INSTRUCTION MANUAL-MODEL 2001-UL

I. Major Hazards

• Before operating the 2001-UL all by-standers must be removed from the extrication area.
• The safety valves between the couplers must never be adjusted. In the event a problem develops with the safety valves, contact your local dealer.
• The pumps should never be connected or disconnected when there is hydraulic pressure in the lines.
• The model 2001-UL must only be operated with the non-toxic mineral based hydraulic oil distributed by Holmatro.
• The vehicle or object must be stabilized before beginning any extrication technique.
• When operating the model 2001-UL, the user must always wear protective clothing and eye wear.
• Only trained and qualified personnel are authorized to use the model 2001-UL.
• Side loading or damaged blades can occur if the tips of the model 2001-UL get buttressed against a fixed object when in the cutting mode.

II. Inspection
Check the model 2001-UL for any leakage or other visual damage that may have occurred during shipping. The warranty card should be completed and returned to the address listed. An instruction manual should be included for the model 2001-UL. If a pump is shipped with the model 2001-UL a manual from that engine will be included from the manufacturer, Briggs & Stratton, Robin, Honda or Yanmar. Briggs & Stratton, Robin, Honda and Yanmar offers a one (1) year warranty on the engine. Any problems occurring during the warranty period should be directed to Briggs & Stratton, Robin, Honda or Yanmar directly.

III. Intended Use
The cutter model 2001-UL is designed to cut the frames of light weight vehicles. The model 2001-UL should only be used for light weight extrication procedures. The tool is a one person operated light weight tool, meaning that one person would be able to position, guide and operated the tool without the assistance of another. To facilitate this usage, the tool is equipped with a chrome plated, U-shaped carrying handle which provides and even balance for use of the tool in all positions, even with one hand. It must be stressed, that the model 2001-UL is a light weight tool and therefore some extrication procedures may require the use of additional equipment. For safety purposes the model 2001-L may only be used in conjunction with other Holmatro equipment or equipment of comparable specifications and capabilities.

IV. High Pressure Quick Connect Coupler Requirements
The tool operates with a non-toxic, mineral based hydraulic oil. The tool, hose and pump are equipped with quick connecting couplers for fast and easy operation. The couplers are equipped with locking rings to prevent accidental uncoupling. Dust caps are also provided to protect the couplers when they are not being used. Couplers must possess working pressures up to 14,500 psi (1000 bar) and be non-drip on connection and disconnection. They must be capable withstanding a test pressure of 21,800 psi (1500 bar) and possess a minimum burst pressure of 37,700 psi (2600 bar). Temperature range -40* C to 100* C. Normal flow diameter will be 3mm, allowing for a flow capacity at 58.8 psi (4 bar) of 7 liters/min. (1.56 GPM).

V. Capacities
Holmatro Hydraulic Rescue Tools work on a maximum operating pressure of 10,500 psi (720 bar). The model 2001-UL is fully operational under water to a depth of 50 feet.

The hoses possess a minimum burst pressure strength of at least 20,000 psi (1360 bar), which is two times their working pressure. The hoses are delivered filled with the proper grade of non-toxic mineral based hydraulic oil. For maximum safety of the operator, only non-toxic mineral based hydraulic oil should be used. Phosphate ester fluid or similar toxic fluid substitutes must never be used. If the user is unsure as to whether a certain fluid is acceptable or not, they should contact their local dealer.

The model 2001-UL has a wet weight of 26.4 pounds (12 kg). The width of the model 2001-UL including the carrying handle is 8 3/4 inches (220 mm).

The blades of the tool are fabricated of drop-forged hi-grade tool steel, hardened for durability. Their blades are constructed with a recess in the cutter edge in order to cut steel rods up to 13/16" diameter. See warning label on model 2001-UL for maximum cutting capacities on specific materials.

Re-grinding may only be performed by Holmatro, Inc. All moving parts are concealed with special covers designed to protect the user. These special covers should never be removed or adjusted. Internal and external aluminum parts of the tool that are susceptible to wear or corrosion are protected by anodization to provide maximum durability.

Holmatro tools are compatible with other tools manufactured by Holmatro. For safety reasons Holmatro tools should only be used with other Holmatro tools and accessories, or tools and accessories provided they are manufactured to comparable specifications and capabilities.

