Amkus IC750 User guide

©Copyright AMKUS Rescue Systems, Inc. 2020 LAI-002 April 29, 2020 Rev00
DANGER Understand manual before use. Operating AMKUS Rescue Systems without understanding the
manual, receiving proper training, and using appropriate personal protective equipment is a
misuse of AMKUS equipment. Obtain safety information at amkus.com.
This instruction manual is intended to familiarize operators and maintenance personnel with the
operation, basic maintenance, and safety procedures associated with this product. This manual
should be kept available to all operating and maintenance personnel.
This manual does NOT address Level 2 & 3 servicing of AMKUS Rescue Systems. Only competent
rescue tool repair technicians are qualified to repair AMKUS equipment.
Read and understand all instructions and warnings included in the packaging for DEWALT lithium
ion batteries and chargers.
ION®Battery Powered
Electro-hydraulic Rescue Tools
AMKUS RESCUE SYSTEMS
AMKUS.com
4201 Montdale Drive, Valparaiso, IN 46383-4098 USA
800-592-6587 • 219-548-5000
CUTTER Model: IC750
COMBI TOOL Model: ICT716
SPREADER Model: IS320
BATTERY DeWALT® Lithium Ion (AMKUS Part#) DCB606 (IBATTFV-6), DCB609
(IBATTFV-9), DCB612 (IBATTFV-12)
CHARGER DeWALT® DCB118 1 Hour Charger, 120 VAC Part#: ICHRG120
HYDRAULIC SYSTEM Self-contained, 10,500 psi (724 bar) high-speed four stage pump
HYDRAULIC FLUID AMKUS MV1 (Mineral Oil base)
Safety Data Sheet (SDS) for AMKUS MV1 Hydraulic Fluid is available at AMKUS.
com and CHEMTREC.com (for equipment stored and operated in environments
below 32°F (0°C) contact AMKUS Rescue Systems for recommendation)
IC750 ICT716 IS320

©Copyright AMKUS Rescue Systems, Inc. 2020 LAI-002 April 29, 2020 Rev00
2
DANGER
PERSONAL RESPONSIBILITY CODE
The member companies of FEMSA that provide emergency response
equipment and services want responders to know and understand the
following:
1. Firefighting and Emergency Response are inherently dangerous activities
requiring proper training in their hazards and the use of extreme caution
at all times.
2. It is your responsibility to read and understand any user’s instructions,
including purpose and limitations, provided with any piece of equipment
you may be called upon to use.
3. It is your responsibility to know that you have been properly trained in
Firefighting and /or Emergency Response and in the use, precautions, and
care of any equipment you may be called upon to use.
4. It is your responsibility to be in proper physical condition and to maintain
the personal skill level required to operate any equipment you may be
called upon to use.
5. It is your responsibility to know that your equipment is in operable
condition and has been maintained in accordance with the manufacturer’s
instructions.
6. Failure to follow these guidelines may result in death, burns or other
severe injury.
FEMSA
Fire and Emergency Manufacturers and Service Association
P.O. Box 147, Lynnfield, MA 01940 • www.FEMSA.org

©Copyright AMKUS Rescue Systems, Inc. 2020 LAI-002 April 29, 2020 Rev00
3
This Safety Manual is not intended as a substitute for proper training in the use of rescue systems as taught from
credible sources such as the National Fire Protection Association (NFPA), The International Fire Service Training
Association (IFSTA), or sources approved by the Authority Having Jurisdiction (AHJ).
Examples of recent publications:
SUPPORTING MATERIALS
The following document and materials contain supporting safety and operating information
pertaining to the equipment described in this manual.
©Copyright Amkus Rescue Systems, Inc. 2014-2016 LAA-004 December 8, 2016 Rev04
SAFETY DATA SHEET
According to OSHA Hazard Communication
Standard, 29 CFR 1910.1200
AMKUS RESCUE SYSTEMS
www.amkus.com
4201 Montdale Drive, Valparaiso, IN 46383-4098 USA
800-592-6587 • 219-548-5000 • Fax [phone]
SECTION 1. IDENTIFICATION
DIULFCILUARDYH1VMSUKMAemaNtcudorP
Manufacturers of suppliers details
AMKUS RESCUE SYSTEMS, INC.
4201 Montdale Drive
Valparaiso, IN 46383-4098 USA
0005-845-912tseuqeRSDS
Customer Service
Emergency telephone number
CERTMEHC0039-424-008noitamrofnIl
lipS
Health Information
Recommend use of the chemical and restrictions on use
liociluardyHesUdednemmoceR
SECTION 2. HAZARDS IDENTIFICATION
*+6&ODVVL¿cation
Not a hazardous substance or mixture
GHS Label element
deriuqerlobmysdrazahoNsmargotcipdrazaH
drowlangisoNdrowl
angiS
:SDRAZAHLACISYHPstnemetatSdrazaH
Not classi¿ed as a physical hazard under GHS criteria.
HEALTH HAZARDS:
Not classi¿ed as a health hazard under GHS criteria.
ENVIRONMENTAL HAZARDS:
Not classi¿ed as an environmental hazard under GHS criteria.
Precautionary statements
Prevention: No precautionary phrases.
Response: No precautionary phrases.
Storage: No precautionary phrases.
Disposal: No precautionary phrases.
2WKHUKD]DUGVZKLFKGRQRWUHVXOWLQFODVVL¿cation
Prolonged or repeated skin contact without proper cleaning can clog the pores of the skin resulting in disorders
such as oil acne/folliculitis.
Used oil may contain harmful impurities.
High-pressure injection under the skin may cause serious damage including local necrosis.
Not classi¿ed as Àammable but will burn.
The classi¿cation of this material is based on OSHA HCS 2012 criteria.
Under normal conditions of use or in a foreseeable emergency, this product does not meet the de¿nition of
a hazardous chemical when evaluated according to the OSHA Hazard Communication Standard, 29 CFR
1910.1200.
Safety Data Sheet (SDS)
AMKUS MV1 HYDRAULIC FLUID
DeWalt Charger Original Packaging DeWalt Battery Original Packaging

