breaching system operation and maintenance...

Breaching System Operation and Maintenance Manual

www.con-space.com

SearchCam® Breaching System Operations Guide

This page is intentionally left blank.

7000-01-013 R03

TABLE OF CONTENTS

www.con-space.com

TABLE OF CONTENTS

OVERVIEW ...................................................................................... 5Breaching System Kit Contents .................................................................................6

SAFETY PRECAUTIONS ....................................................................... 7

SYSTEM SETUP ................................................................................ 8Attaching the Water Collar ........................................................................................8Attaching a Bit ...........................................................................................................9Using the Cooling Water Tank .................................................................................10

ENGINE OPERATION ..........................................................................11Fueling the Engine ...................................................................................................11

Fuel Mixture Guide ..........................................................................................11Starting the Engine ..................................................................................................12Stopping the Engine ................................................................................................14

Normal ............................................................................................................14Emergency ......................................................................................................14

Adjusting the Engine ...............................................................................................15Idle Speed Adjustment ....................................................................................15High Speed Adjustment ..................................................................................17Throttle Stop Adjustment ................................................................................18

CORING BITS ..................................................................................19Diamond Segment Coring Bits ................................................................................20

Self-Sharpening Feature ..................................................................................20CON-SPACE's Bit Advantages .........................................................................21

Carbide Coring Bits .................................................................................................23

BREACHING OPERATIONS ...................................................................24Safety ......................................................................................................................24

System Setup Checklist ..................................................................................24Fueling Precautions .........................................................................................25Protective Gear ...............................................................................................25Exhaust Precautions .......................................................................................25

GENERAL DRILLING OPERATIONS .........................................................26Drilling Tips .............................................................................................................27Bit Orientation .........................................................................................................28Drilling with the Diamond Bit ..................................................................................29

Water Usage with the Diamond Bit..................................................................29Encountering Rebar and Other Materials ........................................................30

Drilling with the Carbide Bit ....................................................................................31Cutting Roofing Material .................................................................................31


www.con-space.com

SYSTEM MAINTENANCE .....................................................................32Routine Maintenance ..............................................................................................32

Fuel System ....................................................................................................32Fuel Filter ........................................................................................................32Air Filter ..........................................................................................................32Ignition System ...............................................................................................33Water Collar ....................................................................................................33Engine Hardware .............................................................................................33Engine Cylinder ...............................................................................................33

CORING BIT MAINTENANCE .................................................................34Diamond Bit ............................................................................................................34Carbide Bit ..............................................................................................................34

SYSTEM STORAGE ............................................................................35

BREACHING SYSTEM SPECIFICATIONS ...................................................37Engine .....................................................................................................................37Spindle ....................................................................................................................37Weight.....................................................................................................................37Water Tank ..............................................................................................................37Bits ..........................................................................................................................37Spindle Extension (Optional) ...................................................................................37

WARRANTY ....................................................................................38Exclusions ...............................................................................................................38Relief .......................................................................................................................38Obtaining Warranty Service ....................................................................................38Disclaimer ...............................................................................................................38

SERVICE ........................................................................................39Service Centres .......................................................................................................39

POWER HEAD PARTS LIST ..................................................................40Engine .....................................................................................................................40Air Filter / Fuel Tank.................................................................................................41Transmission...........................................................................................................42Throttle Assembly ...................................................................................................43

5 www.con-space.com

OVERVIEW

OVERVIEWThe SearchCam® Breaching System is designed to penetrate most common construction materials quickly and efficiently. The system was developed to support the SearchCam® 3000 and SearchCam® 2000, Recon II and Mongoose Victim Location Systems with rapid searches of void spaces in collapsed buildings, but the system can be used for any application at the rescue scene where holes are needed quickly.

No other single drilling tool can provide the speed and versatility of the SearchCam® Breaching System. With the combination of the diamond and carbide bits, the system can breach reinforced concrete, wood, and sheet metal, as well as other material found at the rescue scene.

The system is designed with the real world in mind and many rescue professionals have contributed to its design. Therefore, you should find the system easy to operate and extremely user-friendly. This manual will help you learn how to operate the system in a safe and proper manner. Please read this manual completely before operating the system. If you have any questions about the operation of the system, or have comments on how we can improve the product, please call CON-SPACE Communications at 800-546.3405 or 604-244-9323.

(Handle May Not Be As Shown)

6www.con-space.com


Breaching System Kit Contents

The SearchCam® Breaching System is shipped in a protective transport case partially disassembled. The kit includes:

(1) Hitch Pin


(2) Carbide Coring Bits

(1) Water Collarwith Copper Washer

(1) Water Cooling Tankwith Hose*

(2) Diamond Coring Bits

(1) Motor

7 www.con-space.com

SAFETY PRECAUTIONS

SAFETY PRECAUTIONSRescue operations can be very hazardous. All safety practices must be understood and adhered to while working at the rescue scene.

• Always wear the level of personal protective equipment appropriate for the conditions at the rescue scene. Do not attempt any rescue operation if you do not have the training and experience to safely perform the rescue.

• Vision and hearing protection should always be worn when operating the Breaching System. Do not wear loose clothing that can get caught in the rotating parts of the system. Gloves should be worn when handling the bits to avoid cuts from the sharp edges.

• The Breaching System will conduct electricity. Electrocution can occur if you contact a live power line with the bit. It is your responsibility to ensure that all power sources in the collapse area are disconnected.

• Do not use the system in any flammable atmosphere. Always verify that the atmosphere is clear of any flammable gases or liquids before operating the system. The drill bits can easily cut through gas lines, which can result in the release of flammable gas into the atmosphere. It is your responsibility to ensure that all potential fuel sources are disconnected and properly secured. Failure to take these precautions could result in an explosion.

• The Breaching System is gasoline-powered. Always handle and store gasoline with caution. Gasoline vapors can travel unnoticed into low areas and can be absorbed by clothing. Gasoline fires are very difficult to control and spread rapidly. Keep a fire extinguisher ready when fueling the system. Never fuel the system when the engine is hot. Clean any spilled fuel from the engine before starting. Fuel the engine away from the area of operation. Do not store the system with fuel in the tank.

