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USER MANUAL MINI & MIDI POWER UNIT 3SR ENGLISH USER MANUAL MINI & MIDI POWER UNIT 3SR WWW.RESQTEC.COM

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Page 1: USER MANUAL - resqtec.com€¦ · Dump valve 14 3.7. Connecting the ... sets thatthey have an internal automatic by-pass system, meaning you can ... USER MANUAL MINI & MIDI POWER

USER MANUALMINI & MIDI POWER UNIT 3SR

ENGLISH USER MANUAL MINI & MIDI POWER UNIT 3SR

WWW.RESQTEC.COM

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USER MANUAL MINI & MIDI POWER UNIT 3SR

03RESQTEC Manual 3SR MINI-MIDI POWER UNIT (DM032K07)

1. INTRODUCTION: SAFETY FIRST 041.1. Safety messages 041.2. General safety information 041.3. Safety information 051.4. Productidentification 051.5. Applicable types 061.6. Couplertypeindentification 06

2. PRODUCT SUMMARY 072.1. Introduction 072.2. 3SR power unit description 072.3. Componentidentification 07 2.3.1 Mini GXH50 3SR power unit 07 2.3.2 Midi GX100 3SR power unit 08

3. GENERAL OPERATING INSTRUCTIONS 103.1. Optimized 350 bar 103.2. Initial use 103.3. Preparation before use 103.4. Regular use 113.5. Starting the 3SR power unit 113.6. Dump valve 143.7. Connecting the NEO1 coupler 153.8. Disconnecting the NEO1 coupler 153.9. Shutting down the power unit 163.10. Connecting and disconnecting STD couplers 173.11. Honda internal combustion engine 18

4. SPECIFICATIONS 194.1. Technicalspecifications 19 4.1.1 SI-system data 19 4.1.2 Imperial system data 224.2. Technical drawings 25 4.2.1 SI-system data 25 4.2.2 Imperial system data 28

5. MAINTENANCE & STORAGE 305.1. General maintenance 305.2. Maintenance after each use 305.3. Regular maintenance plan 315.4. Maintenance on couplers 315.5. Draining&replacingthehydraulicfluid 325.6. Recommended storage 345.7. Decommisioning/recycling 345.8. Accessories and spare parts 34

6. WARNINGS & LIMITATIONS 356.1. Temperature range 356.2. Altitude 356.3. Inclined surfaces 356.4. Confinedspaces 356.5. Tampering 35 7. WARRANTY 36

8. DISCLOSURE 37

9. CONTACT 38

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04 RESQTEC Manual 3SR MINI-MIDI POWER UNIT (DM032K07)

1. INTORDUCTION: SAFETY FIRST!1.1. SAFETY MESSAGES

This manual contains safety messages. They point out potential hazards that could hurt you or others around you as well as damage the equipment in use. These messages should therefore be read carefully and understood. They are highlighted by a safety alert symbol shown on the left. The potential hazards are explained as to what could happen and how to avoid or reduce injury or damage.

Important information has been highlighted as well. To point out this information, a light bulb icon is used. It brings topics to your attention that could, for example, facilitate maintenance or to clarify when it is advisable to consult your distributor.

1.2. GENERAL SAFETY INFORMATION

The Resqtec rescue equipment is designed to provide safe operation. All users should read and be thoroughly familiar with the operatinginstructions and safety precautions contained in this manual. Operator safety depends on users being properly trained by the Authority havingjurisdiction and using the tool for the purpose intended. The following safety precautions must be observed at all times.

UNTRAINED USE COULD RESULT IN SERIOUS PERSONAL INJURY AND/OR DAMAGE TO PROPERTY AND/OR EQUIPMENT

•ResqtecrescueequipmentshallonlybeoperatedbypersonsauthorizedandqualifiedbytheAuthorityhavingjurisdiction. • Be aware that this is not an all-encompassing training manual. This manual is meant as a reference-guide for working with this specificequipment,andtheusershouldalreadybetrainedandqualifiedinusingrescueequipment. • Suitable protective equipment shall be worn as directed by the Authority having jurisdiction. At a minimum, this should include gloves, helmet, eye protection, and body protection — such as turnout gear.

• Prior to use, inspect all components for any signs of damage or fraying. Do not use damaged equipment. • Stay alert. Do not operate the system when tired. • Use only Resqtec authorized service parts. • This equipment should only be used with accessories approved by Resqtec. Use of unauthorized accessories can result in unpredictable and unreliable tool operation and is prohibited.

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05RESQTEC Manual 3SR MINI-MIDI POWER UNIT (DM032K07)

1.3. SAFETY INFORMATION

Before using the power unit and its related products and accessories, conduct an overall size-up of the intended use and safeguard against potential hazards before installing the product. Read and understand this manual before using the power unit.

The Warning and Safety labels on the product alert the user to special hazards inherent with its use. Should they become damaged or unreadable, contact the manufacturer to obtain a replacement.

BEFORE INSTALLING THE POWER UNIT, BE AWARE OF THE FOLLOWING:

• When (re)positioning the power unit, make sure that the power unit is carried by more than one person to avoid injury when handling units over 25 kilos. Always carry the power unit by the carry structure. •Wheninusemakesurethepowerunitstandsfirmlyontheground. • NEVER, when in use, pick up the UNIT, and/ or move it around. • Make sure no one on site is, or might get in danger, when using Resqtec equipment. Be aware of your surroundings, the situation you and the people around you are in, and what the consequences of the use of the Resqtec system are. • Before starting the engine of the power unit, make sure that you are not working in an explosive environment. • The power units which are powered by a combustion engine have parts (exhaust) that will get hot during operation! Avoid contact with these parts during and after use. • NEVER, when in use, place your hands or any other body parts on the hot parts of the power unit. Doing so can result in serious personal injury. •Makesurethatnokinkwillforminanyofthehosesduringuse.Makesurethatthehoseprovidesafreeflowatalltimes.Failing to do so may result in damage to the hose assembly and malfunction of your Resqtec system. • Never pull power unit towards you by the hoses & couplers. Pick up the unit by the carry structure instead. • NEVER pull a hose to try to untangle it or to free a hose from an obstacle. Always direct your full attention to the problem; clear the hose from the obstacle or untangle the hose before proceeding.

