POWER UNIT Operations Manual

PTO-TWIN-ATT & PTO-TWIN-ATT-LP POWER UNIT Operations Manual PTO-TWIN-ATT PTO-TWIN-ATT-LP TNT Rescue Systems, Inc. 2490 West Oak Street Ashippun, WI 53003 920-474-4101 or 800-474-4189 E-Mail: email@tntrescue.com! WARNING! Read This Manual Before Operating Equipment TNT-OM # 7.2.3-051 Rev: 03-14-2016 1/44

INDEX 1) INTRODUCTION 3 2) SAFETY INFORMATION 4 3) BEFORE OPERATION CHECKS 5 4) HYDRAULIC FLUID INSTALLATION 6 5) COUPLER OPERATION 7 6) STANDARD 10,500 PSI COUPLER OPERATION 7 7) FLAT FACE 10,500 PSI COUPLER OPERATION 8 8) COAX 10,500 PSI COUPLER OPERATION 9 9) STANDARD 5,500 PSI COUPLER OPERATION 10 10) NEXUS 5,500 AND 10,500 PSI COUPLER OPERATION 11 11) PRE PUMP OPERATION 12 12) STARTING THE POWER UNIT 13 13) PUMP OPERATION 14 14) TOOL OPERATION 17 15) GENERAL MAINTENANCE 17 16) STORAGE 18 17) DECONTAMINATION 18 18) LIMITATION 18 19) TROUBLESHOOTING 19 20) ROUTINE MAINTENANCE 20 21) MAINTENANCE RECORD 21 22) WARRANTY 22 23) WARRANTY REGISTRATION 23 24) SPEC SHEET PTO-TWIN-ATT 10,500 PSI 24 25) SPEC SHEET PTO-TWIN-ATT-LP 5,500 PSI 25 26) MSDS SHEET 10W-30 MOTOR OIL 26-29 27) MSDS SHEET ISO 68 or 32 HYRDAULIC OIL 30-33 28) MSDS SHEET FIRE RESISTANT HYDRAULIC OIL 34-41 29) NOTES 42-43 TNT-OM # 7.2.3-051 Rev: 03-14-2016 2/44

INTRODUCTION The employees of TNT Rescue Systems, Inc. and your local dealer thank you for selecting our quality products. We want to help you to get the best results from your new rescue equipment and to operate it safely. This manual contains basic information on how to do that; please read it carefully before operating your equipment. Our commitment to you and your equipment begins with quality production and service. All information in this manual is based on the latest product information available at the time of printing. TNT Rescue Systems, Inc. reserves the right to make changes at any time without notice and without incurring any obligation. No part of this publication may be reproduced without the written consent of TNT Rescue Systems, Inc. This manual should be considered a permanent part of the tool, and should remain with the rescue equipment if resold. When you need warranty repairs, your authorized dealer is responsible for taking care of your equipment. Certain repairs could require your equipment to be returned to the factory. In the event your local dealer cannot repair your equipment, the dealer may provide you with loaner equipment until the factory can make the necessary repairs. If you should need customer assistance, parts, accessories, or service, please contact your local dealer: If you cannot reach your local dealer, contact TNT Rescue Systems at: 1-800-474-4189 TNT Rescue Systems, Inc. 2490 West Oak Street Ashippun, WI 53003 920-474-4101 or 800-474-4189 TNT-OM # 7.2.3-051 Rev: 03-14-2016 3/44