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Table Of Contents
1.0 MEANING OF SAFETY SIGNAL WORDS
2.0 SAFETY
3.0 GENERAL DESCRIPTION
3.1 VARIOUS MODELS AND TERMS
3.2 SAFETY MARKINGS
4.0 SPECIFICATIONS
4.1 GENERAL SPECIFICATIONS
4.2 CUTTER SPECIFICATIONS
4.3 SPREADER SPECIFICATIONS
4.4 COMBI TOOL SPECIFICATIONS
5.0 SAFETY CONSIDERATIONS
5.1 PROTECTIVE CLOTHING
5.2 TRAINING
5.3 OPERATING CONSIDERATIONS
6.0 SET-UP PROCEDURE
6.1 CHARGE THE BATTERY
6.2 INSTALL THE BATTERY
6.3 POWER BUTTON ON/OFF
6.4 ROTATING HANDLE
6.4.1 HANDLE LIGHTS
6.5 CONTROL VALVE ACTUATOR
7.0 OPERATION
7.1 BATTERY CHARGE STATUS
7.2 WHEN TO CHANGE THE BATTERY
7.3 STORAGE RECOMMENDATIONS
7.4 STATUS LED
7.5 CUTTING
7.6 SPREADING / SQUEEZING / LIFTING
8.0 ACCESSORIES
8.1 EXTENDED REACH SPREADER TIPS (ERT)
8.2 CHAIN USE
9.0 SAFETY GUARDS
10.0 INSPECTION AND MAINTENANCE
10.1 ROUTINE MAINTENANCE
10.1.1 CHECK THE BLADES
10.1.2 HYDRAULIC MAINTENANCE
10.1.3 MOTOR MAINTENANCE
10.1.4 LUBRICATION
10.1.5 HANDLE LIGHT BATTERY REPLACEMENT
11.0 TROUBLESHOOTING
11.1 GENERAL
11.2 TROUBLESHOOTING THE MOTOR
11.3 TROUBLESHOOTING THE HYDRAULICS
12.0 PARTS, SERVICE, AND TECHNICAL INFORMATION
13.0 DECOMMISSIONING
14.0 INSPECTION, CLEANING, DECONTAMINATION, AND STORAGE

