe the handling and safety instrucons provided in these operang instrucons
can result in signicant hazards.
2.1 Intended use
The hydraulic rescue equipment is designed and tested exclusively for the
intended uses described here. All other acvies are fundamentally prohibited.
All appliances are designed as one-man appliances and are therefore only permied to be
operated by one person.

• The S 25-20 cuer may only be used to cut metal bars, chain links, padlocks
and armouring.
• The C 45-9 cuer is designed for cung pipes, grilles, pedals and headrests.
• All cung devices are designed as one-man devices and may therefore only be
operated by one person.

• The door openers are used to open doors or can be used to li mobile loads such as
concrete slabs, iron girders, etc. Furthermore, they can be used during servicing /
maintenance work on machines and in many other situaons.

• This appliance may only be used to li mobile loads in order to create a gap,
for example, to use liing cushions.
l pump EPH 0203
• Compact two-stage hand pump with SKS coupling for operang the DO 120 and
DO 105 door opener and the C 45-9 cuer
Concrete crushers BC 250 MK2, BC 250 MK2 E-FORCE3
• This appliance is used to break up and force open concrete slabs, e.g. aer
a building has collapsed.

SAFETY| 9
WARNING!
 
Any use other than intended use and/or other type of use of these
appliances can cause dangerous situaons!
Therefore, it is absolutely necessary to:
» Only use the appliances for the intended uses described above.
» Observe all other informaon regarding proper use of the appliances
in Chapter 6 (Possible uses).

2.2 Operator responsibility
In addion to the occupaonal safety informaon in these operang instrucons, the safety,
accident prevenon and environmental prevenon regulaons applicable to the operaon site
of the appliance must also be observed. Thereby, the following applies in parcular:
• The operator must inform himself regarding the applicable occupaonal safety
regulaons and carry out a risk assessment to idenfy addional dangers arising
from the special work condions at the operaon site of the appliance.
• The operator must clearly regulate and determine responsibility for installaon,
maintenance and cleaning.
• The operator must ensure that all persons engaged with the appliance have
completely read and understood the operang instrucons.
• Furthermore, he must train the personnel at regular intervals and inform them
of the dangers associated with handling the appliance.
The operator is also responsible for ensuring that the equipment is always in a technically
awless condion. Therefore, the following applies:
• Aer each me the equipment is used, or at least once a year, a visual inspecon
of the appliance by an instructed person is required (acc. to DGUV Prüfgrundsatz
305-002 or country-specic rules).
• Every three years, or whenever a doubt is raised about the safety or reliability of
the appliance, a funcon and load test must also be carried out (acc. to DGUV
Prüfgrundsatz 305-002 or country-specic rules).
NOTE!
Maintenance work can be carried out by instructed persons. Maintenance
measures and repairs may only be carried out by the appliance manufacturer,
or by specialist personnel trained by the appliance manufacturer and the
authorised service partners. Connuous training and instrucon by the
appliance manufacturer is mandatory for a valid training cercate.

SAFETY | 11
2.3 Operang personnel
The following qualicaons for dierent areas of acvity are specied in the operang
instrucons:
• Instructed persons
Have been instructed by the operator regarding the tasks they have been assigned
and the possible dangers caused by improper acons.
• Expert personnel
Because of their professional training, knowledge and experience as well as their
knowledge of the applicable manufacturer’s provisions, expert personnel are
able to carry out the tasks they have been assigned and independently recognize
potenal dangers.
WARNING!
  
Improper handling of these appliances can cause serious injury and property
damage.
Therefore, it is absolutely necessary to:
» Only permit the people specied in the respecve chapters of these
operang instrucons to carry out the special acvity.
» In case of doubt, immediately call in expert personnel.
NOTE!
Never operate the appliance aer consuming alcohol, medicaons or drugs!
NOTE!
Maintenance work can be carried out by instructed persons. Maintenance
measures and repairs may only be carried out by the appliance manufacturer,
or by specialist personnel trained by the appliance manufacturer and the
authorised service partners. Connuous training and instrucon by the
appliance manufacturer is mandatory for a valid training cercate.

