Amkus ion 2.0 User manual

©Copyright AMKUS Rescue Systems, Inc. 2016-2019 LAI-001 January 29, 2019 Rev03
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. This manual does not fully address safety.
Additional safety information is published in AMKUS Safety Manual LAA-001 and Safety
Data Sheet LAA-040. Instructions for safe operation of DEWALT lithium ion batteries
and chargers are included with DEWALT packaging. Obtain safety information at
amkus.com/resources/documentation
Manual: ION 2.0 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: iC550
SPREADER Model: iS240, iS240-L, iS280, iS280-L
COMBI TOOL Model: iCT516
RAM Model: iTR230
BATTERY DEWALT® DCB606 60VDC Lithium Ion Part#: IBATTFV-6
CHARGER DEWALT® DCB118 1 Hour Charger, 120 VAC Part#: ICHRG120
HYDRAULIC SYSTEM Self-contained, 10,150 PSI (700 bar) high-speed single stage pump
HYDRAULIC FLUID AMKUS MV0 (Mineral Oil base) part#: KF0007
Safety Data Sheet (SDS) for AMKUS MV0 Hydraulic Fluid is available at AMKUS.com and
CHEMTREC.com
2.0
60 VOLT
Maximum
Power
Certifi ed Compliant to
NFPA 1936, 2015 Edition

©Copyright AMKUS Rescue Systems, Inc. 2016-2019 LAI-001 January 29, 2019 Rev03
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. Firefi ghting 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
Firefi ghting 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, Lynnfi eld, MA 01940 • www.FEMSA.org
©Copyright Amkus Rescue Systems, Inc. 2016 LAA-001 April 15, 2016 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 www.amkus.com/
This Safety Manual is intended to familiarize rescue workers and maintenance personnel with the safety messages of AMKUS
Rescue Systems, including powered rescue tools (rams, cutters, spreaders, combination tools), power units (electric or gasoline
driven), and powered rescue tool components (cable assemblies, hose assemblies, hose reels, etc.). The safety messages in this
publication supersede safety information appearing in AMKUS publications prior to April 2016.
This manual is intended for use with manuals published by manufacturers of prime movers (engines, electric motors, and pumps)
used in AMKUS power units.
This manual does NOT address operation or servicing of AMKUS Rescue Systems. Only competent rescue tool repair technicians
are quali¿ ed to repair AMKUS equipment. This manual should be available to all personnel involved with AMKUS equipment.
SAFETY MANUAL for AMKUS
RESCUE SYSTEMS
AMKUS RESCUE SYSTEMS
www.amkus.com
4201 Montdale Drive, Valparaiso, IN 46383-4098 USA
800-592-6587 • 630-515-1800 • Fax [phone]
©Copyright AMKUS Rescue Systems, Inc. 2019 LAA-040 January 28, 2019 Rev00
SAFETY DATA SHEET
According to OSHA Hazard Communication
Standard, 29 CFR 1910.1200
AMKUS RESCUE SYSTEMS
AMKUS.com
4201 Montdale Drive, Valparaiso, IN 46383-4098 USA
800-592-6587 • 219-548-5000 • Fax [phone]
SECTION 1. IDENTIFICATION
DIULF CILUARDYH 0VM SUKMAemaN tcudorP
Manufacturers of suppliers details
AMKUS RESCUE SYSTEMS, INC.
4201 Montdale Drive
Valparaiso, IN 46383-4098 USA
0005-845-912tseuqeR SDS
Customer Service
Emergency telephone number
CERTMEHC 0039-424-008noitamrofnI l
lipS
Health Information
Recommend use of the chemical and restrictions on use
lio ciluardyHesU dednemmoceR
SECTION 2. HAZARDS IDENTIFICATION
*+6&ODVVL¿ cation
1 yrogetaCdrazah noitaripsA
GHS Label element
Hazard pictograms
regnaDdrow langiS
:SDRAZAH LACISYHPstnemetatS drazaH
Not classi¿ ed as a physical hazard under GHS criteria.
HEALTH HAZARDS:
H304 May be fatal if swallowed and enters airways.
ENVIRONMENTAL HAZARDS:
Not classi¿ ed as an environmental hazard under GHS criteria.
Precautionary statements
Prevention: No precautionary phrases.
Response: P301 + P310 IF SWALLOWED: Immediately call a POISON
CENTER/doctor. P331 Do NOT induce vomiting.
Storage: P405 Store locked up.
Disposal: P501 Dispose of contents/ container to an approved waste disposal
plant.
Hazardous components which must be listed on the label:
Contains Distillates (Fischer - Tropsch), heavy, C18-50 - branched, cyclic and linear.
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 À ammable but will burn.
The classi¿ cation of this material is based on OSHA HCS 2012 criteria.
Safety information for AMKUS Electric Rescue Tools is found in
document LAA-001, SAFETY MANUAL FOR AMKUS RESCUE
SYSTEMS which is intended to be used in conjunction with this
operations manual.
Safety Data Sheet (SDS) LAA-040 for AMKUS MV0 Hydraulic
Fluid is available at AMKUS.com and CHEMTREC.com