1.4. PRODUCT IDENTIFICATION

Productidentificationistomakesurethatthismanualcomeswithaspecificproductandthatthismanualshouldalwaysbeavailableasareference guide to that equipment. It is mandatory that this manual and accompanying “Service Booklet” are not separated from the product specifiedbelowduringitsservicelife.

STO

MTO

Distributor/Supplier information:

With serial number: Hydraulic Fluid (HF) used in UNIT:RESQTEC OPTI-GREEN HF-15 BIODEGRADABLE

RESQTEC OPTI-GREEN HF-46 BIODEGRADABLE

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06 RESQTEC Manual 3SR MINI-MIDI POWER UNIT (DM032K07)

1.5. APPLICABLE TYPES

This manual covers the following product types;

1.6. COUPLER TYPE INDENTIFICATION

NEO1couplershavethebenefitoverSTD(standardcouplers)setsthattheyhaveaninternalautomaticby-passsystem,meaningthatyoucancoupleanduncoupleunderfreeflowpressure.Thismeansthereisnoneedtoutilizethedumpvalvewhenconnectingand/ordisconnectingthecouplers as opposed to the STD couplers. They are also co-axial and the hoses attached can rotate freely making it nearly impossible to tangle your hose.

3641.1111.**MINI GXH50 STO 1X1 3SR

3641.1121.**MINI GXH50 STO 1X1 3SR +SMART

3642.1112.**MIDI GX100 STO 1X1 3SR

3642.1122.**MIDI GX100 STO 1X1 3SR +SMART

3742.1112.**MIDI GX100 MTO 2X2 3SR

3742.1122.**MIDI GX100 MTO 2X2 3SR +SMART

NEO1 – RQ & BQ STD (HP)/FF – RS, MS, BS & BB

STD OPEN – R0, M0 & B0

STD COUPLER SET

NEO1 COUPLER

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07RESQTEC Manual 3SR MINI-MIDI POWER UNIT (DM032K07)

2. PRODUCT SUMMARY2.1. INTRODUCTION

ThankyouforchoosingResqtec.Weareconfidentthatweliveuptoyourexpectations.Thismanualhasbeencompiledcarefullytosupplythe reader with all the necessary information. Read all the instructions before using the unit to assure safe and optimal use of the unit. These instructions contain aspects relevant to safe and optimal use of the unit.

The unit has been manufactured by RESQTEC Zumro B.V. For addresses look on the back cover of this manual or refer to our internet site at www.resqtec.com.

2.2. 3SR POWER UNIT DESCRIPTION

The3SRpowerunitshavebeendesignedandengineeredtoassistfirefighters,USAR-teamsandotherrescueworkerswiththevariousrescueapplicationstheyencounter.Weareconfidentthatthedesignoftheseproductswillenablethoseworkingintheseenvironmentstonotonlynegotiate the obstacles they encounter, but to perform their work more safely.

The 3SR power unit is designed to power Resqtec double acting hydraulic rescue tools. The system produces an operating pressure of 350 bar/5,075 PSI. The 3SR power unit is designed for optimum performance and ease of use. It is light, silent and features a three stage hydraulic system.Thethreestagepumpdesignmaximizestheengineoutputforefficienthydraulicuse(optimumspeed&powerinyourResqtectools).Theunitisengineeredtoeffectivelydissipateanyheatcreatedinthesystem.Itfeaturesacleverhydraulicfluidreturnsystemtokeepthehydraulicfluidpowermediuminoptimaforma.Reducingaerationandturbulentflowtoaminimumandensuringareactionfreecuttingandspreading performance.

Furtherinformationregardingthehydraulicfluidinyoursystemcanbefoundinthe“MaterialSafetyDataSheet”or“MSDS”whichcamewithyourunit.Fordetailed,technical,informationconcerningyourunit,consultchapter4.1,TechnicalSpecifications.

2.3. COMPONENT IDENTIFICATION OF THE MINI GXH50 STO 1X1 3SR POWER UNIT

2.3.1. MINI GXH50 3SR POWER UNIT

FRAME/CARRY STRUCTURE

FILLER BREATHER CAP

HF TOP LEVEL INDICATOR

FUEL FILLER CAP

CHOKE LEVER

DUMP VALVENEO1 COUPLER

HF LOW LEVEL INDICATOR

FRAME/CARRY STRUCTURE

FUEL FILLER CAP

CHOKE LEVER

DUMP VALVE

THROTTLE LEVER

OIL FILLER/ DIP STICK

STARTER GRIP

HOUR/ TACHOMETER

ENGINE SWITCH

FUEL VALVE OIL FILLER/ DIP STICK

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08 RESQTEC Manual 3SR MINI-MIDI POWER UNIT (DM032K07)