2.4 Personal protecve equipment (PPE)
To minimise danger for the operang personnel, wearing personal protecve equipment (PPE)
when handling the hydraulic rescue equipment is absolutely mandatory.

  
Only wear closely ng work clothing with narrow sleeves and without
projecng pieces while working. It protects against entanglement in moving
appliance parts.
Safety shoes
Always wear steel-capped safety shoes to protect against heavy falling
objects and slipping on slippery srfaces.
  
Wear safety work gloves to protect against sharp edges and glass splinters
when operang the equipment.
Helmet with face shield
Wear a helmet with face shield to protect against ying or falling parts and
glass splinters.
  
In addion to a face mask, protecve goggles should be worn to protect the
eyes from projecle parcles.

that cause noise!
To protect your hearing, ear defenders should be worn in addion to
personal protecve equipment.

SAFETY| 13
2.5 Parcular hazards
The dangers resulng from the risk assessment are presented in the following secon.
To minimize potenal health hazards and prevent dangerous situaons, the safety instrucons
listed below and the warning instrucons in the following chapters of these Operang
Instrucons must be observed.
Electrical current
DANGER!
   
There is an immediate danger of death if live parts are touched. Damage to
insulaon or individual components can be life-threatening.
Therefore:
» If there is damage to the insulaon, disconnect the power supply
immediately and arrange for repairs.
» Only allow electricians to carry out work on the electrical system.
» When any work is being carried out on the electrical system, it must be
disconnected from the mains supply and checked to ensure that it is not
live.
» Before carrying out maintenance, cleaning and repair work, the power
supply must be switched o and secured to prevent it being switched on
again.
» Do not bypass or shut down any fuses. Use fuses with the correct
amperage when replacing.
» Keep live parts away from moisture.
This can cause a short circuit.
WARNING!
The use of E-FORCE3 devices in potenally explosive atmospheres is
prohibited.

Noise
WARNING!

The noise arising in the work area can cause serious damage to the hearing.
Therefore:
» Also wear ear defenders during any special kinds of work that cause
noise!
»Only wear the ear defenders while you are in the danger area.

WARNING!

The hydraulic forces that are released and escaping hydraulic uid can cause
severe injuries.
Therefore:
» Always keep the appliance in sight while working and put it down if
necessary.
» Inspect hose lines and appliances for damage aer each use.
» Avoid skin contact with the hydraulic oil (wear safety gloves).
» Remove hydraulic oil from wounds without delay and consult a doctor
immediately.

SAFETY| 15
WARNING!

Breaking up can cause concrete splinters to y about, which can cause
injuries.
Therefore:
» Wear appropriate protecve clothing (e.g. a visor or safety goggles)
while working
»Do not remain in the working area if you are not involved in the task
2.6 Conduct in dangerous situaons and accidents

• Always be prepared for accidents
• Always have rst-aid equipment (rst-aid kit, blankets, etc.) within reach.
• Familiarize personnel with accident reporng, rst aid and rescue equipment.
• Keep access routes for rescue vehicles open.
In case of incidents
• Immediately shut down appliances.
• Iniate rst-aid measures.
• Remove persons from the danger zone.
• Inform responsible person at the operaon site.
• Alarm doctor and/or re brigade.
• Open access routes for rescue vehicles.

2.7 Signage
The following symbols and instrucon panels are located on the appliances.
They refer to the immediate environment in which they are displayed.

Do not use the designated appliance unl you have read the operang
manual from cover to cover.
WARNING!

As me goes by, adhesive labels and symbols on the appliance
may get dirty, or be rendered illegible in some other manner.
Therefore, it is absolutely necessary to:
» Maintain all safety, warning and operang instrucons on the appliance
in a readily legible condion.
»Damaged signs and adhesive labels must be replaced immediately.