©Copyright AMKUS Rescue Systems, Inc. 2016-2019 LAI-001 January 29, 2019 Rev03
3
Table Of Contents
1.0 MEANING OF SAFETY SIGNAL WORDS.....................................................................................................................................5
2.0 SPECIFICATIONS..........................................................................................................................................................................5
2.1 GENERAL SPECIFICATIONS
2.2 CUTTER SPECIFICATIONS
2.3 SPREADER SPECIFICATIONS
2.4 COMBI TOOL SPECIFICATIONS
2.5 TELESCOPIC RAM SPECIFICATIONS
3.0 DESCRIPTION...............................................................................................................................................................................7
3.1 TOOL COMPONENTS
3.2 SAFETY MARKINGS
4.0 SAFETY CONSIDERATIONS.........................................................................................................................................................8
4.1 PROTECTIVE CLOTHING
4.2 TRAINING
4.3 OPERATING CONSIDERATIONS
5.0 SET-UP PROCEDURE...................................................................................................................................................................8
5.1 CHARGE THE BATTERY
5.2 INSTALL THE BATTERY
5.3 POWER BUTTON ON/OFF
5.4 ROTATING HANDLE
5.4.1 HANDLE LIGHTS
5.5 CONTROL VALVE ACTUATOR
6.0 OPERATION.................................................................................................................................................................................11
6.1 BATTERY CHARGE STATUS
6.2 WHEN TO CHANGE THE BATTERY
6.3 CUTTING
6.4 SPREADING / SQUEEZING / LIFTING
6.5 TELESCOPING RAM OPERATION
7.0 ACCESSORIES............................................................................................................................................................................14
7.1 RAM EXTENSIONS
7.2 EXTENDED REACH SPREADER TIPS
7.3 CHAIN USE
8.0 SAFETY GUARDS .......................................................................................................................................................................16
9.0 MAINTENANCE ...........................................................................................................................................................................17
9.1 ROUTINE MAINTENANCE
9.1.1 CHECK THE BLADES
9.1.2 HYDRAULIC MAINTENANCE
9.1.3 MOTOR MAINTENANCE
9.1.4 LUBRICATION
9.1.5 HANDLE LIGHT BATTERY REPLACEMENT
10.0 TROUBLESHOOTING ...............................................................................................................................................................19
10.1 GENERAL
10.2 TROUBLESHOOTING THE MOTOR
10.3 TROUBLESHOOTING THE HYDRAULICS
11.0 PARTS, SERVICE, AND TECHNICAL INFORMATION ............................................................................................Back Cover
12.0 DECOMMISSIONING ............................................................................................................................................... Back Cover
13.0 INSPECTION, CLEANING, DECONTAMINATION, AND STORAGE ...................................................................... Back Cover