2.3.2 MIDI GX100 3SR POWER UNIT

FUEL FILLER CAP

HF TOP LEVEL INDICATOR

FRAME/CARRY STRUCTURE

MUFFLER COVER

DUMP VALVE

NEO1 COUPLER

HF LOW LEVEL INDICATOR

OIL FILLER/ DIP STICK (R)NEO1 COUPLER

FUEL FILLER CAP

CHOKE LEVER

FUEL VALVE

ENGINE SWITCH

HOUR/ TACHOMETER

DUMP VALVE

STARTER GRIPTHROTTLE LEVER

OIL FILLER/ DIP STICK (L)

FILLER BREATHER CAP

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09RESQTEC Manual 3SR MINI-MIDI POWER UNIT (DM032K07)

3SR+SMART AUTOMATIC SPEED REGULATOR SYSTEM AND MANUAL OVERRIDE

Note that the 3SR+SMART function works optimally when the tools that are used on the system are also optimized for this system. When using a new 3SR+SMART unit with older tools make sure that the control handles and control valves are upgraded to function with the system. Contact your Resqtec distributor/supplier for further details.

+SMART AUTO MODE / MANUAL OVERRIDE SELECTOR SWITCH

SPEED REGULATOR

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10 RESQTEC Manual 3SR MINI-MIDI POWER UNIT (DM032K07)

3.GENERAL OPERATING INSTRUCTIONS3.1. OPTIMIZED 350 BAR

Resqtec products operate at 350 bar/5,075 PSI allowable pressure (Optimized 350 bar), which allows a smooth and more controlled tool operation. To support interoperability, Resqtec can also provide means to connect the equipment to other brands’ system components. Contact your distributor/supplier for information about parts (couplers e.g.) to make your equipment ready for interoperability.

ALWAYS BE AWARE THAT TO CONNECT A RESQTEC PRODUCT TO ANY PUMP, THE SAME HYDRAULIC FLUID AND COUPLERS NEED TO BE USED.

Your equipment can be supplied with the requested coupler(s) or can be changed in a later stadium by your distributor/supplier. It is also possible to purchase an adaptor kit between different connectors. Contact your distributor/supplierifyouwanttoconnecttoanotherpumpandchangethefluidand/orcouplerifnecessary.

3.2. INITIAL USE

When receiving your equipment check for any sign of damage to the box, and report it to your distributor/supplier as damage could have occurred during shipping. Unpack in upright position and check the unit for damage or leaking. To make sure the power unit conforms to your specifications,checktheproductdetailsonthelabellocatedonthebottomofthefootplate.

CHECK THE EQUIPMENT FOR EXTERNAL DAMAGE. NOTIFY THE SUPPLIER / DISTRIBUTOR IMMEDIATELY IF ANY DAMAGE IS FOUND. DO NOT USE DAMAGED EQUIPMENT UNDER ANY CIRCUMSTANCE!

In general we distinguish a couple of different types of operations;• Initial use• Regular use, check before use• Starting the power unit• Connecting the Resqtec NEO1 coupler on power unit• Disconnecting the Resqtec NEO1 coupler on power unit• Using the dump-valve• Shutting down the power unit

3.3. PREPARATION BEFORE USE

Resqtecequipmentcanbesuppliedwithdifferentkindsofhydraulicfluiddependingoncustomerrequest.NEVERconnectthepowerunittoadifferentkindofhydraulicfluidasthiswilldamagethetool.

Normallythepowerunitsthataredrivenbyacombustionenginearealreadyfilledwithmotoroil.However,docheckthemotoroillevelbeforeusingthepowerunitforthefirsttime.Consulttheengine’smanual(alsosupplied)formoredetailedinformationregardingmaintenanceissues.

Combustion driven power units need to be fueled prior to use. Refer to the supplied engine manual for information on this matter.

Onarrival,thehydraulicfluidissuppliedinaseparatecontainer.Thehydraulicfluidreservoirofthepowerunitneedstobefilledtothe‘nominalHFlevel’oftheHFTOPLEVELINDICATOR.Nextstepistoslowlypullthestartergrip10timeswiththeengineswitchonthe‘OFF’position.Thiswillpre-fillthehydraulicsystemandmakesurenoaircanbetrappedinsidethesystemwhichcouldcauseundesirablesituations.

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RESQTEC Manual 3SR MINI-MIDI POWER UNIT (DM032K07)

3.4. REGULAR USE

Check before using the 3SR power unit: • Check the power unit for visible damage. Do not use the equipment if the damage found could endanger normal operation. •Checkthehydraulicfluidlevel(HFtoplevelindicator).Addfluidifnecessary. MAKE SURE THE UNIT IS LEVEL FOR CORRECT READING. • (For combustion engines) Check the motor oil level according to the instructions in the supplied Honda engine manual and add if necessary. • (For combustion engines) Check the fuel level according to the instructions in the supplied Honda engine manual. Make sure you do not have to refuel during operation! • (For electric engines) Check the electrical cord for any obvious damage.

3.5. STARTING THE 3SR POWER UNIT

MAXIMUM HF LEVEL

NOMINAL HF LEVEL

MINIMUM HF LEVEL

MINI GXH50 MIDI GX100

Open the dump valve(s) if starting a unit with STD couplers.

Refer to chapter 3.4 ‘Dump valve’ for instructions. When using NEO1 couplers proceed to step 2.

1

Switchengineswitchto‘on’.

2

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12 RESQTEC Manual 3SR MINI-MIDI POWER UNIT (DM032K07)

Switchfuelvalveto‘open’position.

3

Turn engine choke on (ONLY when performing “cold start”).

4

Set throttle lever to half open position (only for unitswithout +SMART auto mode system).

5

Setselectorswitchto‘O’position(manualoverride)(only for units with +SMART auto mode system).