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1.0 MEANING OF SAFETY SIGNAL WORDS
A safety related message is identified by a safety alert symbol and a signal word to indicate the level of risk involved with a particular
hazard. Per ANSI Z535.6, the definitions of the four signal words are as follows:
DANGER DANGER indicates a hazardous situation which, if not avoided, will result in death or serious
injury.
WARNING WARNING indicates a hazardous situation which, if not avoided, could result in death or serious
injury.
CAUTION CAUTION indicates a potentially hazardous situation which, if not avoided, could result in minor
or moderate injury.
NOTICE NOTICE is used to address practices not related to physical injury.
2.0 SAFETY
DANGER Hydraulic tools can apply many tons of force which can bend, move, or lift large loads storing
potential energy. Loads can become unstable and suddenly move without warning causing severe
injury or death. Never support a load solely by a rescue tool. Use secondary supports to limit the
extent of uncontrolled movements. Never put body parts in a situation where a shifting or falling
load can cause a crushing injury. Stay clear of the path of travel.
• Metal-on-metal contact is likely to slide sideways when the load is not able to deform around
the area of contact. Use care when lifting structural and hardened objects.
• Chains can break when overloaded or improperly loaded.
• Spreader tips and rams can kick (move) when direction of force isn’t perpendicular to load
• Loads can suddenly shift sideways when forced, lifted, or moved. Stabilize load to reduce risk
of movement from ice, gravel, soft ground, precarious positions, objects which can break,
wheels which depressurize or roll, and loading which can change during rescue operations.
WARNING Operating rescue tools can result in injury or death from laceration, projectile (high speed flying
debris), and pinch point injuries. Stay clear of the path of travel. Avoid unnecessary risk. Examples
include:
• Never lift, or hold a rescue tool by its cutting blades or spreader arms. Never place hands
between moving tool and a load. Pinch points are created from tool movement causing risk
of limb amputation (i.e. fingers, hands, arms, feet, legs).
• Sharp metal objects formed during cutting and extrication cause potential for laceration and
puncture wounds
• Projectiles can be ejected during cutting, spreading, or lifting operations when objects break
suddenly under load. Sudden fractures are common with springs and hardened steels.
• Damaging pressurized objects such as airbag cylinders can create projectiles.
• Using a rescue tool beyond its reasonable lifespan increases risk of fatigue failure. Expected
lifetime of the tool is 10 years from the date of manufacture.
• Tools can drift (move side-to-side) as load is applied or released resulting in body parts being
trapped and crushed between tool handles and stationary objects. Always be aware of body,
hand, and finger position. Stop before harmful contact is made.
WARNING Using rescue tools can cause ignition or explosion resulting in injury or death. Ignition or
explosion can result from situations such as:
• Flammable hazards are created when fuel lines, refrigerant lines (atomized oil), or pressurized
hydraulic fluid lines are breached. Ignition sources can suddenly ignite these fuels.
• Flammable vapors can be released by careless refueling or operation of gasoline driven
engines. Refer to engine manufacturer’s manuals for specific details.
• Extrication tools can create sparks as metals are cut and deformed. Avoid unnecessary risk
when flammable vapors are present.
• Power units with electric motors or internal combustion engines are ignition sources.
Flammable vapors heavier than air can accumulate in low spots. Avoid selecting these
locations when setting up the power units. Use detectors to verify safe site selection.

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WARNING Hydraulic fluid (mineral oil) escaping under pressure can puncture the skin, infiltrate eyes, or
lungs resulting in serious injury. Seek medical attention immediately. Avoid the urge to contain
leaks with hands. Injection injuries require immediate medical attention. Safety Data Sheet (SDS)
for AMKUS MV1 and AMKUS MV0 Hydraulic Fluid is available at AMKUS.com and CHEMTREC.
com. Hydraulic leaks can occur from situations such as:
• Leaks at hose crimps and connections can develop from constant use, over-pressurization,
side-loading, or mis-crimping.
• Hose damage from being driven over, stepped on, twisted, kinked, crushed, excessive
vibration, abuse, or neglect.
• Leaks and breaks in hydraulic components can occur from improper maintenance or
exceeding service life expectations. Establish sound practices.
• Connecting hydraulic tools in series can pressurize both sides of double acting cylinders.
Each tool must be separately connected to a power unit.
• Release stored pressure before servicing tools by moving offend stops. Refer to power unit
manuals for proper operation.
WARNING Electric shock can result in injury or death. Rescue tools are made from metal which is a conductor
of electricity. Electric current can flow from the hazard through the rescue tool to shock nearby
people. Maintain awareness of potential hazards. Examples include:
• Never operate electric power units with damaged power cords.
• Do not drive over or crush power cords.
• Use care to avoid cutting power cords on sharp objects.
• Do not strain cords during storage. Hidden cord damage can remain undetected until wet
conditions create an electrocution hazard.
• Power sources and electronics are not waterproof. Do not submerge or douse the power units
or controls. Refer to manuals from battery, charger, and motor manufacturers for specific
details.
• Cutting into concealed spaces can be hazardous. Power cables and battery packs may be
hidden from view in structures and electric vehicles.
• Never operate near damaged electric power lines before power is verified as OFF.
WARNING Misuse of AMKUS Rescue Systems can result in a wide variety of hazards and consequences.
Remain aware of and avoid misuse situations. Examples of misuse include:
• Using low pressure (5000 psi) tools on high pressure (10,500 psi) hydraulic power units
creates high risk of hydraulic cylinder rupture. Ensure compatibility before use.
• Failure to inspect and properly maintain rescue equipment. Inspect all rescue equipment after
each use. Any equipment found damaged or inoperable should be removed from service.
• Storage of rescue equipment in adverse conditions. Always store rescue equipment in clean,
dry, and secure conditions.
• Operation of rescue equipment with missing or illegible safety markings
• Modification of tools and power units inconsistent with manufacturer’s specifications
• Repairs attempted by unqualified workers.
• Use of rescue tools for non-rescue purposes such as construction, production use, demolition,
or as a jack for vehicle service.
• Pressure relief valve set over +5% above the Rated Output Pressure 10,500 psi (724 bar)
• Using tools which have been heat damaged. Heating beyond 212°F (100°C) will compromise
the strength.
CAUTION Lifting or moving rescue tools and power units can result in falling or spine injury. Rescue tools
and power units are heavy. Risk of injury increases in unfavorable conditions such as poor
lighting, inclines, loose, wet, or icy surfaces. Follow accepted safe lifting practices.
NOTICE Use of hydraulic fluids other than AMKUS MV1 or MV0 (see Specifications for fluid for specific tool
lines) can result in equipment damage and loss of function. Some examples include:
• Phosphate ester hydraulic fluids and blends are incompatible with Buna-N seal and hose
materials used in AMKUS Rescue Systems
• Mixing glycol with mineral oils can result in gelling and plugging of pump inlet screens
• Using fluids with wrong viscosity or wear properties. Always use AMKUS MV1 or MV0 as
specified for your tools.