©Copyright AMKUS Rescue Systems, Inc. 2016-2019 LAI-001 January 29, 2019 Rev03
4
1.0 MEANING OF SAFETY SIGNAL WORDS
A safety related message is identifi ed by a safety alert symbol and a signal word to indicate the level of risk involved with a particular
hazard. Per ANSI standard Z535.6-2011, the defi nitions 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 SPECIFICATIONS
2.1 GENERAL SPECIFICATIONS
BATTERY SPECIFICATIONS Part#: IBATTFV-6
Model; DEWALT DCB606
20V/60V MAX* FLEXVOLT 6.0 Ah BATTERY
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)
CHARGER SPECIFICATIONS Part#: ICHRG120
Model; DEWALT 20VMAX* Fan Cooled Fast Charger DCB118
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 MV0 Hydraulic Fluid (part number) KF0007
Maximum operating pressure PSI ( bar ) 10,150 (700)
* The DCB606 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 (6.0Ah) and power in the new 60V MAX and 120V MAX tools.
Also compatible with;
DEWALT DCB609 20V/60V MAX FLEXVOLT 9.0 Ah and DEWALT DCB612 20V/60V MAX FLEXVOLT 12 Ah BATTERY -
AMKUS IBATTFV-9 /IBATTFV-12
DEWALT DCB1800B 1800 Watt Portable Power Station and Simultaneous Battery Charger - AMKUS ICHRG120-4

©Copyright AMKUS Rescue Systems, Inc. 2016-2019 LAI-001 January 29, 2019 Rev03
5
2.2 CUTTER SPECIFICATIONS
Part#: iC550
MECHANICAL SPECIFICATIONS
Dimensions; Length X Width X Height inches ( mm ) 30.6 X 9.5 X 9.5 (777 X 241 X 241)
Weight (excl. battery) LB (kg) 45.9 (20.8)
Weight (ready to use) LB (kg) 48.2 (21.9)
Cutter Opening inches (mm) 5.8 (147)
Cutter Rating NFPA 1936 A6 / B5 / C6 / D7 / E7
2.3 SPREADER SPECIFICATIONS
Part#: iS240
MECHANICAL SPECIFICATIONS
Dimensions; Length X Width X Height inches ( mm ) 31.2 X 11.1 X 9.6 (793 X 282 X 244)
Weight (excl. battery) LB (kg) 48.7 (22.1)
Weight (ready to use) LB (kg) 51.0 (23.1)
Max Spreading Distance inches (mm) 24.5 (622)
Max Spreading Distance (with optional ERT tips) inches (mm) 32.0 (813)
Highest Spreading Force (HSF) LB (kN) 13,620 (60.6)
Lowest Spreading Force (LSF) LB (kN) 7,410 (32.9)
Highest Pulling Force (HPF) LB (kN) 10,350 (46.0)
Lowest Pulling Force (LPF) LB (kN) 5,850 (26.0)
Max Spreading Force LB (kg) 39,120 (174.0)
Part#: iS240-L (with lighted handle)
MECHANICAL SPECIFICATIONS
Dimensions; Length X Width X Height inches ( mm ) 31.2 X 11.1 X 9.6 (793 X 282 X 244)
Weight (excl. battery) LB (kg) 49.1 (22.3)
Weight (ready to use) LB (kg) 51.4 (23.3)
Max Spreading Distance inches (mm) 24.5 (622)
Max Spreading Distance (with optional ERT tips) inches (mm) 32.0 (813)
Highest Spreading Force (HSF) LB (kN) 13,620 (60.6)
Lowest Spreading Force (LSF) LB (kN) 7,410 (32.9)
Highest Pulling Force (HPF) LB (kN) 10,350 (46.0)
Lowest Pulling Force (LPF) LB (kN) 5,850 (26.0)
Part#: iS280
MECHANICAL SPECIFICATIONS
Dimensions; Length X Width X Height inches ( mm ) 32.9 X 11.1 X 9.6 (836 X 282 X 244)
Weight (excl. battery) LB (kg) 50.5 (22.9)
Weight (ready to use) LB (kg) 52.8 (24.0)
Max Spreading Distance inches (mm) 28.0 (711)
Max Spreading Distance (with optional ERT tips) inches (mm) 36.0 (914)
Highest Spreading Force (HSF) LB (kN) 12,720 (56.6)
Lowest Spreading Force (HSF) LB (kN) 6,610 (29.4)
Highest Pulling Force (HPF) LB (kN)) 9,590 (42.7)
Lowest Pulling Force (HPF) LB (kN) 4,960 (22.1)