• Gasoline-powered equipment produces harmful exhaust gases. Use the system in well ventilated areas only. If the system is used in a confined space, forcibly ventilate the space with fresh air. If forced ventilation is used, continuously monitor the carbon monoxide level in the atmosphere. Dangerous levels of carbon monoxide will accumulate within minutes if the system is used in confined spaces.

• The Breaching System is a powerful machine that produces high torque. Maintain good balance and a secure footing when drilling. If the bit gets stuck in the material being drilled, additional and unexpected torque will be momentarily transmitted to the operator before the clutch disengages.

• It is your responsibility as the operator of the SearchCam® Breaching System to operate the system in a safe manner. Adequate training and judgement are necessary to reduce the inherent risks in the rescue environment.

8www.con-space.com


SYSTEM SETUPThe SearchCam® Breaching System is packed into the transport case partially disassembled and must be assembled in order to operate.

Attaching the Water Collar

The water collar performs two functions: it provides a method of attachment for the various coring bits available for the system and allows for cooling water to be delivered to the spinning diamond bit. The system cannot function without the water collar; therefore, it is imperative that the collar be installed and maintained properly.

1. Place the water collar on the output shaft of the power head.

2. Align the locking pin bore in the output shaft of the power head to the bore in the water collar input socket.

3. Pin the collar to the shaft using only the spring lock pin provided with the system. This pin is clipped to the left side of the locking pin. Any other type of pin may become unlocked during operation causing the power head and water collar to separate.

Water Collar

Output Shaft

Align the lockingpin bores and pin the collar to the shaft using the spring lock pin


9 www.con-space.com

SAFETY PRECAUTIONS

Bit

Water Collar

Copper Washer

Attaching a Bit

Note: Before attaching a bit, make sure that you are selecting the correct bit for the task. Refer to the section entitled “Coring Bits” in this manual before performing the following steps.

1. Select the proper bit for the coring application.

2. Place the copper washer onto the threaded shaft of the water collar and hand-thread the bit to the right. Ensure that the bit seats firmly against the copper washer and that the washer is seated against the shaft shoulder. The washer should be tight between the bit and the shoulder of the shaft. A small amount of lubricant applied to the threads of the bit will assist in installation of the bit. The purpose of the copper washer is to absorb shock transmitted to the water collar shaft by the bit during coring operations. The washer will aid in removing the bit from the collar shaft after use. The system may be operated without the copper washer installed; however, bit removal may require a significant amount of effort.

10www.con-space.com


Using the Cooling Water Tank

If concrete coring is planned, the cooling water tank should be filled, pressurized, and the hose connected to the water collar. If the carbide wood bit is selected, water should NOT be used. Water will cause the wood to swell, locking the bit in the material. Cutting operations are covered in greater detail in the section entitled “Breaching Operations” in this manual.

Water Tank

Connect toWater Collar


11 www.con-space.com

SYSTEM STARTUP

ENGINE OPERATION

Fueling the Engine

The power head of the SearchCam® Breaching System is a two-stroke engine. Two-stroke engines require a mixture of lubrication oil and gasoline for fuel. The oil in the fuel provides the only lubrication of the internal components of the engine. Improper fuel mix will lead to rapid engine failure.

The fuel mix should consist of 1 part two-cycle oil to 25 parts gasoline. Always use fresh fuel mix when fueling the Breaching System since contaminants can build up in the tank and foul the fuel system. Contaminated fuel is the most common maintenance problem with all two-stroke engines. Virtually all fuel system problems can be eliminated by always using clean, fresh fuel, and by draining and purging the fuel system after each use.

Only prepare the amount of fuel mixture needed for each period of operation. Do not leave the fuel mixture in the container for prolonged periods.

Fuel Mixture Guide

GASOLINE TWO-CYCLE OIL

US Gallon US Ounce

1 2.56

2 5.12

5 12.8

Liter CC

5 100

10 200

25 500

To fuel the Breaching System, remove the fuel cap and add fuel to the tank. The tank should only be filled to about 3/4 capacity to allow for fuel expansion. The fuel capacity of the tank is 32 oz. (1 Liter).

Do not attempt to fuel the engine while the engine is running. Do not remove the fuel cap while the engine is running. Engine vibration will cause the fuel to splash out, which could ignite.

12www.con-space.com


Starting the Engine

Perform the following steps for reliable starting when the engine is cold. The Breaching System can be started in any position; however, it is usually easier to lay the system on its side with the throttle up.

1. Open the fuel valve at the bottom of the fuel tank.

2. Prime the carburetor using the priming bulb until a few drops of fuel come out of the drain tube.

3. Set the choke in the “closed” position.

Fuel Valve

Choke set to closed position

Priming Bulb


SYSTEM STARTUP

4. Place the throttle at the one half open position and lock using the locking button on the throttle grip.

5. Switch the ignition switch to “start”.

6. While holding the unit firmly, pull the starter handle until you meet resistance, then pull quickly with a short, sharp stroke. Repeat until the engine fires.

7. Once the engine fires, move the choke to the “open” position.

8. Continue pulling the starter handle until the engine starts. Once the engine is running, allow it to run at high RPM for about five minutes to completely warm up the system. Once warmed up, the unit is ready for use.

Throttle at onehalf open position

Locking Button

Choke set to open position

14www.con-space.com


Stopping the Engine

NormalNormal engine shut down is accomplished by first allowing the engine to cool at idle speed for about five minutes and then closing the fuel tank valve. The engine will quickly run out of fuel and shut down. Once the engine has shut down, move the ignition switch to “stop”.

Normal shut down allows the fuel to be removed from the carburetor and prevents flooding during restarting.

EmergencyEmergency engine shut down is accomplished by switching the ignition switch to the “stop” position. This will cause the engine to stop immediately.