6

Pullthestartedgripfirmlyandfasttostarttheengine.(repeat if necessary).

7

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RESQTEC Manual 3SR MINI-MIDI POWER UNIT (DM032K07)

Close engine choke. Do this gently and notice the motor starts making a different sound.

DON’T WAIT TOO LONG WITH THIS ACTION; THE ENGINE MIGHT STALL WITH TOO MUCH CHOKE.

8

Set throttle lever to the desired position (fully opened when operating) (only for for units without +SMART auto mode system).

Whenunitissufficientlyheatedyoumayswitchtheselectorswitchto‘I’position(+SMARTautomode)forautomatic speed regulation.

Closethedumpvalve(s)tomakesurepumpflowisdirected to the tools.

Do this only with hoses and tools connected to avoid building up pressure inside the connectors or attached hose when using STD connectors.

9

10

11

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3.6. DUMP VALVE

Eachuseableportofthepowerunitisequippedwithamanuallyoperated‘dumpvalve’whichonlyneedstobeusedincaseunforeseensituations are encountered during operation, or when the unit is equipped with STD couplers. The dump valve enables a neutral position for the portofthepowerunitmeaningitdivertsthehydraulicfluidstraightbacktothereservoir.

Whenengagingthe‘dumpvalve’allflowandpressureonthatsideofthepumpislost.

Presstoopenthedumpvalvetoreliefthesystemofflowandpressure(theribsarestilllined up).

Rotate the dump valve to keep engaged (detent function) The ribs don’t line up any more. Maximum rotation ±30°.

Rotatebacktodisengageandrestorehydraulicflowandpressure(springreturn).Green rim becomes visible again, and the ribs line up again.

Dump valve in normal open (operation) position, ready for system use (the ribs are lined up).

1

2

3

4

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RESQTEC Manual 3SR MINI-MIDI POWER UNIT (DM032K07)

3.7. CONNECTING THE NEO1 COUPLER

3.8. DISCONNECTING THE NEO1 COUPLER

Remove the NEO1 male dust cap by simply pulling the dust cap straight from the NEO1male coupler.

Rotate the NEO1 female coupler unlock ring in the direction of the arrow on the coupler and push backwards.

The NEO1 male coupler on the hose will now automatically eject. Note, a few drops on fluid will come free, this is normal.

Align the NEO1 hose male coupler with the NEO1 female coupler on the power unit.

Rotate the NEO1 female coupler unlock ring in the direction of the arrow on the coupler and push backwards. The NEO1 male coupler on the hose will now automatically eject.Note, a few drops on fluid will come free, this is normal.

Push the NEO1 male coupler onto/into the NEO1 female coupler in one movement.

Make sure it clicks and locks into place.

Replace the NEO1 male dust cap on the NEO1 male coupler on the now detached hose.

1

1

2

2

3

3

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3.9. SHUTTING DOWN THE POWER UNIT

LET THE UNIT COOL DOWN BEFORE STORING.

Disconnect couplers.

Rotateengineswitchto‘off’.

Close the fuel valve. Set the throttle lever to low if desired.

1

2

3

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RESQTEC Manual 3SR MINI-MIDI POWER UNIT (DM032K07)

3.10. CONNECTING AND DISCONNECTING STD COUPLERS

Make sure the dump valve is engaged (pushed in and rotated into detented positionso the ribs are NOT lined up).

Make sure a tool is connected at the other end of the hose, and then open the dumpvalve to resume operation.

To disconnect make sure the dump valve is engaged (pushed in and rotated into detentedposition so the ribs are NOT lined up) and rotate the lock ring on the coupler to line up the groove with the ball.

Pull/push back on the lock ring to disconnect.

Connecttheoutersidecouplerfirst.

Connect the inner side coupler.

1

2

3

4

5

6

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3.11. HONDA INTERNAL COMBUSTION ENGINE

ALWAYS HAVE A MINIMUM RUNTIME OF 5-10 MINUTES AFTER STARTUP BEFORE SHUT DOWN, THIS TO AVOID TROUBLE IN THE STARTING SEQUENCE THE NEXT TIME;

Resqtec advises to use Aspen4 if possible, or refer to Honda information below:

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RESQTEC Manual 3SR MINI-MIDI POWER UNIT (DM032K07)

4. SPECIFICATIONS4.1. TECHNICAL SPECIFICATIONS

4.1.1 SI-SYSTEM DATA

MINI GXH50 STO 1X1 3SR NEO1-COUPLER STD-COUPLERNominal pressure 350 bar

EN-13204 designation STO

+SMART auto speed regulator with manual override

Standard on GXH50 STO 1x1 3SR +SMART(art.nr. 3641.1121.**)

Running time Ca. 180 Min.

Engine / power supplyHonda 1.6kW

(2.1 HP) 4-stroke petrol

Fuel tank capacity 0,77 liter

EN-13204 noise level at 1 meter distance Lpa 80 dB

NFPA emission sound level at 4 meter distance Lpa 74 dB

Dimensions (L x W x H) 376 x 296 x 495 mm (±10 mm)

EN-13204 weight (ready use HF & fuel full)

Excl.SMART speed

regulator

Incl.SMART speed

regulator

Excl.SMART speed

regulator

Incl.SMART speed

regulator19.1 kg (±0.2 kg) 19.6 kg (±0.2 kg) 19.2 kg (±0.2 kg) 19.7 kg (±0.2 kg)

Weight with HF but no fuel 18.4 kg (±0.2 kg) 18.9 kg (±0.2 kg) 18.5 kg (±0.2 kg) 19.0 kg (±0.2 kg)