VI. Preparing For Use

Note: Before connecting pumps, be sure the hydraulic lines are not under pressure. The high pressure hoses and the valve block of the pump are equipped with a quick connect lock-able coupler.

A. To Connect The Pump:

The high pressure hoses should be connected as follows: remove the dust caps; pull back the ‘C' ring (retaining ring) of the female coupler ‘A' and push in the male coupler ‘D' of the pump unit releasing the ‘C' ring. Lock the couplers by turning the ‘B' lock ring against retaining ring ‘C' to prevent the hose from disconnecting inadvertently. In the event the connection is not done properly, oil will leak between the couplers and the equipment will not operate at its full capacity. Snap the dust cap together to protect the quick disconnect coupler against dust or dirt. Dust or dirt can damage the oil seals or other sealing parts of the tool. Over time, if dust or dirt is allowed to remain in the tool, its working capacity will be severely diminished. Connect all other couplers in the same manner as previously described.

After connecting the model 2001-UL to the pump, check the operating by activating the pump and turning the deadman handle into the open position. The cutter blades should open when the deadman handle is activated. In the closed position, the blades should close. Once the deadman handle is released, it should return to the neutral position. The deadman handle is activated by twisting the rotary handle, located at the base of the tool. When the deadman handle is released, it should return to the neutral position automatically. The deadman handle provides one handed control for cutting . The deadman handle is located in such a way that it can be operated, guided and supported easily by right and left handed operators without having to change the position of the hands. Check for visible oil leaks from the couplers. If oil has leaked from the couplers, recheck the oil level.

B. To Disconnect The Couplers

The pump control valves should be put in the neutral or release position to prevent the oil from traveling through the hoses to the equipment. If a relief valve is present, it should also be opened. Disconnect the high pressure hoses according to the following procedure: detach the dust caps, and turn lock nut ‘B' as far away from ring ‘C' as possible: pull ring ‘C' back and at the same time disconnect the couplers. Under no circumstances should the hydraulic lines be disconnected while under pressure.

WARNING: In the event a coupler is not connected properly, a safety valve will be activated. Under no circumstances should the safety valve between the couplers be adjusted. Any repairs or alternations must be performed by an authorized distributor, dealer or manufacturer of Holmatro Rescue Tools.

VII Functions of the Model 2001-UL

Cutting
The cutting force in the recess (C1) is no less than 63,400 lbs. (28,800 kg), and the cutting force in the middle of the blade teeth (C2) is no less than 41,000 lbs. (18,600 kg). The blades are developed for cutting the framework of vehicles, i.e., door posts, support pillars or rods. In emergencies, the nader bolt or similar sized bolts can be cut with the special recess located at the base of the blade. However, such repeated action will cause permanent damage to the blade or tool. When cutting, the operator must be on level ground and the tool must not be allowed to twist during operation. Place the model 2001-UL, blades open at right angles to the object being sheared, then close the blades. The blades will create an even cutting action. Make sure that the blades remain 90 degrees to the material. In the event the tool twists rapidly, stop immediately and take another position. If the user continues with twisted blades the blades will become permanently damaged. If the tip of the blade hits a fixed object when cutting, take another bite or side-loading will occur. Side-loading will not only damage the equipment but it is also dangerous to the user. If the tool is used to cut the ‘B' post, it should never be done through the seat belt harness reinforcement plate. Cutting through the seat belt harness area will damage the tool and blades and may shear pieces of metal

Diagram of Blades at 90 Degrees
Side loading of the blades is a situation that can severely damage the tool and break the blades. Side loading of the blades is not a warranty item; it is a result of misuse. Side loading of the blades can happen in two ways.

The first is caused by allowing metal, from the object being cut, to get between the blades and separate them. This metal creates a "wedge" effect that will damage the blades. If the operator sees that metal is about to get between the blades, STOP. Reposition the blades and resume cutting. Sometimes trying to cut too much material will force metal between the blades. If this happens, make smaller cuts to prevent damage. The material being cut must be secured to prevent twisting.

The second will occur when the cutter's blades are not kept perpendicular to the object being cut. When this happens, the blades begin to twist around in a motion that will make them seem parallel to the object. This twisting motion can separate the blades and cause damage. When cutting an object, if the blades begin to twist, STOP. Reposition the blades to a 90* angle with the object and finish the cut.