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3.0 GENERAL DESCRIPTION
AMKUS manufactures a complete line of ION battery powered electro-hydraulic rescue tools. These rescue tools continue the
AMKUS tradition of superior craftsmanship and quality. AMKUS backs these tools with a standard warranty published on the AMKUS
website.
The AMKUS ION tool’s self-contained hydraulic system provides the motive forces needed to operate the tool. The brushless direct
current (BLDC) motor operates from energy stored in a 60 Volt battery. The BLDC motor drives a high pressure pump. Hydraulic
fluid from the pump passes through a user operated control valve and moves the piston as directed by the user. Moving the piston
actuates the arms or blades of the rescue tool.
3.1 VARIOUS MODELS AND TERMS
Battery
Lighted
Handle
Guard
Cutter Blades
Grip
Control Valve
Actuator
Figure 3.1A
iC750 Cutter
Removable
Tips
Cutter
Blades
ON/OFF
Switch
Figure 3.1B
iCT716 Combination Tool

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3.1 VARIOUS MODELS AND TERMS
Spreader
Arms
Removable
Tips
Status
LED
Lighted
Handle
Figure 3.1C
iS320 Spreader
3.2 SAFETY MARKINGS
Valve Operation
Product Information
Safety Label
Model #
Serial # (also engraved on tool)
Date of Manufacture
Fluid Type
Figure 3.2

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4.0 SPECIFICATIONS
4.1 GENERAL SPECIFICATIONS
BATTERY SPECIFICATIONS
20V/60V MAX* FLEXVOLT 6.0 Ah BATTERY
Model: DeWALT DCB606
AMKUS Part # IBATTFV-6
Dimensions: Length x Width x Height inches (mm) 4.9 x 3.3 x 3.6 (124 x 84 x 91)
Weight LB (kg) 2.25 (1.0)
20V/60V MAX* FLEXVOLT 9.0 Ah BATTERY
Model: DeWALT DCB609
AMKUS Part # IBATTFV-9
Dimensions: Length x Width x Height inches (mm) 5.4 x 3.8 x 3.6 (137 x 97 x 91)
Weight LB (kg) 3.2 (1.45)
20V/60V MAX* FLEXVOLT 12.0 Ah BATTERY
Model: DeWALT DCB612
AMKUS Part # IBATTFV-12
Dimensions: Length x Width x Height inches (mm) 5.4 x 3.8 x 3.6 (137 x 97 x 91)
Weight LB (kg) 3.2 (1.45)
CHARGER SPECIFICATIONS
Model: DeWALT 20VMAX* Fan Cooled Fast Charger DCB118
AMKUS Part # ICHRG120
Input Power [Volts AC] 120
Output [Volts DC] 20
Charge Current [A] 8
Dimensions: Length x Width x Height inches (mm) 7.6 x 4.7 x 3.3 (193 x 120 x 84)
Charge Time (minutes) 60
OPERATING LIMITS
Operating Temperature Range: Degrees F (C) -25 TO 140 (-32 TO 60)
ELECTRIC DRIVE SPECIFICATIONS
Motor Type Brushless
Input Voltage [Volts DC] 60
Rated Input Current: minimum / maximum [Amps] 9.8 / 25.0
HYDRAULIC SPECIFICATIONS
Fluid Type: AMKUS MV1 Hydraulic Fluid (Part#) KF0001
Maximum Operating Pressure PSI (bar) 10,500 (724)
Figure 4.1
The 20V/60V MAX Battery pack changes voltage when you change tools, powering a line of powerful 60V MAX tools, 120V MAX
tools, and backwards compatible to existing 20V MAX tools and chargers. The battery pack is smart enough to know when to provide
runtime for 20V MAX tools and power in the new 60V MAX and 120V MAX tools.
Also compatible with:
DEWALT DCB1800B 1800 Watt Portable Power Station and Simultaneous Battery Charger - AMKUS ICHRG120-4