Dry shipping weight (with motor oil) 15.7 kg (±0.2 kg) 16.2 kg (±0.2 kg) 15.7 kg (±0.2 kg) 16.2 kg (±0.2 kg)

Pump 3-stage radial piston

Totalhydraulicfluidcapacity 3,0 liter

Effectivehydraulicfluidcapacity 2,0 liter

1st stage (0 – 120 bar) 3,600 cc/min (3.6 l/min)

2nd stage (120 – 240 bar) 1,890 cc/min (1.9 l/min)

3rd stage (240 – 350 bar) 945 cc/min (0.9 l/min)

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MIDI GX100 STO 1X1 3SR NEO1-COUPLER STD-COUPLERNominal pressure 350 bar

EN-13204 designation STO

+SMART auto speed regulator with manual override

Standard on GX100 STO 1x1 3SR +SMART(art. nr. 3642.1122.**)

Running time Ca. 180 Min.

Engine / power supplyHonda 2.1kW

(2.8 HP) 4-stroke petrol

Fuel tank capacity 0.77 liter

EN-13204 noise level at 1 meter distance Lpa 80 dB

NFPA emission sound level at 4 meter distance Lpa 76 dB

Dimensions (L x W x H) 424 x 340 x 512 mm (±10 mm)

EN-13204 weight (ready use HF & fuel full)

Excl.SMART speed

regulator

Incl.SMART speed

regulator

Excl.SMART speed

regulator

Incl.SMART speed

regulator26.5 kg (±0.2 kg) 27.2 kg (±0.2 kg) 26.6 kg (±0.2 kg) 27.2 kg kg (±0.2 kg)

Weight with HF but no fuel 25.8 kg (±0.2 kg) 26.4 kg (±0.2 kg) 25.9 kg (±0.2 kg) 26.5 kg (±0.2 kg)

Dry shipping weight (with motor oil) 22.6 kg (±0.2 kg) 23.2 kg (±0.2 kg) 22.7 kg (±0.2 kg) 23.3 kg (±0.2 kg)

Pump 3-stage radial piston

Totalhydraulicfluidcapacity 3.8 liter

Effectivehydraulicfluidcapacity 2.8 liter

1st stage (0 – 120 bar) 5,883 cc/min (5.8 l/min)

2nd stage (120 – 240 bar) 3,153 cc/min (3.2 l/min)

3rd stage (240 – 350 bar) 1,918 cc/min (1.9 l/min)

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MIDI GX100 MTO 2X2 3SR NEO1-COUPLER STD-COUPLERNominal pressure 350 bar

EN-13204 designation MTO

+SMART auto speed regulator with manual override

Standard on GX100 MTO 2x2 3SR +SMART(art. nr. 3742.1122.**)

Running time Ca. 180 Min.

Engine / power supplyHonda 2.1kW

(2.8 HP) 4-stroke petrol

Fuel tank capacity 0.77 liter

EN-13204 noise level at 1 meter distance Lpa 78 dB

NFPA emission sound level at 4 meter distance Not applicable

Dimensions (L x W x H) 424 x 340 x 512 mm (±10 mm)

EN-13204 weight (ready use HF & fuel full)

Excl.SMART speed

regulator

Incl.SMART speed

regulator

Excl.SMART speed

regulator

Incl.SMART speed

regulator28.6 kg (±0.2 kg) 29.5 kg (±0.2 kg) 29.3 kg (±0.2 kg) 30.2 kg (±0.2 kg)

Weight with HF but no fuel 27.9 kg (±0.2 kg) 28.8 kg (±0.2 kg) 28.6 kg (±0.2 kg) 29.5 kg (±0.2 kg)

Dry shipping weight (with motor oil) 24.9 kg (±0.2 kg) 25.8 kg (±0.2 kg) 25.6 kg (±0.2 kg) 26.5 kg (±0.2 kg)

Pump 3-stage radial piston

Totalhydraulicfluidcapacity 3.8 liter

Effectivehydraulicfluidcapacity 2.8 liter

1st stage (0 – 120 bar) 2x 3,200 cc/min (3.2 l/min)

2nd stage (120 – 240 bar) 2x 1,972 cc/min (2.0 l/min)

3rd stage (240 – 350 bar) 2x 986 cc/min (1.0 l/min)

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4.1.2 IMPERIAL SYSTEM DATA

MINI GXH50 STO 1X1 3SR NEO1-COUPLER STD-COUPLERNominal pressure 5,075 PSI

EN-13204 designation STO

+SMART auto speed regulator with manual override

Standard on GXH50 STO 1x1 3SR +SMART(art.nr. 3641.1121.**)

Running time Ca. 180 Min.

Engine / power supplyHonda 1.6kW

(2.1 HP) 4-stroke petrol

Fuel tank capacity 0.20 US gallon

EN-13204 noise level at 1 meter distance Lpa 80 dB

NFPA emission sound level at 4 meter distance Lpa 74 dB

Dimensions (L x W x H) 14 3/4’’ x 11 5/8’’ x 19 1/2’’ (±3/8’’)

EN-13204 weight (ready use HF & fuel full)

Excl.SMART speed

regulator

Incl.SMART speed

regulator

Excl.SMART speed

regulator

Incl.SMART speed

regulator42.1 lbs (±0.4 lbs) 43.2 lbs (±0.4 lbs) 42.4 lbs (±0.4 lbs) 43.5 lbs (±0.4 lbs)

Weight with HF but no fuel 40.6 lbs (±0.4 lbs) 41.7 lbs (±0.4 lbs) 40.8 lbs (±0.4 lbs) 41.9 lbs (±0.4 lbs)