Switch to “STOP”

Fuel Valve

Switch to “STOP”


SYSTEM STARTUP

Air Filter Cover

Adjustment screws located behind air filter

Adjusting the Engine

Each SearchCam® Breaching System is tested and adjusted at the factory. However, differences in elevation and quality of fuels may require the engine to be slightly adjusted for optimum performance.

All adjustments should be made with the engine warmed up and the water collar and bit installed. The three adjustments on the carburetor are the idle speed adjustment, the high speed adjustment, and the throttle stop. When adjusting the engine, always wear hearing and vision protection. In addition, because the body will be very close to the rotating parts of the system, do not wear loose fitting clothing that may get caught in the rotating parts of the Breaching System.

Adjustment of the engine requires a moderate level of mechanical skill. A two-stroke engine mechanic should be consulted if the operator does not possess adequate skills.

Idle Speed AdjustmentThe idle speed adjustment screw is a needle valve that changes the fuel flow through the carburetor at low speeds. Adjust the screw labeled “L” (or with white limit cap installed) to obtain the best idle when the throttle is closed.

1. Remove the air cleaner cover to allow access to the adjustment screws.

16www.con-space.com


2. Position the system upright with the bit off the ground.

3. Start the engine and allow the engine to warm up.

4. Once the engine is warm, release the throttle and allow the engine to idle.

5. Adjust the screw in either direction to obtain the best idle. The bit should not turn when the engine is at idle.

6. Once the best idle is attained, run the engine at high RPM for a couple of minutes and then allow it to return to idle.

7. If necessary, readjust the idle to achieve the best idle without bit rotation at idle speed.

Idle Speed AdjustmentHigh Speed Adjustment


SYSTEM STARTUP

High Speed AdjustmentThe high speed adjustment screw is a needle valve that changes fuel flow through the carburetor at high speeds. Adjust the screw labeled “H” (or with red limit cap installed) to obtain the best engine performance at maximum RPM.

Note: The High Speed Adjustment screw is located with the Idle Speed Adjustment screw. The same procedure applies with regards to accessing both adjustment screws.

1. Remove the air cleaner cover to allow access to the adjustment screws.

2. Position the system upright with the bit off the ground.

3. Start the engine and allow the system to warm up.

4. Once the engine is warm, squeeze the throttle and allow the engine to run at maximum RPM.

5. Adjust the screw so that the engine appears to have reached its highest RPM.

6. Once the engine is at its highest RPM, the screw should be turned back 1/8 to 1/4 turn to bring the engine off the high RPM. The goal is to adjust the engine so that maximum RPM is reached and set the adjustment so that the engine is running slightly below maximum RPM.

The exhaust gas from the engine should be visible with a slight blue tint. Squeeze the throttle a few times to vary the RPM from low to high speed to verify that the engine speed accelerates smoothly. If the engine appears to run smooth, shut down the engine and replace the air cleaner cover.

18www.con-space.com


Throttle Stop Adjustment

Throttle Stop AdjustmentThe throttle stop adjustment changes the position of the throttle stop. Turning the screw clockwise increases engine RPM at closed throttle. Turning the screw counter-clockwise decreases engine RPM at closed throttle.

This is a mechanical adjustment to the throttle position in relationship to the throttle cable. It is used to allow fine adjustments to the throttle cable after the throttle cable has been repaired or replaced. Use this adjustment to fine tune throttle position after the throttle cable has been replaced or stretched by age. Do not use this adjustment to set the idle speed.


SYSTEM STARTUP

CORING BITSThe SearchCam® Breaching System is designed to breach most common construction materials quickly and easily. Each system is equipped with two types of coring bits specifically designed for the system:

The Diamond Segment Coring Bit and Carbide Coring Bit provide the ability to core through most construction materials. Each bit is designed to handle different types of materials and each has specific characteristics that should be understood to maximize cutting speed and bit life.

The standard diameter of the bits supplied with the system is two inches. The system includes two-inch bits since the minimum diameter access hole required for the SearchCam® 2000 SearchCam® 3000 Victim Location System is two inches (5 cm). Using only the smallest diameter needed for the SearchCam® allows the fastest drilling possible.

The SearchCam® Breaching System is capable of powering bits up to four inches (10 cm) in diameter. The bits can drill through material up to 17 inches (43 cm) thick. Optional 12-inch (30 cm) long spindle extensions are available to the allow the system to drill deeper. Up to three spindle extensions can be used, which will allow the system to drill to a total depth of 53 inches (1.3 m).

Diamond SegmentCoring Bit

Carbide Coring Bit

20www.con-space.com


Diamond Segment Coring Bits

Diamond Segment Coring Bits are designed to cut through very hard materials such as concrete, masonry, and even stone. These bits require water for cooling and to promote diamond exposure during coring.

Diamond core bits are constructed of four components: the diamond, the bond matrix, the weld joint, and the core. The diamond abrasive is the actual cutting tool consisting of very small industrial grade diamond material. These diamonds are held in a usable form by the bond matrix and the matrix is cast into the size and configuration desired for the bit. The steel core provides a heat sink to dissipate the heat generated by the cutting process and provides a means to couple the bit to the power head. The weld joint is the method of attaching the cast diamond bond matrix to the core. With coring bits, the weld joint is silver solder and on dry diamond saw blades the joint may be laser welded.

Self-Sharpening FeatureThe diamond bit is unique in the fact that as the bit is used, it actually resharpens itself.

A single diamond particle contains cleavage planes. These cleavage planes are weaker defects that run throughout the diamond. As the diamond becomes dull during the cutting process, continued pressure from the cutting operation causes the diamond to fracture on these cleavage planes exposing a fresh sharp edge. The diamond particle is exposed to continue the cut.

Since there are thousands of diamond particles embedded into the bond matrix, the bit will continue to cut as effectively as when it was new until the bond matrix is consumed.