©Copyright AMKUS Rescue Systems, Inc. 2016-2019 LAI-001 January 29, 2019 Rev03
6
2.3 SPREADER SPECIFICATIONS (cont)
Part#: iS280-L (with lighted handle)
MECHANICAL SPECIFICATIONS
Dimensions; Length X Width X Height Inches ( mm ) 32.9 X 11.1 X 9.6 (836 X 282 X 244)
Weight (excl. battery) LB (kg) 50.7 (23.0)
Weight (ready to use) LB (kg) 53.1 (24.1)
Max Spreading Distance inches (mm) 28.0 (711)
Max Spreading Distance (with optional ERT tips) inches (mm) 36.0 (914)
Highest Spreading Force (HSF) LB (kN) 12,720 (56.6)
Lowest Spreading Force (HSF) LB (kN) 6,610 (29.4)
Highest Pulling Force (HPF) LB (kN) 9,590 (42.7)
Lowest Pulling Force (HPF) LB (kN) 4,960 (22.1)
2.4 COMBI TOOL SPECIFICATIONS
Part#: iCT516
MECHANICAL SPECIFICATIONS
Dimensions; Length X Width X Height Inches ( mm ) 33.9 X 9.5 X 9.5 (861 X 241 X 241)
Weight (excl. battery) LB (kg) 48.7 (22.1)
Weight (ready-to-use) LB (kg) 51.0 (23.1)
Max Spreading Distance inches (mm) 15.5 (394)
Highest Spreading Force (HSF) LB (kN) 8,920 (39.7)
Lowest Spreading Force (LSF) LB (kN) 6,650 (29.6)
Cutter Opening inches (mm) 7.3 (185)
Cutter Rating A6 / B7 / C6 / D7 / E7
2.5 TELESCOPIC RAM SPECIFICATIONS
Part#: iTR230
MECHANICAL SPECIFICATIONS
Dimensions; Length X Width X Height Inches ( mm ) 17.8 X 7.3 X 11.4 (452 X 185 X 290)
Weight (excl. battery) LB (kg) 37.5 (17.0)
Weight (ready-to-use) LB (kg) 39.8 (18.1)
Length Retracted inches (mm) 11.4 (290)
Length Extended inches (mm) 22.6 (574)
Highest Spreading Force (HSF) Piston 1 LB (kN) 48,360 (215.1)
Lowest Spreading Force (LSF) Piston 2 LB (kN) 17,170 (76.4)
Extension Lengths Available inches (mm) 10, 18 and 27
(254, 457 and 686)
Max Extended Length (achieved with 27” extension) inches (mm) 49.6 (1260)