Dry shipping weight (with motor oil) 34.7 lbs (±0.4 lbs) 35.8 lbs (±0.4 lbs) 34.7 lbs (±0.4 lbs) 35.8 lbs (±0.4 lbs)

Pump 3-stage radial piston

Totalhydraulicfluidcapacity 0.79 US gallon

Effectivehydraulicfluidcapacity 0.53 US gallon

1st stage (0 – 120 bar) 3,600 cc/min (0.95 US gal/min)

2nd stage (120 – 240 bar) 1,890 cc/min (0.50 US gal/min)

3rd stage (240 – 350 bar) 945 cc/min (0.24 US gal/min)

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MIDI GX100 STO 1X1 3SR NEO1-COUPLER STD-COUPLERNominal pressure 5,075 PSI

EN-13204 designation STO

+SMART auto speed regulator with manual override

Standard on GX100 STO 1x1 3SR +SMART(art. nr. 3642.1122.**)

Running time Ca. 180 Min.

Engine / power supplyHonda 2.1kW

(2.8 HP) 4-stroke petrol

Fuel tank capacity 0.20 US gallon

EN-13204 noise level at 1 meter distance Lpa 80 dB

NFPA emission sound level at 4 meter distance Lpa 76 dB

Dimensions (L x W x H) 16 3/4’’ x 13 3/8’’ x 20 1/8’’ (±3/8’’)

EN-13204 weight (ready use HF & fuel full)

Excl.SMART speed

regulator

Incl.SMART speed

regulator

Excl.SMART speed

regulator

Incl.SMART speed

regulator58.5 lbs (±0.4 lbs) 60.0 lbs (±0.4 lbs) 58.7 lbs (±0.4 lbs) 60.0 lbs (±0.4 lbs)

Weight with HF but no fuel 56.9 lbs (±0.4 lbs) 58.2 lbs (±0.4 lbs) 57.1 lbs (±0.4 lbs) 58.5 lbs (±0.4 lbs)

Dry shipping weight (with motor oil) 49.9 lbs (±0.4 lbs) 51.2 lbs (±0.4 lbs) 50.1 lbs (±0.4 lbs) 51.4 lbs (±0.4 lbs)

Pump 3-stage radial piston

Totalhydraulicfluidcapacity 1.00 US gallon

Effectivehydraulicfluidcapacity 0.74 US gallon

1st stage (0 – 120 bar) 5,883 cc/min (1.53 US gal/min)

2nd stage (120 – 240 bar) 3,153 cc/min (0.85 US gal/min)

3rd stage (240 – 350 bar) 1,918 cc/min (0.50 US gal/min)

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24 RESQTEC Manual 3SR MINI-MIDI POWER UNIT (DM032K07)

MIDI GX100 MTO 2X2 3SR NEO1-COUPLER STD-COUPLERNominal pressure 5,075 PSI

EN-13204 designation STO

+SMART auto speed regulator with manual override

Standard on GX100 MTO 2x2 3SR +SMART(art. nr. 3742.1122.**)

Running time Ca. 180 Min.

Engine / power supplyHonda 2.1kW

(2.8 HP) 4-stroke petrol

Fuel tank capacity 0.20 US gallon

EN-13204 noise level at 1 meter distance Lpa 78 dB

NFPA emission sound level at 4 meter distance Not applicable

Dimensions (L x W x H) 16 3/4’’ x 13 3/8’’ x 20 1/8’’ (±3/8’’)

EN-13204 weight (ready use HF & fuel full)

Excl.SMART speed

regulator

Incl.SMART speed

regulator

Excl.SMART speed

regulator

Incl.SMART speed

regulator63.1 lbs (±0.4 lbs) 65.1 lbs (±0.4 lbs) 64.6 lbs (±0.4 lbs) 66.6 lbs (±0.4 lbs)

Weight with HF but no fuel 61.5 lbs (±0.4 lbs) 63.5 lbs (±0.4 lbs) 63.1 lbs (±0.4 lbs) 65.1 lbs (±0.4 lbs)

Dry shipping weight (with motor oil) 54.9 lbs (±0.4 lbs) 56.9 lbs (±0.4 lbs) 56.5 lbs (±0.4 lbs) 58.5 lbs (±0.4 lbs)

Pump 3-stage radial piston

Totalhydraulicfluidcapacity 1.00 US gallon

Effectivehydraulicfluidcapacity 0.74 US gallon

1st stage (0 – 120 bar) 2x 3,200 cc/min (0.85 US gal/min)

2nd stage (120 – 240 bar) 2x 1,972 cc/min (0.53 US gal/min)

3rd stage (240 – 350 bar) 2x 986 cc/min (0.26 US gal/min)

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4.2. TECHNICAL DRAWINGS

The technical drawings in this chapter only present actual tool dimensions. Coupler dimensions are excluded from these drawings.

4.2.1 SI-SYSTEM DATA

MINI GXH50 STO 1X1 3SR

MINI GXH50 STO 1X1 3SR +SMART

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26 RESQTEC Manual 3SR MINI-MIDI POWER UNIT (DM032K07)

MIDI GX100 STO 1x1 3SR

MIDI GX100 STO 1x1 3SR +SMART

MIDI GX100 MTO 2x2 3SR

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MIDI GX100 MTO 2x2 3SR+SMART

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28 RESQTEC Manual 3SR MINI-MIDI POWER UNIT (DM032K07)

4.2.2 IMPERIAL SYSTEM DATA

MINI GXH50 STO 1X1 3SR

MINI GXH50 STO 1X1 3SR+SMART

MIDI GX100 STO 1X1 3SR

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MIDI GX100 STO 1x1 3SR+SMART

MIDI GX100 MTO 2x2 3SR

MIDI GX100 MTO 2x2 3SR+SMART

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30 RESQTEC Manual 3SR MINI-MIDI POWER UNIT (DM032K07)

5. MAINTENANCE & STORAGE5.1. GENERAL MAINTENANCE

Generally speaking it is most important is to keep your equipment clean. Clean equipment will not wear down as fast; hence a longer service life can be achieved.