Cooling water must always be used with the diamond coring bit for two reasons. The water provides a method to cool the bond matrix to prevent the silver solder from melting, which would allow the matrix to separate from the core and destroy the bit. The water also contributes to the bit sharpening process by mixing with cut material to form a slurry. This slurry of water and concrete dust is very abrasive and grinds away the bond material to free new diamond particles.

As the diamond particles break off, the matrix material wears

exposing new diamond particles

Diamond Particles

Matrix Material


SYSTEM STARTUP

If used improperly, the matrix material can become

glazed over preventing diamond particles from

being exposed.

Diamond Particles

Glazed Over

Matrix Material

There are some diamond blades that do not require water during cutting. These tools use the laser welding method to attach the bond matrix to the core and since the laser weld will not melt at the temperatures generated during dry cutting, the matrix remains undamaged. However, since the water slurry is not available to aid in freeing the diamond particles, the cutting process can be slower with dry diamond tools. There are very few dry coring bits manufactured and these are much larger in diameter than what is needed for the SearchCam®. Dry bits may also be used with cooling water without problems.

CON-SPACE's Bit AdvantagesThe diamond bits used in the SearchCam® Breaching System are custom designed to cut very fast through a wide variety of concrete. These bits will cut through steel reinforcing bar (rebar) embedded within reinforced concrete. The bond matrix segments are spaced close together to facilitate cutting through steel cable used in tensioned concrete structures. If the bit segments are spaced too far apart, the individual cable strands can catch on the segment edges causing them to break off the bit. Coring speed will be reduced somewhat as the bit cuts through the steel.

The SearchCam® Breaching System diamond bit employs a “thin kerf” design to allow higher pressure to be applied to the cutting surface, which increases the coring speed of the bit. Some sacrifice in bit usable life is made for the higher coring speed, but this is minimal. The cutting speed of the SearchCam® Breaching System diamond bit

Glazing

The cooling water also prevents the bit from “glazing”. If the matrix material heats to extreme temperatures, the surface of the material can harden. While the diamond particles wear and break away, the matrix material does not, preventing the bit from sharpening itself. If the bit becomes “glazed”, it must be cleaned by properly drilling with cooling water into concrete or another highly abrasive material.

22www.con-space.com


will vary depending on many factors. These factors include the type and size of the aggregate used in the concrete, presence and placement of “rebar”, cooling water flow, and operator experience. Under real conditions in non-reinforced concrete, coring speeds averaged three inches (8 cm) per minute. Diamond bit life will be influenced by the same factors that govern coring speed. The SearchCam® Breaching System bits have an estimated life of 600 inches (15 m) in concrete under “average” conditions. This is 150 holes through a typical four inch thick concrete slab.

While the diamond bits that are packed with the SearchCam® Breaching System have been optimized for use with the system and will provide the fastest coring speeds obtainable, it is not necessary to use only SearchCam® diamond bits. Any diamond bit with a proper threaded collar of 1 1/4” - 7 TPI that does not exceed four inches (10 cm) in diameter will function with the system.


SYSTEM STARTUP

Carbide Coring Bits

The SearchCam® Breaching System is unique in the fact that it allows rescue teams to breach most common construction material with only one system. The carbide coring bit provides this versatility, allowing the system to bore through wood, nails, sheet metal, and roofing material. Water should not be used when coring with the carbide bit. If water is used during the coring of wood, the water will cause the wood to swell, trapping the bit in the wood.

The carbide bit is constructed similarly to the diamond bit and consists of four components. The core and weld are identical to the diamond bits. The bond matrix holds the carbide fragments in place just as the bond holds the diamond abrasive in place in the diamond bit. The main differences between the two bits are in the type and size of the abrasive material.

Carbide belongs to a class of metals that are very hard, although not as hard as diamond. Various grades of carbide are used on thousands of different types of cutting tools around the world. Carbide retains a sharp cutting edge many times longer than other types of cutting steel and therefore is ideal for rescue work.

The carbide bit used in the SearchCam® Breaching System is somewhat different than other carbide cutting tools. The carbide is fragmented into small, irregular shapes. These fragmented pieces are then cast into the size and configuration desired for the bit. Then the carbide and bond matrix is attached to the core by the silver solder. If this sounds like the construction process for a diamond bit, it is. The main difference is that the cable fragments are about 100 times larger than the diamond fragments. The construction of the carbide bit provides a very important advantage to cutting holes at the rescue scene: it is very durable. Because the carbide fragments are arranged randomly, each individual fragment tracks through the material at a different point on the circumference of the cut. Since there are hundreds of these carbide cutting points within each bit, the bit can cut effectively even with many points damaged.

Cutting speed and bit life of the carbide bit are similar to that of the diamond bit. As with the diamond bit, the material being cut will have the greatest impact on bit life and cutting speed. Coring through lumber with no nails will be much faster and easier on the bit than coring through a 40 year old built-up roof.

24www.con-space.com


BREACHING OPERATIONS

Safety

Operating the SearchCam® Breaching System is very similar to operating any other type of power equipment. Safe operation is the most important consideration when using any power tool. The SearchCam® Breaching System is a powerful machine that must be used properly to ensure the safety of the operator, other team members, and any potential victims.

System Setup ChecklistBefore beginning any breaching operation...

• Review the SearchCam® Breaching System setup instructions

• Make sure the unit is assembled properly

• Make sure the water collar is securely attached with the locking pin installed

• Verify that the water collar spins freely

• Make sure the bit is appropriate for the material being cored

• Make sure the bit is tight against the shoulder of the water collar spindle and that the copper washer is between the bit and the spindle shoulder


BREACHING OPERATIONS

Fueling Precautions• Fill the fuel tank with fresh fuel mix

• Move the fuel container away from the starting area

• Wipe off any spilled fuel from the system. DO NOT attempt to start the system will spilled fuel on the engine. The engine can easily ignite spilled fuel causing a serious fire

• Whenever possible, start the engine away from the area where the system was fueled

• Store extra fuel and any equipment used during fueling away from the actual work area

NOTE: Do not to use synthetic oil in the oil/gas mixture as this will inevitably cause the power unit to seize.