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4.2 CUTTER SPECIFICATIONS
Part#: IC750
MECHANICAL SPECIFICATIONS
Dimensions: Length x Width x Height Inches (mm) 33.7 x 8.7 x 11.9 (857 x 222 x 302)
Weight (excluding battery) lb (kg) 55.0 (25)
Weight (ready to use) lb (kg) 57.25 (27)
Cutter Opening Inches (mm) 7.0 (177.8)
Cutter Rating NFPA 1936 A7/B9/C7/D9/E9
Figure 4.2
4.3 SPREADER SPECIFICATIONS
Part#: IS320
MECHANICAL SPECIFICATIONS
Dimensions: Length x Width x Height Inches (mm) 38.0 x 11.1 x 11.9 (966 x 282 x 302)
Weight (excluding battery w/tips) lb (kg) 55.3 (25.1)
Weight (excluding battery w/out tips) lb (kg) 50.2 (22.7)
Weight (ready to use) lb (kg) 57.45 (26.1)
Max Spreading Distance Inches (mm) 32.0 (812)
Max Spreading Distance (w/optional ERT tips) Inches (mm) 39.1 (993)
Highest Spreading Force (HSF) lb (kN) 14,750 (65.6)
Lowest Spreading Force (LSF) lb (kN) 10,000 (44.5)
Max Spreading Force lb (kN) 39,500 (175.7)
Highest Pulling Force (HPF) lb (kN) 11,500 (51.1)
Lowest Pulling Force (LPF) lb (kN) 7,500 (33.4)
Figure 4.3
4.4 COMBI TOOL SPECIFICATIONS
Part#: ICT716
MECHANICAL SPECIFICATIONS
Dimensions (w/out tips): Length x Width x Height Inches (mm) 34.8 x 8.7 x 11.6 (885 x 222 x 295)
Dimensions (w/tips): Length x Width x Height Inches (mm) 36.1 x 8.7 x 11.6 (917 x 222 x 295)
Weight (excluding battery w/tips) lb (kg) 58.65 (26.6)
Weight (excluding battery w/out tips) lb (kg) 54.55 (24.7)
Weight (ready to use) lb (kg) 60.9 (27.6)
Weight w/out tips (ready to use) lb (kg) 56.8 (25.7)
Max Spreading Distance inches (mm) 15.8 (401)
Highest Spreading Force (HSF) lb (kN) 8,260 (36.7)
Lowest Spreading Force (LSF) lb (kN) 6,620 (29.4)
Cutter Opening Inches (mm) 9.1 (231)
Figure 4.4

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5.0 SAFETY CONSIDERATIONS
5.1 PROTECTIVE CLOTHING
WARNING Tool operators bear responsibility for ensuring use of appropriate protective clothing and
equipment. The chosen protective clothing and equipment must provide protection from potential
hazards users may encounter while operating AMKUS rescue tools. Requirements for protective
clothing and equipment are determined by the Authority Having Jurisdiction (AHJ).
5.2 TRAINING
AMKUS tools facilitate the extrication of entrapment victims. Only trained emergency services personnel should attempt victim
extrication. All personnel using AMKUS rescue tools are assumed to have completed a training course covering safe extrication of
entrapment victims. The training must be acknowledged as educationally sound by the local Authority Having Jurisdiction (AHJ) over
such training.
5.3 OPERATING CONSIDERATIONS
NOTICE AMKUS ION tools are intended for intermittent use. Allow sufficiently long pauses for the rescue
tool to cool. If the tool’s exterior becomes too hot to touch, the temperature is likely above 120°F
(49°C). An overheated rescue tool operates less effectively. When hydraulic oil temperature
reaches 158°F (70°C), the tool’s efficiency drops significantly, and the tool should be stopped to
cool down.
To avoid rescue tool overheating:
• Keep motor cooling vent holes unobstructed.
• Remove the battery prior to cleaning, servicing, or inspecting
the tool.
• After use, clean offany accumulated oil, grease, dirt, or
corrosive substances with a damp cloth and soapy water.
Cooling Vent Holes
Figure 5.3
NOTICE Operating the rescue tool continuously against an end stop may cause overheating resulting in an
inoperable tool. Permanent damage to the tool may occur. When an end stop is reached, release
the control valve actuator to return the control to the neutral position.
NOTICE Store electric tools in a dry place.
6.0 SET-UP PROCEDURE
Normally, AMKUS equipment is prepared and serviced by your dealer prior to delivery. If, however, you have decided to place the
equipment into service yourself, remove equipment from the packing cartons and carefully inspect for damage. Damage that occurs
during shipment should be reported immediately to the carrier.
6.1 CHARGE THE BATTERY
WARNING Read and understand the battery and charger manufacturer’s documentation before using the
battery and charger.