5.2. MAINTENANCE AFTER EACH USE

It is recommended to carry out the following steps after use of your Resqtec power unit.

• Check the general condition of the unit.• Clean and dry the unit and any accessories before storage.•Checkthelevelofhydraulicfluidinthereservoirandrefillifnecessary.•Checktheleveloffuelinthetankandrefillifnecessary.•Checkthelevelofmotoroilintheengineandrefillifnecessary.•Checkforanysignoffluidleakageandcleanifnecessary.• Clean the couplers with a cloth.

CHECK THE UNIT FOR ANY EXTERNAL DAMAGE SUSTAINED DURING OPERATION.

WEAR PERSONAL PROTECTION EQUIPMENT DURING MAINTENANCE. ENSURE THAT THE USED HYDRAULIC FLUID IS COLLECTED AND DISPOSED OF IN A RESPONSIBLE MANNER.

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5.3. REGULAR MAINTENANCE PLAN

Your power unit is equipped with a combined hour-/tacho meter, this registers the amount of hours the unit has been operating (shows when motor is off) and the RPM when in operation.This enables an effective maintenance plan according to usage and helps plan when what maintenance is needed.

Every 3 months or 25 hours•Checkairfilter/cleanerforcontaminationandreplaceifnecessary (article# 3425.0301 for GX100, 3425.0298 for GXH50);•Filterhydraulicfluid(article#prod/servicefilterunit(PB)3800.0180);• Check motor RPM setting and adjust if necessary (should be ±3,250rpm for GX100, ±4,500rpm for GXH50);

Every 6 months or 50 hours• Change motor oil;•Replaceairfilter/cleaner(article#3425.0301forGX100,3425.0298forGXH50);• Check spark plug and clean or replace if necessary (article# 4000.0735 for GX100, 3425.0299 for GXH50);

Every 12 months or 100 hours• Replace spark plug (article# 4000.0735 for GX100, 3425.0299 for GXH50);•Replacehydraulicfluid(ResqtecOPTI-GREENHF-15;5lcanarticle#3801.0305);•GetannualprofessionalmaintenancefromyourResqteccertifiedsupportdistributorformakingsureyourunit is in optimum operational state.

AnnualResqteccertifiedmaintenancecomprehends;•Hydraulicfluidreplacement&systemflush;• Pressure & changeover check and adjustments if needed;• Flow check and repairs if needed;• Full engine maintenance;• Replacement of any worn parts if needed (vibration dampers, footplate, dust caps, sleeves, stickers, etc.);

5.4. MAINTENANCE ON COUPLERS

ThestandardQUICKACTIONCOUPLERSarelubricatedbythehydraulicfluid.Clean,goodworkingcouplingstherefore need not other means of lubrication.

HOUR/ TACHOMETER

1

Check and clean couplers thoroughly.

• Preferably use dry, clean paper cloth.• Mild soapy water can be used if necessary.• Verify smooth operation by connecting and disconnecting al couplings at least three times.

Do not use any additional means of lubrication as some products might have a negative effect on the connector.

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5.5. DRAINING & REPLACING THE HYDRAULIC FLUID

Hydraulicfluidcanbehotafteruse,makesuretheunitiscooleddownpriortodraining&replacingthefluid.Haveanoilsumpready tocatchallfluidoutofthepowerunit,thiscanbeupto4liters.

Remove the drain plug located on the bottom of the carter. BE CAREFUL, HYDRAULIC FLUID WILL COME OUT.

Remove the HF low level indicator.

Remove the drain plug located behind the HF low level indicator.

BE CAREFUL, HYDRAULIC FLUID WILL COME OUT.

MAKE SURE NOT TO DROP THE DRAIN PLUG INTO THE FLUID RESERVOIR.

Removethefillerbreathercapontopofthetank.

1

2

3

4

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Ifapplicable;checkadditionalinstructionsintypespecificQuickReferenceGuide.

When all maintenance is conducted and all checks are found to be satisfactory, the system as a whole should be tested. Connect all components of your system and test all functions and if applicable all accessories. All tools should at least make two complete cycles.

RESQTEC RECOMMENDS THE MAINTENANCE OPERATOR TO BE TRAINED BY A RESQTEC CERTIFIED MAINTENANCE PERSON.

Movetheunitaroundabittomakesureallhydraulicfluidisdrainedfromallcorners.

Reassemble all drain plugs, level indicators and caps.

Refillthesystemwithcleanandnewhydraulicfluidtothenominallevelofthefluidlevelindicator located on the top of the carter tank.

Makesuretheengineswitchis‘OFF’&pullstartergrip5xtopumpthehydraulicfluidoutof the pump.

DO NOT START THE ENGINE!

Makesuretheengineswitchis‘off’andpullstartergrip5timestopumpthehydraulicfluidout of the pump.

DO NOT START THE ENGINE!