©Copyright AMKUS Rescue Systems, Inc. 2016-2019 LAI-001 January 29, 2019 Rev03
7
3.0 DESCRIPTION
3.1 TOOL COMPONENTS
AMKUS ION 2.0 tools have a 60 Volt direct current brushless motor which drives a hydraulic pump. Pressurized hydraulic fl uid moves
a piston to operate the tool.
Cutter Blades
Grip
Control Valve Actuator Battery
Guard
Lighted Handle
Oil Cap
FIGURE 3.1a
Handle
Spring Loaded
Handle Release
FIGURE 3.1b
3.2 SAFETY MARKINGS
OPENCLOSE
FIGURE 3.2
4201 Montdale Drive, Valparaiso, IN 46383-4098
800-592-6587 • 219-548-4000
KEL0001
UNDERSTAND MANUAL BEFORE USE.
OPERATING AMKUS RESCUE SYSTEMS
WITHOUT UNDERSTANDING THE
MANUAL, RECEIVING PROPER TRAINING,
AND USING APPROPRIATE PERSONAL
PROTECTION EQUIPMENT IS A MISUSE
OF AMKUS EQUIPMENT. OBTAIN SAFETY
INFORMATION AT WWW.AMKUS.COM
DANGER
SERIAL NO: K123456
DATE OF MFG: 04/2018
MODEL: AMK—IC550
SYSTEM PRESSURE:
10,150 PSI (700 BAR)
FLUID TYPE: AMKUS MV0
60VDC, lmin 2.75, lmax 4.75

©Copyright AMKUS Rescue Systems, Inc. 2016-2019 LAI-001 January 29, 2019 Rev03
8
4.0 SAFETY CONSIDERATIONS
NOTICE AMKUS electric motors, batteries, and chargers are not waterproof and are not intended for
immersion.
Consult Safety Manual LAA-001 for risk associated with electric rescue tools. Consult DEWALT safety data sheet for risk associated
with DEWALT DCB battery and charger. Observe warnings provided with the battery and charger.
4.1 PROTECTIVE CLOTHING
It is the responsibility of the user to ensure that appropriate protective clothing and equipment are used to provide protection from
those hazards to which personnel are exposed or could be exposed while working with this product.
4.2 TRAINING
The AMKUS ION tool design facilitates the extraction of entrapment victims by emergency services personnel. Only trained
personnel should attempt extrication. All personnel using this equipment are assumed to have completed a course of instruction that
is acknowledged as being educationally sound by the local authority having jurisdiction over such training. This document contains
basic operating and maintenance instructions only.
4.3 OPERATING CONSIDERATIONS
AMKUS ION tools are intended for intermittent use with suffi ciently longs pauses to allow the oil to cool. If the tool becomes too hot
to touch, the temperature is above 120°F (49°C). When oil temperature reaches 158°F (70°C) the effi ciency is signifi cantly reduced
and the tool should be stopped to cool down.
• Avoid rescue tool overheating.
• Keep motor cooling vents unobstructed and the heat sink fi ns clean.
• Remove the battery prior to cleaning, servicing, or inspecting the tool.
• Make sure to power off tool prior to replacing removable spreader tips.
• After use, clean off any accumulated oil, grease, dirt, or corrosive substances.
• Use a damp cloth and soapy water to clean components.
WARNING Operating the rescue tool continuously against an end stop may damage the tool or cause injury
to operator.
NOTICE Store electric tools in a secure dry place that can only be accessed by authorized staff .
5.0 SET-UP PROCEDURE
AMKUS equipment is manufactured with superior craftsmanship and quality that is backed by the standard warranty which is
published on the AMKUS website. 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.
5.1 CHARGE THE BATTERY
Charge the battery before use;
• Plug the charger into 110 VAC power outlet before inserting a battery pack
• Insert the battery pack into the charger
• The charger has a light charge indicator that blinks according to the state of the charge of the battery pack
• Charging is complete when the red light remains ON
• The battery is fully charged and may be used, or left in the charger
Figure 5.1