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12
6.2 INSTALL THE BATTERY
CAUTION An accidental start-up may cause injury. Always make the tool safe by turning the tool off, removing
the battery, and removing hands from the controls when making adjustments or removing/
installing attachments or accessories.
A quick push slides the battery into the tool. Slide the battery onto the tool until the latch clicks.
Figure 6.2
6.3 POWER BUTTON ON/OFF
To Power ON - Press and release the silver power button to activate the rescue tool. The power is on when the status LED indicator
light is on.
To Power OFF - Press, hold for 1 second, and release the power button to shut offthe rescue tool. The power is offwhen the status
LED indicator light is off.
The rescue tool will power offautomatically after 20 minutes of inactivity.
Power
Button
Status
LED
Figure 6.3
6.4 ROTATING HANDLE
ION Cutter and Combi Tools come equipped with a 360° swiveling handle that has variable tension.
RELEASE
LOCK
TENSION
SCREW
Flip the red latch up on the tool’s cuffto rotate the rescue tool.
Flip the latch down to lock the handle position.
To increase rotating handle tension,
tighten the tension screw shown above.
Figure 6.4

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6.4.1 HANDLE LIGHTS
AMKUS dual handle lights operate at three levels of intensity. To operate these lights, press the button located behind each light. The
lights can be powered OFF by scrolling through each setting to OFF, or by a single button press from a setting that’s been powered
ON for over 5 seconds. Continuous use time is about 60 hours on low. Battery saver function will turn the lights offafter 15 minutes
of continuous use.
Button press:
1st light level low
2nd light level medium
3rd light level high
4th power off light
Figure 6.4.1
6.5 CONTROL VALVE ACTUATOR
The control valve actuator has three positions, CLOSE, OFF, and OPEN. The control valve actuator includes a deadman safety
feature which returns the control valve actuator to the OFF position (neutral) when released. When the control valve is in the OFF
position, the tool movement stops, and holds position and load. The control valve actuator controls the motor and hydraulic pump.
Electronics within the tool prevent electrical overload during operation.
Verify operation of control valve actuator by checking to see it returns automatically to the neutral position when released.
7.0 OPERATION
7.1 BATTERY CHARGE STATUS
Check the battery charge status using the indicator lights on the battery by pushing the status button on the battery.
Figure 7.1

©Copyright AMKUS Rescue Systems, Inc. 2020 LAI-002 April 29, 2020 Rev00
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7.2 WHEN TO CHANGE THE BATTERY
ION tools keep power ON until turned off, or after 20 minutes of inactivity. The battery management system maintains power until
the battery is drained. Push the status button on the battery to check the battery status. The indicator light bars display the battery’s
charge status.
Change the battery if the battery no longer continuously operates the tool, there is one bar left on the battery charge indicator, or the
Status LED indicates “red” for low battery.
7.3 STORAGE RECOMMENDATIONS
1. The best storage place is cool and dry, away from direct sunlight and excess heat or cold.
2. For long storage, it is recommended to store a fully charged battery pack in a cool dry place out of the tool and charger for optimal
results.
7.4 STATUS LED
During tool operation, the brightness of the LED will adjust to indicate to the user the amount of power the tool is currently using to
operate. The brighter the LED the more power being applied to cutting or spreading. The LED is also used to communicate status
of important tool conditions to the operator. Error codes will not prevent the tool from operating. The codes are intended to alert the
operator of a potentially harmful condition.
LED COLOR STATUS MESSAGE
Green Battery Good
Red Battery Low
Yellow Tool in Error
• Temperature is over 125°F (52°C)
• Temperature is under -25°F (32°C)
• Actuator ON, motor not running
• Actuator NOT ON, motor running
7.5 CUTTING
Rotation of the control valve actuator runs the electric motor and pump. Rotating the control valve actuator regulates the hydraulic
flow rate and power delivered to the tool. Turning the control valve actuator to the end stops provides maximum hydraulic flow rate
and power.
Figure 7.5A

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7.5 CUTTING (CONTINUED)
To perform a cutting operation, first, open the cutter blades. Place the blades around the object being cut. Close the blades to cut the
object. Obtain the maximum cutting forces nearest the pivot point. Start the cut with the blades as fully engaged as possible. Make
the cut. Open the blades and remove the tool when finished.
WARNING When operating the cutter, take care to be positioned to the side of the cutter. As the cutter blades
meet resistance, the rescue tool may rotate or drift. If tool rotation places the user, operator, or
others in jeopardy, immediately release the control valve actuator. The deadman safety feature
of the control valve actuator should immediately return the control valve actuator to the center
(neutral) position stopping blade movement. Reposition the cutter as needed for optimal cutting
performance.
WARNING Blades can break if positioned incorrectly, causing hazardous projectiles and an inoperable tool.
If blades start to flex sideways (tool rolls as space between blades increases), stop immediately
and reconsider cutting strategies.
CAUTION The blades on AMKUS cutters effectively cut steering columns, brake pedals, door mechanisms,
and other vehicle items as necessary for extrication. However, using AMKUS cutters as a piercing
tool for heavy metal is not recommended. Therefore, when cutting, take care to insure the blade
tips move through a clear path of travel. The blade tips can pierce automotive sheet metal body
panels. Avoid obstacles like the heavy metal backing plates hidden behind seat belt mounts, door
hinges, and latching mechanisms or locks.
NOTICE Cutting hardened metals can potentially dent or deform the blade’s cutting edge. Blades may
break at these weak spots on subsequent cuts, especially if cutting near the tips. Avoid cutting
hardened solids of unknown strength such as:
• Padlock shackles
• Tie rods
• Leaf springs
• Spindles
• Hardened bolts
• Tool steel
• Heat treated chain
Blade damage or breakage that results from cutting hardened metals or solids is not covered by
the AMKUS Rescue Systems warranty.
The blades are intended and designed to cut hardened auto bodies and components without
damage.
We recommend an Authorized AMKUS Rescue Systems Dealer inspect, evaluate, and replace
dented or damaged blades as necessary.
CORRECT BLADE POSITION INCORRECT BLADE POSITION
BLADE TIPS STAY TOGETHER BLADES FLEX FORCING TIPS APART
Figure 7.5B