5

6

7

8

9

NOMINAL HF LEVEL

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5.6. RECOMMENDED STORAGE

The following storage recommendations count for all 3SR power units:• Store out of direct sunlight• Store the equipment in a dry, well-ventilated area:

ALWAYS LET THE UNIT COOL DOWN BEFORE STORING

5.7. DECOMMISIONING/RECYCLING

Thevariouspartscanbere-usedattheendoftheirservicelife.Collectthehydraulicfluidanddisposeofitseparately.RefertotheMSDSthatwas supplied with your unit and/ or follow local regulations on disposal. The unit consists of steel, aluminum, neoprene (seals) and plastic. The unit does not contain any pressurized components. Consult yoursupplier / distributor for further information on recycling.

5.8. ACCESSORIES AND SPARE PARTS

Tools, accessory-sets and spare parts are available for regular maintenance. Contact your supplier / distributor for the necessary maintenance toolsandtherequiredspareparts.Yoursupplier/distributorcanalsoinformyouonhowtobecomeauthorizedandqualifiedtoconductpropermaintenance on Resqtec tools.

Recommended storage temperature range 10˚C–30˚C/50°F-86°F

Recommended storage relative humidity 0 – 60%

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6. WARNINGS & LIMITATIONS6.1. TEMPERATURE RANGE

The power unit is engineered, tested and approved to be used within an ambient temperature range from -20 °C to +55 °C / -4 °F to +131 °F.

THE HYDRAULIC FLUID AND POWER UNIT COMPONENTS CAN REACH TEMPERATURES ABOVE THIS RANGE.

Withminoradjustmentsanduseofdifferenttypesoffluidsthetemperaturerangecanbeoptimizedforcertainenvironmentswithprevailingtemperature ranges (being extremely cold or warm climates).

6.2. ALTITUDE

The power unit is engineered, tested and approved to be used from sea level to 1,000 m / 3,281 ft. above sea level.

With minor alterations high altitude operation can be increased, this however will result in a slight decrease in output capacity. Contact your local Resqtec representative to get your units optimized for altitudes above 1,000 m / 3,281 ft. above sea-level.

Operation below sea level is not an issue as long as it is on dry surface.

6.3. INCLINED SURFACES

THE POWER UNIT IS ENGINEERED, TESTED AND APPROVED TO BE USED ON INCLINED SURFACES UP TO 20°. IT IS HOWEVER ALWAYS STRONGLY RECOMMENDED TO OPERATE THE UNIT AS LEVEL AS POSSIBLE.

6.4. CONFINED SPACES

WHEN USING THE UNIT INDOORS OF IN CONFINED SPACES, MAKE SURE THERE IS NO POSSIBLE DANGER OF EXPLOSIONS AS SOME COMPONENTS GET HOT AND MIGHT SPARK (EXHAUST). NOTE THAT EXHAUST GASSES CAN ACCUMULATE AND HARM LIVING ORGANISMS, INCLUDING THE OPERATORS OF THE EQUIPMENT AND THOSE BEING RESCUED.

6.5. TAMPERING

TAMPERING WITH PUMP & ENGINE SETTINGS IS NOT ALLOWED AND WILL VOID ANY WARRANTY ON THE UNIT.

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7. WARRANTY

Resqtec offers two years warranty upon the purchase of this product. For extending your warranty or information about the Resqtec service program, please contact your Resqtec distributor/supplier.

WARRANTY IS ONLY VALID IF THE REGULATIONS AND RESTRICTIONS, AS DESCRIBED IN THE USER MANUAL APPLICABLE ON THE USED PRODUCT(S), ARE UNDERSTOOD AND FOLLOWED, AND IF THE MAINTENANCE AS ADVISED IN THE USER MANUAL IS DONE BY AN AUTHORIZED RESQTEC TECHNICIAN. DISREGARDING ANY OF THE APPLICABLE REGULATIONS AND RESTRICTIONS, AS DESCRIBED IN THE USER MANUAL APPLICABLE ON THE USED PRODUCT(S), WILL CAUSE THE WARRANTY TO VOID.

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All rights reserved. No part of this publication whatsoever may be reproduced without the prior written consent of Resqtec.

All information herein was carefully gathered and examined. However, we cannot be held responsible for eventual mistakes or incompleteness. Resqtecmayexercisetherighttochangeormodifypartsoftheequipmentatanytimewithoutnotification.Thismanualmaybesubjecttoerror,revisionandtechnicalmodifications.Fordetailedinformation,andasweconstantlyimproveourequipment,pleasecheckthelatestspecificationsheet. This manual is based on and refers to current production models only. Resqtec accepts no liability for any damage and/or injuries resulting from the use of this manual in connection with any equipment which has been or may be supplied. For any additional information concerning the useofthemanualorthemaintenanceorrepairofResqtecequipment,pleasecontacttheResqtecdistributororanofficiallyappointeddistributor. Utmost care has been taken in the preparation and accuracy of this manual. Resqtec cannot however be held liable for errors,omissions or consequential liabilities in the use of it.

8. DISCLOSURE

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9. CONTACT

ADDRESSES RESQTEC OFFICES

Europeanoffice

Meer en Duin 822163 HC Lisse, the NetherlandsT +31 (0)252 419002F +31 (0)252 411794

E [email protected] www.resqtec.com

USAoffice

300 Forge Way, Suite 2Rockaway, New Jersey, 07866T: +1 973 627 4646F: +1 973 627 4622

Asiaoffice

Lot 5, Jalan Delima 1/1 Subang Hi-Tech Industrial Park47 500 Selangor, MalaysiaT +603 5621 5298F +603 5621 2895

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RESQTEC Zumro B.V.

Meer en Duin 82 2163 HC Lisse, the Netherlands

T +31 (0)252 419002 F +31 (0)252 411794 E [email protected] WWW.RESQTEC.COM