Protective GearAll persons working around or with the SearchCam® Breaching System should wear personal protective equipment.

• The minimum equipment needed to safely operate the SearchCam® Breaching System are eye and ear protection, and gloves should also be worn

• Head protection is required whenever working in areas where there is a danger of falling objects

• Do not wear excessively loose clothing that could become entangled in the rotating bit

Exhaust PrecautionsExhaust gases produced by the Breaching System engine are potentially dangerous if the system is used in confined areas. If the exhaust gases accumulate, the carbon monoxide present in the exhaust can reach harmful levels within minutes.

Always provide for adequate ventilation of the work area. Monitor the space with a Carbon Monoxide Detector if ventilation is necessary to assure that sufficient air exchange occurs.

26www.con-space.com


GENERAL DRILLING OPERATIONSDrilling a hole with the SearchCam® Breaching System is a relatively simple process and is very similar to drilling with other types of equipment.

1. Make sure you are using a suitable bit for the material to be drilled. If a diamond bit is used, connect the water pressure tank to the water collar and pressurize the tank. Keep the valve closed until ready to drill to conserve water.

2. With the engine running at idle (bit should not spin), place the bit firmly against the work material with the bit perpendicular to the plane of the material.

3. Squeeze the throttle slowly to start the bit turning.

4. Run at low speed until the bit has cut deep enough into the material to prevent the bit from sliding across the surface of the material (“Walking”).

5. Once the bit is set, ramp up the engine to full speed and apply moderate downward force to the machine until the hole is drilled. Both the diamond and carbide bits are designed to run at full engine speed of 950 RPM. Always use full engine speed, except when first starting the bit.

6. Once the hole is completed, a slug of material will be released. This slug will either remain in the center core of the bit, or it will fall out of the bit and into the completed hole. If the slug remains in the bit, it can be removed by tapping the bit against a hard surface while running the machine at low speed.


GENERAL DRILLING OPERATIONS

Bit

Stand on plate guide

Scrap Lumber 1/2” (1 cm) to 1” (2.5 cm) thick8” (20 cm) to 12” (30 cm) wide by

about 18” (46 cm) long

Cut “V” pattern 6” (15 cm) deep

Drilling Tips

In some situations, the bit will “walk” out of the starting point and it may seem impossible to start the bit drilling into the material. This may occur with various types of hard material like concrete and stone.

A guide plate can be fabricated to help start the bit.

1. Locate a scrap piece of lumber or plywood that is about 1/2 to 1 inch (1 to 2.5 cm) thick and about 8 - 12 inches (20 to 30 cm) wide. The piece should be about 18 inches (46 cm) in length.

2. Cut a 6 inch (15 cm) deep “V” pattern into the narrower width of the guide plate.

3. Place the guide plate on the material to be drilled and align the “V” cut over the area to be drilled.

4. Stand on the plate guide and place the bit into the “V” cut and begin drilling. The guide will prevent the bit from walking and can be moved out of the way once the hole is started.

28www.con-space.com


Bit Orientation

It is important to keep the bit positioned as perpendicular to the material as possible when drilling. This keeps the downward force evenly distributed across the bit kerf, which provides for the fastest cutting through the material.

If the bit is not kept square to the material, the side walls of the core can rub against material causing the bit to bind at the hole. When the system is aligned properly, the Breaching System will seem to “float” evenly around the hole and will be well balanced. If the alignment is off, the bit will bind frequently and the operator will struggle to keep the machine balanced.

The SearchCam® Breaching System can be used at any angle. When drilling horizontally, the system can be supported by a line tied to an overhead point. This will relieve the operator of the system weight and allow for greater control.

Bit kept perpendicularto the material.

Bit not perpendicular.Side walls hit material

causing bit to bind.

90°



Drilling with the Diamond Bit

Steel reinforced concrete is a very strong material which literally forms the foundation of the modern world. Penetrating reinforced concrete can be quite a challenge and represents the most difficult aspect of urban search and rescue operations.

There are few better tools to make small breaches in reinforced concrete than the SearchCam® Breaching System and its diamond coring bit. When using the SearchCam® Breaching System, drilling through concrete is similar to drilling through other construction materials, except that cooling water must be used and embedded steel rebar will be encountered.

Water Usage with the Diamond BitUsing water when drilling with the diamond bit serves two functions; it cools the bond matrix below the melt point of the weld solder and the water forms an abrasive slurry with the debris to help expose new diamond particles.

It is usually the assumption that the more water applied, the better. However, this is not true and too much water is actually counterproductive to the drilling operation. Too much water will tend to wash the cutting debris away from the bit contact area and dilute the slurry to the point that it is no longer effective. In addition, since the water tank has a limited capacity, using too much water will slow the drilling operation since the tank will need to be refilled more than necessary.

Determining the proper water flow is a matter of observation. Start the water flow immediately before starting the actual drilling by opening the valve on the supply hose attached to the water collar. Never use the diamond bit without water flowing.

Once the bit has begun to cut the concrete, observe the slurry discharge for color and consistency. The color should be a distinct medium gray and the consistency of a light motor oil. Some color change in the slurry may be observed as the bit cuts through aggregate or rebar.

Water management is dynamic due to several variables. These variables include the pressure in the water tank, the position of the valve, the type of concrete, the amount and type of aggregate, and the size and location of the rebar.

Some experimentation will always be necessary to achieve the best water consumption to cutting speed relationship. Experience has shown that under average conditions, 24 to 30 inches (61 to 76 cm) of concrete can be drilled with two gallons (7 liters) of water.

30www.con-space.com


Encountering Rebar and Other MaterialsSteel reinforcing is a critical component in making concrete structures possible. Steel rebar will be encountered when drilling through reinforced concrete.

The rebar does not pose much of a problem for the diamond bits as long as the steel is embedded within the concrete. Some reduction in drilling speed will be noticed when steel is encountered. The degree of reduction in cutting speed will depend on the size of the rebar. With rebar less than 1/2 inch (1 cm) in diameter, the only indication that the rebar has been encountered is a darkening of the water slurry coming out of the hole.