©Copyright AMKUS Rescue Systems, Inc. 2020 LAI-002 April 29, 2020 Rev00
16
7.6 SPREADING / SQUEEZING / LIFTING
Rotating the control valve actuator regulates the hydraulic flow rate and power delivered to the tool. Turning the control valve actuator
to the end stops provides maximum hydraulic flow rate and power.
Figure 7.6A
WARNING When operating the spreader, the tool may rotate as it meets resistance. If tool rotation places
the user, operator, or others in jeopardy, immediately release the control valve actuator. Stop and
modify the extrication procedure. The deadman safety feature returns the control valve actuator
to the center (neutral) position stopping arm movement. Seek another purchase point to proceed
with the extrication.
WARNING Spreading, squeezing, pulling, and lifting operations can cause loads to become unstable.
Unstable loads can cause injury or death. To avoid load instability:
• Position the spreader tips to maintain maximum contact with the surfaces to be spread,
gripped or lifted.
• Always stabilize the object being lifted.
TIPS MAY SLIP
INCREASE GAP AND
REPOSITION TIPS
CORRECT
STARTING POSITION
INCORRECT
STARTING POSITION
Figure 7.6B
For exchanging spreader tips, See Section 8.1 on page 17.

©Copyright AMKUS Rescue Systems, Inc. 2020 LAI-002 April 29, 2020 Rev00
17
8.0 ACCESSORIES
8.1 EXTENDED REACH SPREADER TIPS (ERT)
The ION spreaders use removable tips. To remove the spreader tip, use a thumb and finger to depress the spring loaded tip pins, and
remove the tips. To re-install the spreader tip, slide the tip back into place. Be sure that both pins return fully to their original positions.
The reach and versatility of the spreader can be increased by using the Extended Reach Tips (ERT). ERT tips are interchangeable
with the standard tips.
GATOR TIP ERT
COMBINATION
GATOR TIP AND ERT
COMBINATION
OFFSET ERT
Figure 8.1
8.2 CHAIN USE
WARNING Transport chain is NOT rated for overhead lifting. Injury or death may occur from improper chain
use. Observe chain safety guidelines established by the Authority Having Jurisdiction (AHJ).
Chain kits are available for spreaders. Setup and operation of
both chain kits are the same:
• Secure chains around the load removing slack using grab
hooks to latch fully across the chain (tip of hook must not
be inserted into holes of the chain link)
• Remove slack in the chain using quick adjust links
(spreader)
• Tension the chain slightly and check to see that the
connections are stable and safe
• Activate the control valve actuator to close the arms and
draw the load
Chain Rating: 3/8” grade 70 Transport chain, working load limit
6600 lbs (29.94 kN)
Figure 8.2A
LOCK
RELEASE
Figure 8.2B

©Copyright AMKUS Rescue Systems, Inc. 2020 LAI-002 April 29, 2020 Rev00
18
9.0 SAFETY GUARDS
Tools with moving blades have a guard over the moving parts. The guard is secured with screws which can be removed to clear
debris during maintenance. Reinstall guards after maintenance.
Figure 9.0
10.0 INSPECTION AND MAINTENANCE
PERIODIC MAINTENANCE SCHEDULE
Frequency
(Hours of Use)
Operation Method Responsible
Party
AFTER EVERY USE CHECK BLADES, TIPS, AND ARMS FOR WEAR or DAMAGE Visual
O
EVERY 8 HOURS
CHECK THE TOOL FOR DAMAGE, VERIFY OPERATING
CONTROLS BEFORE AND AFTER EACH USE Visual
ENSURE ALL NUTS AND BOLTS ARE SECURE Visual and
Hand Tools
Figure 10.0
WARNING Perform all maintenance, inspection, and cleaning operations after the battery is removed and
the tool is cooled down to avoid injury or damage to the tool (see the Responsible Party in the
maintenance schedule).
Clean and inspect the tool before starting any maintenance work. Annual tool maintenance shall
be completed regardless of how many hours the tool has been used since its last maintenance.
10.1 ROUTINE MAINTENANCE
10.1.1 CHECK THE BLADES
The use of damaged blades decreases the cutting efficiency of the tool and can overheat the motor.
Replace the blades when they become worn, cracked, or gouged. (Consult AMKUS Rescue Systems)
Check the torque on the cutter & combination tool pivot bolt monthly. Proper pivot bolt torque is 120 ft-lbs (163 N-m).
10.1.2 HYDRAULIC MAINTENANCE
The pressure relief valve (PRV) is not user adjustable.Attempting to adjust the PRV may cause damage and make the PRV inoperable.
10.1.3 MOTOR MAINTENANCE
Keep the motor cooling vents clean and unobstructed.
Cooling Vent Holes
Figure 10.1.3