!! IMPORTANT SAFETY INFORMATION!! IN THE EVENT OF ANY DAMAGE TO YOUR TNT RESCUE EQUIPMENT, REMOVE THE TOOL FROM SERVICE AND CONTACT YOUR AUTHORIZED TNT SERVICE REPRESENTATIVE Understand the operation of all controls and learn how to stop the engine quickly in case of emergency. Make sure the operator receives adequate instructions before operating the equipment. Do not allow children to operate the equipment. Keep children and untrained personnel away from the area of operation. Your engine s exhaust contains poisonous carbon monoxide. Do not run engine without adequate ventilation, and never run engine indoors. The engine and exhaust becomes very hot during operation. Keep engine at least 1 meter (3 feet) away from buildings and other equipment during operation. Keep flammable materials away, and do not place anything on engine while it is running. Prior to and after each use, the tools, hoses, and connections should be cleaned and inspected for damage. Only trained and qualified personnel should use extrication equipment! Before any operation begins, the object to be worked on must be stabilized. When operating rescue tools always wear a full complement of protective equipment including, but not limited to: Protective clothing covering the arms, legs, and neck Helmet with face shield and eye protection Protective gloves Boots Do not mix 10,500psi hydraulic equipment with 5,500psi equipment. Never reach between the cutter blades, or spreader arms. Do not position yourself between the rescue tool and an object to be worked on. When spreading or cutting, be sure to control all material being moved, avoid creating projectiles. Never disconnect the hoses, couplers, fittings, etc. under pressure. Never cut objects under tension or pressure (ex. shock absorbers, springs, pressurized cylinders). CUTTING THESE AND SIMILAR OBJECTS RISKS INJURY TO THE OPERATOR AND BYSTANDERS FROM PROJECTILE PIECES. Do not cut or crush fuel tanks, lines, or fill hoses. Use caution in cutting, crushing, or spreading as to avoid hazards in vehicle construction such as: air bag controllers and components, seat belt pre-tensioners, and onboard computers. If at any time the cutter twists or rolls, stop cutting immediately and reposition the tool. Not maintaining a 90-degree working angle could result in cutter blade damage. Be sure not to cut any hardened material. Never cut energized electrical cables. Avoid cutting a loose end of materials. The cut portion could become a projectile. If cutting a loose end is absolutely necessary, be sure to secure the loose end. There are no user serviceable parts on your TNT rescue equipment. Damaged hoses or equipment should not be used. Only use TNT Hydraulic fluid in your TNT rescue tools. Do not store rescue equipment under pressure never leave a tool in the fully open or fully closed position. Never leave a working tool unattended. FAILURE TO HEED THESE WARNINGS MAY RESULT IN PERSONAL INJURY, UNNECESSARY PROPERTY DAMAGE AND OR DEATH. TNT-OM # 7.2.3-051 Rev: 03-14-2016 4/44

Before Operation Checks: 1) Remove product from shipping container. 2) Product should consist of ( 1- Power Unit, 1-Gallon of Hydraulic Oil (ISO 68), 1-actual crankcase volume of 10w-30 Motor Oil, and 1- Power Supply Operating Manual) 3) Check for any visual damage (If damage has occurred during shipping please contact carrier.) 4) Be sure to read the engine s owner manual completely before operating the equipment. 5) Remove all dirt or debris, especially around the muffler and recoil starter and couplers. 6) Look around and underneath the power unit for signs of oil or gasoline leaks. 7) Check engine fluid levels. 8) Be sure the control valve is in the neutral position. Control Valve Neutral Position Control Valve Neutral Position TNT-OM # 7.2.3-051 Rev: 03-14-2016 5/44

Hydraulic Fluid Installation: 1) Remove the vent/filler Plug using an 11/16 open end wrench turning counterclockwise. Vent / filler Plug 2) Using a funnel, pour the hydraulic fluid into the vent/filler hole until the proper level is reached on the sight glass. (1/2 3/4 in the sight glass) Sight Glass High Oil Level Low Oil Level 3) Replace vent/filler plug, tighten clockwise securely. TNT-OM # 7.2.3-051 Rev: 03-14-2016 6/44

Coupler Operation: Standard 10,500 PSI Coupler Operation 1) Rotate locking collar counter clockwise until it lines up with pin and pull back to the open position.(see Fig. 1) 2) Insert the male coupler into the female coupler and release the locking collar to the locked position. (See Fig. 2) 3) Pull on couplers to confirm a completed connection. 4) To release, rotate locking collar clockwise to line up with pin and pull back to release the male coupler. Open Position Locked Position Insert Male Coupler Locking Collar Pull Back Rotate Pin Female Coupler Fig. 1 Fig. 2 TNT-OM # 7.2.3-051 Rev: 03-14-2016 7/44