©Copyright AMKUS Rescue Systems, Inc. 2016-2019 LAI-001 January 29, 2019 Rev03
9
5.2 INSTALL THE BATTERY
A quick push slides the battery into the tool. Slide the battery onto the tool until the latch clicks.
Figure 5.2
5.3 POWER BUTTON ON/OFF
Press and hold the silver power button momentarily. Release the button when the light stays lit. Press and hold the power button
to shut off the rescue tool. The power is off when the lights are off . The rescue tool will power off automatically after 20 minutes of
inactivity.
Figure 5.3
5.4 ROTATING HANDLE
ION cutter and combi tools come equipped with a 360° swiveling handle that has variable tension.
RELEASE
LOCK
TENSION
SCREW
To increase rotating handle tension,
tighten the tension screw shown above.
Flip the red latch handle up on the tool’s cuff to rotate the rescue tool,
and flip it down to lock the handle position.
Figure 5.4

©Copyright AMKUS Rescue Systems, Inc. 2016-2019 LAI-001 January 29, 2019 Rev03
10
5.4.1 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 off after 15 minutes
of continuous use.
Button press:
1st light level low
2nd light level medium
3rd light level high
4th power off light
Figure 5.4.1
5.5 CONTROL VALVE ACTUATOR
The control valve actuator is equipped with a deadman safety feature, which causes the control valve actuator to return to the OFF
position (neutral) when released (see fi g. 5.5). The movement of the tool will stop and hold its position and load. The control valve
actuator controls the motor and hydraulic pump. The tool contains electronics that prevent overload during operation. The control
valve actuator has three positions (see fi g. 5.5)
OPEN:
clockwise rotation
closes the tool
OFF (Neutral postion):
The control valve actuator returns to
the center with motor stopped
CLOSE:
counter clockwise rotation
opens the tool
Figure 5.5
Verify operation of control valve actuator by checking to see it returns automatically to the neutral position. The silver indicator will be
lined up with the center axis of the hand grip in the neutral position.

©Copyright AMKUS Rescue Systems, Inc. 2016-2019 LAI-001 January 29, 2019 Rev03
11
6.0 OPERATION
6.1 BATTERY CHARGE STATUS
Figure 6.1
Check the battery charge status using the indicator lights on the battery by pushing the status button on the battery.
6.2 WHEN TO CHANGE THE BATTERY
ION tools always keep power ON when you’re running the tool. Operation can continue until the motor starts to slow down. When
the motor sounds slower, stop & change to a charged battery. The battery management system maintains power until the battery is
drained. Allow the battery to cool before charging. Also allow the battery to fully charge before using it again.
Figure 6.2
NOTICE Draining a battery’s charge completely may result in overheating or battery damage reducing
the battery’s longevity. Wait for the battery to cool down before placing the battery in a charger.
Ensure the battery is completely charged before installation in a tool.
CAUTION Shorting the battery terminals together may cause burns or a fi re. When battery pack is not in use,
keep it away from other metal objects, like paper clips, coins, keys, nails, screws, or other small
metal objects, that can make a connection from one terminal to another.
CAUTION Liquid ejected from the battery may cause irritation or burns. Under abusive conditions, liquid
may be ejected from the battery; avoid contact. If skin or eye contact accidentally occurs, fl ush
with water. If liquid contacts eyes, additionally seek medical help.

©Copyright AMKUS Rescue Systems, Inc. 2016-2019 LAI-001 January 29, 2019 Rev03
12
6.3 CUTTING
A slight rotation of the control valve actuator runs just the electric motor and pump. Rotating the control valve actuator regulates the
hydraulic fl ow rate and power delivered to the tool. Rotating the control valve actuator to the end stops provides maximum hydraulic
fl ow rate and power.
Figure 6.3a
To perform a cutting operation, open the cutter blades. Place the blades around the object to be cut. Close the blades to cut the
object. Maximum cutting forces are obtained nearest the pivot point. Start the cut with the blades engaged as deep as possible.
After making the cut, open the blades and remove the tool. 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 (drift). If tool rotation places the user 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, and the movement of the blades will stop. Reposition cutter as needed to
maintain optimum cutting performance.
The blades on AMKUS cutters have been proven eff ective for cutting steering columns, brake pedals, latching mechanisms, and other
such items as may be necessary for extrication. However, this cutter is not intended as a piercing tool for heavy metal. Therefore,
when cutting, care must be taken to insure that the tips of the blades have a clear path of travel. The tips of the blades will pierce the
sheet metal body panels of most automobiles, but care must be taken to avoid obstacles like the heavy metal backing plates behind
seat belt mounts, door hinges, and latching mechanisms or locks.
WARNING Blades can break if positioned incorrectly. If blades start to fl ex sideways (tool rolls as space
between blades increases), stop immediately and reconsider cutting strategies.
NOTICE Cutting hardened solids 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, and heat treated chain. Blade damage or breakage that results from
cutting these hardened 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
blades as necessary.
CORRECT POSITIONING
Figure 6.3b
INCORRECT POSITIONING
Blades start to flex sideways
Figure 6.3c