An obvious question usually comes to mind at this point. If the diamond bit cuts through steel rebar, can it be used to drill through steel beams or plate? The answer is NO. Steel alone will not produce enough debris to strip away the bond matrix to reveal new diamond particles. Once the first layer of the diamond abrasive is stripped away, the bit is left trying to cut with the relatively soft bond material. The diamond bit must have abrasive elements of the concrete and masonry materials to function properly.

Pre and post tensioned concrete structures use cables that are tightened during construction. These cables function similarly to solid rebar in reinforcing the structure, but give the builders more flexibility in design. Since these cables are wound together out of smaller diameter cables, just like rope, the smaller diameter cable can catch on the diamond segment edges and cause damage to the bit. The SearchCam® Breaching System diamond bits are designed with close segment spacing to prevent damage from the cable. If other brand diamond bits are used, care should be taken when drilling through tensioning cable.



Drilling with the Carbide Bit

Drilling with the carbide bit is somewhat easier since cooling water is not used with this bit. The material most commonly drilled using the carbide bit is wood. Drilling through wood is a very easy and relatively fast operation. Because the wood is soft, the bit cuts into the wood quickly and does not want to walk around the surface of the material.

Most holes drilled will be through a thin section of sub-flooring or roof covering. These typically do not exceed 1 1/2 inches (4 cm) in thickness. However, the bit is capable of drilling through wood timbers as thick as 17 inches (43 cm) without difficulty.

It is very important not to use cooling water when drilling in wood. Since the wood is very porous and dry, it tends to absorb water quickly. As the water is absorbed, the wood begins to swell and expand. This causes the new hole that is being cut into the wood to shrink around the bit. If this happens, the bit begins to become stuck in the hole. The bit would then have to be abandoned or cut free using another saw.

Cutting Roofing MaterialThe carbide bit is very effective in drilling though built-up roof covering. A built-up roof can be deceptively difficult to penetrate because there are usually multiple layers of roof covering, aggregate, and dried tar all laid on top of the roof decking. The roof may have been recovered several times and the layers of the roofing material can grow several inches thick. The carbide bit will quickly cut the layers of the roofing material and then through the wood decking.

The carbide bit is capable of handling metal better than the diamond bit. While the carbide bit is not designed to drill through thick steel structural members, it can penetrate through sheet metal up to 1/8 inch thick. The bit will also cut through nails that are embedded into wood.

Because sheet metal is hard, the bit will tend to slip or walk around the surface of the material. To make starting the bit easier, lay a piece of plywood over the sheet metal and then drill through the plywood and metal at the same time.

32www.con-space.com


SYSTEM MAINTENANCEThe SearchCam® Breaching System requires very little routine maintenance. However, it is important that the maintenance items be performed as required to keep the machine running reliably and ready for response.

Routine Maintenance

Fuel SystemOne of the most important maintenance considerations with the Breaching System is keeping the fuel system clean and free from contaminants. If the following guidelines are practiced, most potential engine problems can be avoided. These three simple steps will prevent almost all of the maintenance problems caused by the engine’s fuel system.

1. Use only clean and fresh fuel

2. Use quality two-cycle engine oil mixed to a ratio of 50:1

3. Drain and purge the fuel system after every use

Fuel FilterThe fuel filter located at the end of the fuel pick up tube inside the fuel tank should be checked after every 10 hours of operation. If the filter is dirty, it should be cleaned or replaced.

Air FilterThe air filter should be cleaned after every 10 hours of operation. To clean the air filter, remove the filter cowling located on the engine and pull the filter out of the cowling. The filter is a rectangular shaped foam insert. Rinse the filter in clean gasoline several times and then dry the filter before reinstalling.

Fuel Filter

Air Filter


SYSTEM MAINTENANCE

Ignition SystemThe engine ignition system is electronic and requires no maintenance. The spark plug should be inspected after every five hours of operation. If the spark plug is dirty, clean or replace the plug.

Ignition System Data

Component Type Electrode Gap

Spark Plug CJ-7Y .025 (0.6 mm)

Magneto N/A .012 (0.3 mm)

Water CollarAfter each use, inspect the water collar to make sure both bearings spin freely and are not damaged. The bearings are sealed to direct the cooling water through the bit core. If water is leaking out around any other part of the collar, the collar should be repaired immediately.

If the bearing seal is damaged, water can cause the bearing to seize. This will couple the water collar to the bit causing the supply line hose to rapidly wind up around the spinning bit and may cause injury to the operator or nearby personnel.

Engine HardwareAfter each use, inspect and tighten the engine and handle hardware. Vibration can cause the fasteners to loosen.

Engine CylinderAfter each use, remove the spark plug and squirt a few drops of motor oil into the cylinder. Reinstall the spark plug and pull the starter rope a few times to distribute the oil around the cylinder wall. This helps protect the cylinder and other components from corrosion during storage.

34www.con-space.com


CORING BIT MAINTENANCEThe bits should be inspected and serviced after each use. Since the bits are the working end of the system, their condition directly effects the successful operation of the system. Routine maintenance ensures that the bits will be safe and ready for operation when needed.

Diamond Bit

The diamond bit should be cleaned and then inspected. A wire brush can be used to remove any accumulated concrete dust. Inspect the core to make sure it is in good condition. Look for large dents, out of roundness, or distortion along the length of the bit. If this damage is found, the bit should be replaced. Inspect the diamond segments to verify that all are present and in good condition. If less than 1/4 inch (.63 cm) of the segments are remaining, consider replacing the bit.

Carefully inspect the kerf. The small diamond particles should be clearly visible. These will look like small black specks embedded in the bond. If none can be seen, the bit should be dressed. To dress the bit, simply drill through a concrete masonry block or through a few inches of asphalt. Since these materials are very abrasive, they will quickly remove the bond matrix to expose fresh diamond particles.