Flat Face 10,500 PSI Coupler Operation: 1) Insert the male coupler into the female coupler until it snaps in the locked position.(see Fig. 1) and (Fig. 2) 2) Pull on couplers to confirm a completed connection. 3) To release, rotate locking collar clockwise until it stops and pull back to release the male coupler. (See Fig. 2) Open Position Locked Position Insert Male Coupler Locking Collar Rotate Pull Back Female Coupler Fig. 1 Fig. 2 TNT-OM # 7.2.3-051 Rev: 03-14-2016 8/44

COAX 10,500 PSI Coupler Operation: 1) Insert the male coupler into the female coupler until it snaps in to the locked position. (See Fig. 1 ) and ( Fig. 2 ) 2) Pull on couplers to confirm a completed connection. 3) Pull back on the leverage collar to release the male coupler. (See Fig. 1) Open Position Locked Position INSERT Male Coupler Leverage Collar Female Coupler Fig. 1 Fig. 2 TNT-OM # 7.2.3-051 Rev: 03-14-2016 9/44

Standard 5,500 PSI Coupler Operation 1) Rotate locking collar counter clockwise until it lines up with ball and pull back to the open position.(see Fig. 1) 2) Insert the male coupler into the female coupler and release and rotate the locking collar clockwise to the locked position. (See Fig. 2) 3) Pull on couplers to confirm a completed connection. 4) To release, rotate locking collar counter clockwise to line up with ball and pull back to release the male coupler. Open Position Locked Position Male Coupler Insert Locking Collar Rotate Pull Back Ball Female Coupler Fig. 1 Fig. 2 TNT-OM # 7.2.3-051 Rev: 03-14-2016 10/44

Nexus 5,500 and 10,500 PSI Coupler Operation: 1) Line up the alignment screws. (See Fig. 1) 2) Insert the male coupler into the female coupler and rotate clockwise until it snaps into the locked position. (See Fig. 2) 3) Pull on couplers to confirm a completed connection. 4) To release, pull back the Locking collar and rotate the male coupler counter clockwise and remove from female coupler, release collar.(see Fig. 2) Open Position Locked Position Male Coupler Rotate Insert Rotate Alignment Screws Locking Collar Pull Back Female coupler Fig. 1 Fig. 2 TNT-OM # 7.2.3-051 Rev: 03-14-2016 11/44

Pre Pump Operation: 1) Before starting the power unit, be sure all the control valves are in the neutral position. (See Fig 1 ) PUMP CONTROL VALVE Neutral Position Neutral Position Neutral Position FIG 1 2) Connect one end of the hydraulic twin line hose to the power unit and the other end to a rescue tool. (See coupler operation for specific coupler being used, pages 7,8,9,10 and 11. 3) BE SURE TO PULL ON ALL COUPLER S TO INSURE A COMPLETED CONNECTION! 4) Once the connections are made, the power unit can be started. TNT-OM # 7.2.3-051 Rev: 03-14-2016 12/44

Starting The Power Unit: 1) Refer to the hydraulic switch box pictured below. Note: the switch locations may vary by unit. 2) Engage Master Hydraulic Switch 3) Engage Rescue Tools 4) This engages the Rescue Tool Circuit. Now we have power to the rescue tool pump. TNT-OM # 7.2.3-051 Rev: 03-14-2016 13/44

PUMP OPERATION 1) Once the rescue tool and hydraulic twin line hose have been properly connected and the engine started, engage the control valves on the power unit to the pressure position to allow the hydraulic oil to circulate through the rescue tool.( Note: Never engage the power unit without a hydraulic hose and rescue tool connected) PRESSURE POSITION (SIMO MODE) Simo Acceleration Simo Control Valve Control Valve Control Valve Pressure Position Neutral Position Pressure Position TNT-OM # 7.2.3-051 Rev: 03-14-2016 14/44

PRESSURE POSITION (ACCELERATION MODE) (RIGHT SIDE) Simo Acceleration Simo Control Valve Control Valve Control Valve Neutral Position Acceleration Position Neural Position NOTE: When using Acceleration mode make sure both Simo control valves are in the neutral position. TNT-OM # 7.2.3-051 Rev: 03-14-2016 15/44