©Copyright AMKUS Rescue Systems, Inc. 2020 LAI-002 April 29, 2020 Rev00
19
10.1.4 LUBRICATION
Cutter blades, combi blades, spreader arms, links, and pins are lubricated with white lithium grease. Annual re-lubrication is
recommended for average service conditions. More frequent lubrication may be required for severe or frequent usage conditions.
10.1.5 HANDLE LIGHT BATTERY REPLACEMENT
To replace the batteries for either of the independent lights located at
opposite ends of the handle:
1. Remove the corresponding lid screws with a 3mm hex key.
2. Remove and replace the CR123A battery in each of the battery
holders.
3. Use the hex key to tighten the lid screws back into position.
REMOVE
SCREWS
Figure 10.1.5
11.0 TROUBLESHOOTING
11.1 GENERAL
NOTICE Immediately remove malfunctioning or damaged tools from service. Consult your dealer or
AMKUS Rescue Systems.
ALL SERVICE MUST BE PERFORMED BY QUALIFIED SERVICE TECHNICIANS IN OBSERVANCE
OF SAFETY REGULATIONS.
Malfunctions can be divided into three sections:
1. Malfunction of the electric motor
2. Malfunction of the hydraulic system
3. Malfunctions related to other rescue tool components or systems
M = Maintenance technician is responsible
O = Operator is responsible
11.2 TROUBLESHOOTING THE MOTOR
PROBLEM POSSIBLE REASON POSSIBLE REMEDY PERFORMED BY
MOTOR DOES
NOT START
Battery defective Replace battery O
Tool not turned on Press and release the
power button O
Battery not charged Charge battery O
PROBLEM POSSIBLE REASON POSSIBLE REMEDY PERFORMED BY
ELECTRONIC
MOTOR
OVERHEATED
Battery overheated Allow battery to cool O
Cooling vents obstructed Clean cooling vents O
Table 11.2
11.3 TROUBLESHOOTING THE HYDRAULICS
PROBLEM POSSIBLE REASON POSSIBLE REMEDY PERFORMED BY
STROKE DOES
NOT BEGIN
Control valve actuator damaged Replace control valve M
MOTOR DOES
NOT STOP
Battery shorted Replace battery O
Control valve actuator stuck Blow out control valve with air/
Consult Authorized AMKUS
Service Tech
M, O
STROKE
DISCONTINUOUS
Max. pressure valve fault Consult AMKUS Service
Department
M, O
Table 11.3

©Copyright AMKUS Rescue Systems, Inc. 2020 LAI-002 April 29, 2020 Rev00
AMKUS RESCUE SYSTEMS
AMKUS.com
4201 Montdale Drive, Valparaiso, IN 46383-4098 USA
800-592-6587 • 219-548-5000
12.0 PARTS, SERVICE, AND TECHNICAL INFORMATION
Parts, service, and technical information may be obtained from your local AMKUS dealer, or at amkus.com
13.0 DECOMMISSIONING
When decommissioning any AMKUS Rescue Systems Tool or power supply, follow local regulations. For proper disposal information,
contact your local AMKUS Rescue Systems dealer.
14.0 INSPECTION, CLEANING, DECONTAMINATION, AND STORAGE
1. Always store the tool securely in a clean, cool, dry space.
2. Relieve the pressure on the tools after use by backing offthe end stop.
3. Remove the battery from the tool.
4. Charge the battery.
BEFORE BEING PLACED BACK IN SERVICE, the rescue tool must be inspected to this list:
1. Check to see that all rescue tool markings are legible.
Contact your local dealer or AMKUS Rescue Systems for replacement labels.
2. Wipe the tool clean.
3. If the rescue tool becomes contaminated, determine the nature of the contamination. Follow the decontamination guidelines
provided by the Authority Having Jurisdiction (AHJ). Technical advice may be requested from AMKUS Rescue Systems.
4. Inspect the tool, controls, and battery after each use for damage, leakage, and excessive wear.
5. If rescue tool damage or excessive wear is noticed, remove the rescue tool from service immediately.
Contact your local AMKUS dealer or AMKUS Rescue Systems for service.
6. Install battery and verify tool operation.
WARNING Any rescue tool failing any part of this checklist is unsafe for use and must have the problem
corrected before use or being placed back in service. Operating a rescue tool that has failed the
checklist is a misuse of this equipment. Contact your local AMKUS dealer or AMKUS Rescue
Systems.