Inspect the mounting threads for form and verify that the bit will thread onto the spindle. Apply a thin coat of light oil on the thread to prevent rust.

Carbide Bit

Clean the carbide bit thoroughly to remove any tar or wood resins. Inspect the bit for any irregularities in the core structure. Replace the bit if serious damage is found. Inspect the carbide fragments for damage. If more than 30% of the carbide is missing, consider replacing the bit.

Inspect the mounting threads for form and verify that the bit will thread onto the spindle. Apply a thin coat of light oil on the thread to prevent rust.


SPARE PART INVENTORY

SYSTEM STORAGEAfter all the maintenance issues have been addressed, the SearchCam® Breaching System should be returned to the storage case. Before repacking, clean and dry all the system’s components. This should include the power head, water tank, bits, water collar, and the accessory storage bag.

It is very important to make sure that all the system components are completely dry before storing the system. Because the storage case is air tight, moisture cannot escape and the presence of moisture will cause rust to form rapidly. If the system must be repackaged in the field wet, open the case lid and storage bag zipper pouch as soon as possible after returning. With the lid open, the air flow will allow the moisture to escape and slow the oxidation long enough to allow the system to be cleaned at a more convenient time.

Never leave fuel in the system during storage. Drain and purge the fuel system before repacking the system. Do not store spare fuel in the storage case.

Store the system in a dry location that is not exposed to excessive heat or cold.

The Breaching System should be started and run for about 10 minutes at least every six months. Periodic operation keeps the engine seals lubricated and prevents internal engine corrosion from accumulating.

36www.con-space.com




BREACHING SYSTEM SPECIFICATIONS

BREACHING SYSTEM SPECIFICATIONS

Engine

Manufacturer EFCO (Italy)

Type Two-Stroke

Displacement 40 CC

Horsepower 2.75

Ignition Electronic

Carburetor Membrane

Clutch Centrifugal

Fuel Mix 4% - 25:1

Fuel Capacity 1 Liter

Output Shaft Speed 950 RPM

Spindle

Thread 1 1/4 - 7 TPI

Weight

Power Head with Water Collar 25 lbs (11.3 kg)

System Weight in Case 81 lbs (37 kg)

Water Tank

Construction Epoxy Lined

Capacity 2 US Gallons (7.5 Liters)

Hose 3/8 inch ID x 12 foot Length

Bits

2 inch Diamond, Thin Kerf, Close Segment, 17 inch depth

Qty. 2

2 inch Carbide, 17 inch depth Qty. 2

Spindle Extension (Optional)

A 12 inch spindle extension is available to increase drill depth. Up to three spindle extensions may be used.

38www.con-space.com


WARRANTYThe SearchCam® Breaching System is warranted to be free from all defects in material and workmanship under normal usage for a period of one year. This warranty is granted only to the original purchaser and is subject to the following provisions.

Exclusions

• Parts of the unit that require replacement under normal use, such as batteries.

• Damages or malfunctions caused by negligence, abuse, inadequate maintenance, or use not in accordance with the intended purpose of the unit.

• Defects or damages cause by unauthorized service, modification, or use of non-genuine CON-SPACE parts.

• Defects or damages caused by operation outside of environmental specification.

• Damage caused by common carrier or airline.

Relief

CON-SPACE, Ltd will, at its option, repair or replace a defective unit or unit part that is covered by this warranty. As a matter of warranty policy, CON-SPACE will not refund the consumer’s purchase price.

Obtaining Warranty Service

To obtain warranty service, you must contact CON-SPACE Communications to obtain a Return Merchandise Authorization number (RMA) and instructions.

Disclaimer

This warranty is expressly in lieu of all other warranties. CON-SPACE specifically disclaims any liability for any general, special, or consequential damages arising out of sale, manufacture, or use of this product, whether based upon contract, tort, or any other legal theory. CON-SPACE makes no warranties, express or implied (including, but not limited to, any warranty of merchantability or fitness for any purpose) with respect to the identified products.


WARRANTY & SERVICE

SERVICEIf your system should require service or if you have a question regarding the SearchCam® Breaching System contact CON-SPACE at 604-244-9323 (1-800-546-3405) for assistance. Always contact CON-SPACE before returning a system for service. For service outside North America, contact service by phone at 604-244-9323, by fax at 604-270-2138 or www.con-space.com.

Before you return the SearchCam® Breaching System for repairs or upgrades:

1. Contact CON-SPACE for a Return Merchandise Authorization (RMA) number.

2. Insure the system for the purchase price of the system.

3. Place the address label on the outside and the inside of the shipping container. Shipping labels can be downloaded at www.con-space.com.

4. Include contact information, return address, and a description of the reason for the return.

5. Customers are required to pay shipping to and from CON-SPACE

For international shipments, mark the shipping document as follows:

Service Centres

US Repairs Canadian Repairs UK & European Repairs CON-SPACE CON-SPACE Lowe Electronics 2025 SW 5th Street 505-5600 Parkwood Way Sandyhill Park Lincoln, NE 68522 Richmond, B.C. V6V 2M2 Middleton, Matlock DE4 4LR

“Goods of US origin being returned for repair”

According to most export laws, the customs value stated on the return shipment will be either the repair price in the case of billable repairs or the cost of repair to the manufacturer in the case of warranty repairs. The recipient is responsible for payment of all customs charges such as duty upon re-entry to their country. Documents showing proof of original export for repair may be required to minimize these charges. Return documents will state an Insurance Value for the equipment in case of loss. This value is usually much higher than the Customs Value. An Ex-Works return shipment can be requested if the customer chooses not to insure the return shipment.

User comments and suggestions are always appreciated. We continually strive to improve our products and this can only be done with your help. Let us know what you like and what changes would help make the system better to suit your needs.