PRESSURE POSITION (ACCELERATION MODE) (LEFT SIDE) Simo Acceleration Simo Control Valve Control Valve Control Valve Neutral Position Acceleration Position Neural Position NOTE: When using Acceleration mode make sure both Simo control valves are in the neutral position. TNT-OM # 7.2.3-051 Rev: 03-14-2016 16/44

Tool Operation: 1) Once the power unit, rescue tool and hydraulic twin line hose have been properly connected and the pump control valve engaged to the pressure position, the tool is ready to operate. 2) Check the operation of the rescue tool by turning the control valve on the tool to the open and closed position.(see the rescue tool operation manual) Fully open and close the rescue tool one to two times to purge any air from the system. 3) The Rescue tool is equipped with a dead man feature. When the valve is released it will return to the neutral position and stop the operation of the rescue tool. 4) Once the use of the rescue tool is done or a tool change is needed, return the control valve on the power unit to the neutral position.(note: TNT hydraulic hoses and rescue tools are equipped with a pressure relieving coupler, disconnecting hoses and or rescue tools with the control valve on the power unit in the pressure position will cause hydraulic fluid to be released to the environment.) General Maintenance: 1) Disconnect hydraulic hose and rescue tool from the power unit before working on any equipment. 2) Visually inspect for loose or missing parts. 3) Check couplers for proper operation and cleanliness. Remove all dirt and debris from dust covers. 4) Check engine oil, change oil per manufacturer s guidelines. 5) Check fuel level, fuel should be changed periodically in order to reduce the chance of fuel problems.(see engine operation manual). 6) Check hydraulic fluid level, fill to ½ to ¾ on the sight glass.(see hydraulic fluid installation, page 6). 7) Run the power unit and operate the rescue tools, check for proper operation of the power unit and rescue tools. 8) Clean the pump by lightly spraying with a silicone based protectant and wipe clean. TNT-OM # 7.2.3-051 Rev: 03-14-2016 17/44

Storage: 1) Never store your power unit and rescue tools under pressure. 2) Always store power unit with fuel valve off. 3) Turn the engine switch to the on position and the choke lever to the on position to be ready for next use. 4) Store your power unit and rescue tools in a clean, dry location. 5) Be sure to store your power unit and rescue tools securely, loose tools can cause serious injury or property damage. 6) Power unit should only be stored in the upright position. 7) Do not store a hot engine in an enclosed compartment. 8) Replace dust covers on couplers. Decontamination: In the event your TNT rescue equipment is exposed to blood borne pathogens, chemicals, hazardous materials, etc., follow your department s standard blood borne/hazardous materials guidelines for equipment decontamination. Limitations: Your TNT rescue equipment is intended for use in automobile extrication. Due to the variety of vehicle construction styles and materials, and the inherent unpredictability of vehicle accidents, please consult your authorized TNT representative with questions regarding the limitations of these tools. The Important Safety Information (page 2) section of this manual provides basic guidelines to help ensure your safety and that of victims, bystanders, and other rescuers. TNT Rescue Systems, Inc. recommends that only trained and qualified personnel operate this equipment. Manufacturers Data: Your TNT rescue equipment is made in the USA. Final assembly and testing of the tool, as well as the manufacture of all major components takes place at the TNT world headquarters in Ashippun, Wisconsin. Feel free to contact TNT directly with any questions, comments, or concerns about your TNT rescue equipment. Troubleshooting: TNT-OM # 7.2.3-051 Rev: 03-14-2016 18/44