©Copyright AMKUS Rescue Systems, Inc. 2016-2019 LAI-001 January 29, 2019 Rev03
13
6.4 SPREADING / SQUEEZING / LIFTING
Figure 6.4a
The spreader can be used for spreading, squeezing, pulling and lifting operations. When spreading, squeezing or lifting, make sure
that the spreader tips are positioned to maintain maximum contact with the surfaces to be spread or gripped. Always stabilize the
object being lifted. When operating the spreader, the tool may rotate as it meets resistance. If tool rotation places the user or others in
jeopardy, immediately release the control valve actuator and modify your procedure. The deadman safety feature should immediately
return the control valve actuator to the center (neutral) position, and the movement of the arms will stop. Then seek another purchase
point that does not cause the same problem.
TIPS MAY SLIP
INCREASE GAP AND
REPOSITION TIPS
CORRECT
STARTING POSITION
INCORRECT
STARTING POSITION
Figure 6.4b
See 7.2 for exchanging spreader tips

©Copyright AMKUS Rescue Systems, Inc. 2016-2019 LAI-001 January 29, 2019 Rev03
14
CORRECT STARTING POSITION INCORRECT STARTING POSITION
Too much space
Space filled with
an extension or
blocking
Figure 6.5b
6.5 TELESCOPING RAM OPERATION
Spring Release
Figure 6.5a
The telescopic ram has two stages that extend out in sequence. The larger diameter fi rst stage has a higher force than the second
stage due to its larger diameter. The head on the second stage is permanently installed, whereas the base of the ram is removable
so an extension may be added. (See section 7.1)
Identify the crush zone. These are areas under the load and around the load with risk of crushing from a falling or rolling load. Position
the ram base securely against a support surface. Excess space may be taken up using cribbing, or a ram extension. Extend the lifting
head to the object being displaced. Ensure nearby people are clear of the crush zone before lifting or retracting. Displace the object
only as far as needed. Stop to stabilize the load in increments as the load is lifted or lowered. The telescoping ram is used in pushing
and lifting objects with pistons extending. The load is held when the control valve actuator is in OFF (neutral) position. The ram is
NOT to be used for pulling tension loads with pistons retracting.
The handle position is adjustable by pulling out the spring loaded handle release and rotating the handle as needed. Re-position the
carrying handle to avoid interference with the load. The tool may be carried with the handle in any locked position.

©Copyright AMKUS Rescue Systems, Inc. 2016-2019 LAI-001 January 29, 2019 Rev03
15
7.0 ACCESSORIES
7.1 RAM EXTENSIONS
Ram extensions are available in three lengths and fi t onto the telescopic ram.
To Remove:
Line up the dots and pull
To Install:
Line up the dots, push on and twist
A
MK-TCE10 - 10 inch ram extension (254 mm)
A
MK-TCE18 - 18 inch ram extension (457 mm)
A
MK-TCE27 - 27 inch ram extension (686 mm)
A
MK-TCE-KIT - all three extensions
OR OR
Figure 7.2
WARNING Stacking extensions adds pivot points that may cause the load to become unstable. Sudden
movement can occur in unstable loads having potential to cause severe injury or death. Only use
one extension at a time. (For examples, see LAA-001 Safety Manual For AMKUS Rescue Tools)