40www.con-space.com


POWER HEAD PARTS LIST

Engine

REF. PART# USE # DESCRIPTION1 4138-439 STARTER ASSY.2 3801-010 SCREW3 3819-006 WASHER4 3918-006 WASHER5 3916-008 FLAT WASHER6 4191-020A HANDLE7 40-00132R RECOIL SPRING8 4138-438BR PULLEY9 3801-015 SCREW10 3633-049 SCREW11 4098-073 ROPE12 60-00829 NYLON WASHER13 3912-009 FLYWHEEL NUT14 4138-455 SHORT BLOCK15 4138-484 PISTON ASSY.16 4161-151 PAWL PIN17 4138-441 PAWL18 4161-186A SPRING19 4138-446A FLYWHEEL

REF. PART# USE # DESCRIPTION21 49-00061 SNAP RING22 3050-009 SEAL23 3034-011 MAIN BEARING24 4098-232 FLYWHEEL KEY25 3037-013 WRIST PIN BEARING26 4100-311 CRANK SHAFT27 4179-087 CABLE28 4098-017 P13700S0C COIL29 50-00019 W22MP-U SPARK PLUG30 946-00097A SPARKY31 3801-014 SCREW32 3801-003 SCREW33 3819-005 LOCK WASHER34 40-00015 PISTON RING35 3833-073 WASHER36 4174-165 FAN HOUSING37 3916-004 FLAT WASHER38 4179-036 PISTON PIN

1

410

11

12 7

39

36

13

1617

18 192223

23

35

3120

15

2134

38

24

252629

28

27

323337

30 14SHORT BLOCK

22

8 5

23

6



Air Filter / Fuel Tank

REF. PART# USE # DESCRIPTION1 4174-087A INTAKE GASKET2 4174-150 ADAPTOR3 3819-006 WASHER4 3801-013 SCREW5 4174-093A CARB. GASKET6 2318-520 ZC1Q-E3 CARBURETOR7 4190-051 FUEL LINE (OUT)8 4098-377 CLAMP9 4174-127 FUEL LINE (IN)10 3916-006 FLAT WASHER11 3819-010 LOCK WASHER12 60-00235 SCREW13 4174-126A AIR FILTER CVR14 4174-099 AIR FILTER15 3049-004 O-RING16 4161-177 CHOKE LEVER17 4174-149A AIR FILTER SUPPORT18 4161-178 CHOKE PLATE19 4120-070 WASHER20 3760-018 SCREW21 4174-097 FILTER COVER NUT22 3833-073 WASHER23 3801-012 CARB. SCREW

REF. PART# USE # DESCRIPTION24 3078-007 WASHER25 4174-098B KNOB26 5501-0021 MUFFLER CVR27 4100-353 COVER SUPPORT28 3806-026 MUFFLER BOLT29 4095-211 LOCK PLATE30 4190-014A MUFFLER31 4095-036 MUFFLER GASKET32 3819-005 WASHER33 3801-010 SCREW34 4138-461A FUEL TANK BRACKET35 3055-048 FUEL VALVE36 3049-006 WASHER37 3055-098 WASHER38 946-00450 FUEL FILTER39 4174-170B FUEL TANK40 4151-258R FUEL CAP41 4098-658A GAS CAP VENT42 4100-378 FUEL LINE (IN TANK)43 3912-011 FUEL VALVE NUT44 3918-005 WASHER45 ZGND-18 DIAPHRAGM KIT46 ZRB-47 REPAIR KIT

14

25

2415

13

1211

10

21

23

22

20

18

19

16

17

3

1 2 5 6

33

27

44

26

121011

2928

30

31

32

33

34

3

33

9

39

36

38 43

33

14

37

35

41

40

42

4 9 7 8

45 DIAPHRAGM KIT46 REPAIR KIT

42www.con-space.com


Transmission

REF. PART# USE # DESCRIPTION1 3751-00012A CLUTCH WASHER2 3751-00011A CLUTCH DRUM3 4190-033 CLUTCH DRUM HOUSING4 3035-019 CLUTCH BEARING5 3035-011 UPPER GEAR BEARING6 3751-00075A UPPER GEAR7 3801-013 SCREW8 3078-012 GASKET9 3906-103 GREASE PLUG10 4190-036 GEAR CASE11 3801-030 GEAR CASE SCREW12 946-00042 PIN13 3914-003 NUT

REF. PART# USE # DESCRIPTION14 3819-006 LOCK WASHER15 3024-015 SNAP RING16 3025-022 SNAP RING17 3034-014 BEARING18 3751-00076B LOWER GEAR19 3020-00029 LOWER GEAR BEARING20 3801-016 SCREW21 3050-020 SEAL22 3751-00036A CLUTCH ASSY.23 49-00137B CLUTCH SPRING24 3751-00005 CLUTCH HUB25 3916-010 FLAT WASHER

1

4 7

10

11

12

7

9

13

16

15

1718

19

23

21 20

24

25

14

8

5

5

2

3

6

22



Throttle Assembly

REF. PART# USE # DESCRIPTION1 4190-015A LEAD ASSY.2 3901-016 SCREW3 4174-245 TRIGGER4 4190-016 THROTTLE CABLE5 4138-361 TRIGGER SPRING6 3960-029 SCREW7 4174-246 TRIGGER INTERLOCK8 4138-360 RETURN SPRING

REF. PART# USE # DESCRIPTION9 2317-021 SWITCH10 4100-098B SPRING T-LOCK11 3960-021 SCREW12 4138-359 SPACER13 6104-0131 THROTTLE COVERS14 3914-003 NUT15 4138-358 PIN

1

4

12

7

9

13

13

1510

11

14

8

5

2

3

6


44www.con-space.com



Thank you for your support.

Please visit our website to see how our other search rescue gear can assist in your searches.

www.con-space.com

SEARCHCAM®, Delsar®, EntryLink®, and TacTIC® are Registered Trade Marks of Con-Space Communications, Inc. Speci�cations subject to change without prior notice. WeatherPak® is a registered trademark of Coastal Environmental Systems, Inc.

280-13775 Commerce Parkway

Richmond, BC V6V 2V4 Canada

604-244-9323 • 800-546-3405

Fax: 604-270-21387000-01-013

R03