S 25-20 S25-20 E-FORCE2
448 mm 537,00 mm
179 mm 179,00 mm
239,5 mm 260,00 mm
7,7 kg 11,5 kg
25 mm 25,00 mm
720 bar 700 bar
1065612 1088176
C 45-9 C 120 MK2 C120 MK2 E-FORCE3
267 mm 585 mm 745 mm
66 mm 188 mm 188 mm
88 mm 196 mm 238 mm
3,9 kg 19,3 kg 23,1 kg
45 mm 120 mm 120 mm
700 bar 700 bar 700 bar
AC120D-19,3 AC120D-23,1
1070758 1105034 1105035
BC 250 MK2 BC 250 MK2 E-FORCE3
729 mm 890 mm
380 mm 380 mm
303 mm 302 mm
17,7 kg 21,5 kg
250 mm 250 mm
700 bar 700 bar
1103954 1103955
TECHNICAL SPECIFICATIONS | 17

3.1 S 25-20 Cuer
* in acc. with EN 13204 ** weight ready to use
3.2 C 45-9 Cuer, C120
* in acc. with EN 13204** weight ready to use
3.3 BC 250 MK2 Concrete crusher
* in acc. with EN 13204** weight ready to use

Width



Nominal pressure
Id no.

Width



Nominal pressure
Id no.

Width



Nominal pressure
NFPA-class.
Id no.

DO 140 MK2 E-FORCE3
605 mm
168 mm
241 mm
13,2 kg
140 mm
101 kN
700 bar
1101946
SPK 250 MK2 SPK 250 MK2 E-FORCE3
610 mm 770 mm
150 mm 150 mm
115 mm 241 mm
9,0 kg 12,9 mm
61 mm 61 mm
248 KN 248 mm
700 bar 700 bar
1101215 1101981
3.4 SPK 250 MK2 Expansion wedge
3.5 DO 140 MK2 E-FORCE3 Door opener
* in acc. with EN 13204
* in acc. with EN 13204 ** weight ready to use

Width




Nominal pressure
Id no.

Width


Stroke

Nominal pressure
ID no.


Gewicht 7,1 kg
 164 X 116 X 278 mm
 115kN
Hub 120 mm
ID Nr. 1075922
Handpumpe DPH 0705
Gewicht 5,3 kg
 351 x 146 x 110 mm
 0,7 l
1. Hub bis 20 bar 7,2 cm3
2. Hub über 20 bar 0,9 cm3
Max. Arbeitsdruck 700 bar
ID Nr. 1069626

Gewicht 15,6 kg
Arbeitsdruck 600 x 400 x 160 mm
 3 m
ID Nr. 1075344
7,1 kg
164 X 116 X 278 mm
115kN
120 mm
1075922
5,3 kg
351 x 146 x 110 mm
0,7 l
7,2 cm3
0,9 cm3
700 bar
1069626
15,6 kg
600 x 400 x 160 mm
3 m
1075344
TECHNICAL SPECIFICATIONS | 19
3.6 Door opener set DO 120
* in acc. with EN 13204
3.8 Operang condions
Door oopener DO 120
 7,1 kg
Dimensions 164 X 116 X 278 mm
 115kN
Stroke 120 mm
ID no. 1075922
Handpump DPH 0705
 5,3 kg
Dimensions 351 x 146 x 110 mm
 0,7 l
1st stroke < 20 bar 7,2 cm3
2nd stroke > 20 bar 0,9 cm3
 700 bar
ID no. 1069626
Complete set
 15,6 kg
 600 x 400 x 160 mm
 3 m
ID no. 1075344

3,3 kg
40 kN (57 MPa - EPH0203)
49 kN (70 MPa - DPH0705)
105 mm
141 X 127 X 225 mm
1099556
3,4 kg
0,3 l
1,8 cm3
430 x 100 x 161 mm
1099835
11,4 kg
600 x 400 x 223 mm
1100718
3.7 Door opener set DO 105
in acc. with EN 13204
* nach EN 13204
Door opener DO 105


Stroke
Dimensions
ID no.
Handpump EPH 0203


Flow rate per stroke
Dimensions
ID no.
Complete set

Dimensions
ID no.