Side loading of the tool is a situation that can severely damage the tool, specifically the piston rod, cylinder, and blades. Side loading of the tool is not a warranty item; it is a result of misuse.

Side loading of the tool happens when the operator is performing an operation and the rear of the tool hits a firm object. If the operation is not stopped immediately, the blades can be cracked or broken, the piston can be bent, or the couplings can be snapped off. If the operator sees that the back of the tool is coming close to a fixed object, it is their responsibility to reposition the tool and continue the operation.

Maintenance
Check the model 2001-UL blades for visible cracks or distortions before and after each use. Check the deadman handle to make sure it is fully operational. Once the deadman handle is released, it should return to the neutral position. Clean the couplers with a silicone based lubricant or compressed air. If the couplers are not properly cleaned the internal seals will be damaged. If dirt is found in the system, the whole system should be flushed out immediately. The model 2001-UL should not be reused until it has been properly cleaned the internal seals will be damaged. If dirt is found in the system, the whole system should be flushed out immediately. The model 2001-UL should not be reused until it has been properly cleaned. Ensure that the lock rings are in proper working order. The dust caps must be cleaned with a silicone based lubricant or compressed air after each use. The model 2001-UL must be stored with partially closed blades. With the pump running and pressure to the tool, open the blades. Operate the handle to close the blades just until they overlap. Release pressure at the pump. Disconnect the cuter and place the dust caps over the couplers on the cutter. All of the bolts should be securely fastened. If they are not securely fastened, the tool should be sent to the local dealer for repairs. Any loose bolt must be tightened by the dealer and the user should not attempt to fix it.

The hinge parts and blades must be greased at least every six months or more frequently if used under water, or in wet or dusty conditions (SEE WARNING LABEL). The hydraulic mineral based fluid needs to be replaced a least once a year. Check for oil leakage between the couplers. If leaking occurs, contact your dealer for instructions, do not attempt to adjust the safety valves. After using the model 2001-UL under water, have authorized Holmatro dealer rinse with clean water and grease the pivotal parts with ‘Never-Seize" lubricant. External parts inside the deadman's control should be smeared with white lithium grease.

VIII. Safety Requirements
Compliance with all of the instructions set forth in this manual is necessary for the safe and proper operation of Model 2001-UL. If the purchaser elects to use non-Holmatro equipment, parts or accessories in conjunction with Model 2001-UL (provided they are compatible), purchaser assumes all risks related to such use, including, but not limited to, all safety issues. Holmatro makes no representation or warranty as to the safety of the use of such non-Holmatro equipment, parts or accessories in connection with Model 2001-UL. If the purchaser fails to strictly observe each and every one of the obligations set forth in this manual or if the purchaser fails to use any equipment, parts or accessories specified to be used by Holmatro in conjunction with Holmatro Model 2001-UL, then the purchaser agrees to defend, indemnify and save Holmatro harmless from any liability or obligation, including the costs and attorney's fees related thereto, incurred by Holmatro as a result of persons being injured or property being damaged, directly or indirectly, in connection with the operation of Model 2001-UL or related parts and accessories.

IX. Trouble Shooting

Problem: The couplers on hoses cannot be connected.
Solution:

1. Loosen lock nut B.
2. The hose is pressurized; open the relief valve on the pump.
3. Use relief tool on hoses.

1. Check the coupler connections.
2. Check the pumps:
   • change over-valve position
   • relief valve
   • oil level

1. Check all couplers to make sure they are properly connected. The safety valve should not be adjusted.

1. Check for visual distortions to the handle. If damaged, contact your local dealer.

Repairs
Repairs may only be made by qualified persons authorized by Holmatro. The sealed parts can only be disassembled by an active and presently authorized Holmatro dealer. If other problems occur, contact your dealer for further advice. In the event you are unable to contact your dealer, write Holmatro at:

Holmatro, Inc.
1110 Benfield Boulevard
Millersville, Maryland 21108
Fax: (410) 987-1638

In the event back-up equipment is unavailable and an extreme emergency occurs, phone Holmatro at (410)-987-6633 from 8:30 am to 5:00 pm EST. Inquiries should be directed to the customer service department.