PROBLEM CAUSE REMEDY The couplers cannot be connected. 1) There is dirt or debris in the coupler. 2) The system is under pressure. 1) Remove the debris and ensure the couplers are clean. 2) Disengage the pump. The tool does not react when turning the valve to the open or closed position. 1) The power unit is in the neutral position. 2) The power unit is not running 3) The tool is not properly connected. 4) There is an insufficient amount of hydraulic fluid in the power unit. 1) Engage the power unit. 2) Start power unit 3) Ensure that couplers are connected. 4) Fill power unit to the proper level. *Call Your Authorized TNT Distributor For Maintenance And Annual Service Care / Preventative Maintenance.* TNT Rescue Systems, Inc. 2490 West Oak Street Ashippun, WI 53003 920-474-4101 or 800-474-4189 E-Mail: email@tntrescue.com TNT-OM # 7.2.3-051 Rev: 03-14-2016 19/44

Routine Maintenance Schedule: Daily Inspection Visually inspect all tools and components for damage, leaks and general cleanliness. Inspect couplings; insure smooth operation, clean with silicone spray if necessary. Check fluid levels in power unit: Motor Oil Hydraulic Oil Operate the power unit. Run engine and power at least one tool. Allow engine to run until normal operating temperature is reached. Add fuel if necessary. Weekly or after use inspection Visually inspect all tools and components for damage, leaks and general cleanliness. Additionally: Inspect cutter blades, look for debris in yoke area Inspect spreaders for debris in yoke area. Inspect couplings; insure smooth operation, clean with silicone spray if necessary. Check fluid levels in power unit: Motor Oil Hydraulic Oil Operate the power unit. Run engine and power at least one tool. Allow engine to run until normal operating temperature is reached. Add fuel if necessary. Monthly Inspection Visually inspect all tools and components for damage, leaks and general cleanliness. Additionally: Inspect cutter blades, look for debris in yoke area Inspect spreaders for debris in yoke area Inspect couplings; insure smooth operation, clean with silicone spray if necessary. Check fluid levels in power unit: Motor Oil Hydraulic Oil Fuel Operate the power unit. Run engine and power at least one tool. Allow engine to run until normal operating temperature is reached. Change fuel (for optimum performance never use fuel that is more than 30 days old). Clean air filter Clean spark plug, set gap (replace if necessary)- as per engine manual. Annually Inspection Have complete system serviced by an authorized / certified technician Note: Appropriate Personal Protective Equipment should be worn while conducting the above maintenance. Contact an authorized TNT Service Technician if any problems are found at any time. An authorized TNT Certified Service Technician must perform annual service. TNT-OM # 7.2.3-051 Rev: 03-14-2016 20/44

Maintenance Record: DATE SERVICE PERFORMED BY UNIT SERIAL # TNT-OM # 7.2.3-051 Rev: 03-14-2016 21/44

Warranty: TNT-OM # 7.2.3-051 Rev: 03-14-2016 22/44

Warranty Registration Organization Street Address City State County Zip Phone E-mail Contact Title Phone Chief Phone Date Purchased / / Date Placed in Service / / Dealer Model Number Serial Number Power Unit(s) Spreader(s) Cutter(s) Ram(s) Please fax or mail this document to TNT Rescue Systems, Inc. and retain a copy for your records. FAX NUMBER (920) 474-4477 TNT-OM # 7.2.3-051 Rev: 03-14-2016 23/44

PTO-TWIN-ATT 10,500 PSI SPEC SHEET: TNT-OM # 7.2.3-051 Rev: 03-14-2016 24/44

PTO-TWIN-ATT-LP 5,500 PSI SPEC SHEET: TNT-OM # 7.2.3-051 Rev: 03-14-2016 25/44

MSDS Sheet 10W-30 Motor Oil TNT-OM # 7.2.3-051 Rev: 03-14-2016 26/44

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MSDS Sheet ISO 68 Hydraulic Oil TNT-OM # 7.2.3-051 Rev: 03-14-2016 30/44

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MSDS Sheet Fire Resistant Hydraulic Oil TNT-OM # 7.2.3-051 Rev: 03-14-2016 34/44

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NOTES TNT-OM # 7.2.3-051 Rev: 03-14-2016 42/44

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TNT Rescue Systems, Inc. 2490 West Oak Street Ashippun, WI 53003 920-474-4101 or 800-474-4189 E-Mail: email@tntrescue.com TNT-OM # 7.2.3-051 Rev: 03-14-2016 44/44