©Copyright AMKUS Rescue Systems, Inc. 2016-2019 LAI-001 January 29, 2019 Rev03
16
7.2 EXTENDED REACH SPREADER TIPS
The ION spreaders use removable tips. To remove the spreader tip, use a thumb and fi nger 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 TIP COMBO TIP 1 COMBO TIP 2
Figure 7.2a
Figure 7.2b
7.3 CHAIN USE
Chain kits are available for spreaders.
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.
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 to be inserted into
holes of the chain link)
• Remove slack in the chain using quick adjust links (spreader), or grab
hooks (combi)
• 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
Figure 7.3a
Chain rating; 3/8” grade 70 Transport chain, working load limit 6600 lbs (2994 kg)
RELEASE
LOCK
K-CHAIN24-30 (for use on iS240 & iS280 Spreaders)
Figure 7.3b Figure 7.3c

©Copyright AMKUS Rescue Systems, Inc. 2016-2019 LAI-001 January 29, 2019 Rev03
17
8.0 SAFETY GUARDS
Tools with moving blades or arms have a guard over the moving parts. The guard is secured with screws which can be removed to
clear debris during maintenance. Replace guards after maintenance.
WARNING Operating rescue tools can result in injury or death from laceration, projectile (high speed fl ying
debris) and pinch point injuries. Stay clear of the path of travel. Do not operate without guards.
Avoid unnecessary risk. (For examples, see LAA-001 Safety Manual For AMKLUS Rescue Tools)
Guard
Guard
Figure 8.0
9.0 MAINTENANCE
PERIODIC MAINTENANCE SCHEDULE
Frequency
(Hours of Use) Operation Method Person in charge
AFTER USE CHECK BLADES, TIPS AND ARMS FOR WEAR or DAMAGE SEE 9.1.1 Operator
EVERY 8 HOURS CHECK THE TOOL FOR DAMAGE, VERIFY OPERATING
CONTROLS
Visual Operator
EVERY 8 HOURS ENSURE ALL NUTS AND BOLTS ARE SECURE Operator
Perform all maintenance, inspection, and cleaning operations with the battery removed and the tool cool (see the person responsible
in the maintenance schedule); Annual tool maintenance shall be completed regardless of how many hours the tool has been used
since it’s last maintenance. Clean and inspect the tool before starting any maintenance work.
9.1 ROUTINE MAINTENANCE
9.1.1 CHECK THE BLADES
The use of damaged blades decreases the cutting effi ciency of the tool and can overheat the motor.
Replace the blades when they become: worn, cracked, or gouged. (Consult AMKUS Rescue Systems)
9.1.2 HYDRAULIC MAINTENANCE
NOTICE Immediately remove malfunctioning or damaged tools from service. Consult your dealer or AMKUS
Rescue Systems.
NOTICE Do not adjust pressure relief valve . User adjustment of the pressure relief valve voids the warranty.
WARNING Misuse of AMKUS Rescue Systems can result in a wide variety of hazards and consequences.
Remain aware of and avoid misuse situations. (For examples, see LAA-001 Safety Manual For
AMKUS Rescue Tools)
AMKUS Electric tools are equipped with an internal relief valve. In case of
an unexpected pressure drop have a qualifi ed AMKUS repair technician
check the pressure relief valve to ensure that it’s operating properly.
• User adjustment of the pressure relief valve is a misuse of the tool.
See document LIK-055 SERVICE PROCECURE: ION OIL FILL (Level 3
service Technician).
Pressure
Relief Valve

©Copyright AMKUS Rescue Systems, Inc. 2016-2019 LAI-001 January 29, 2019 Rev03
18
9.1.3 MOTOR MAINTENANCE
Keep the motor cooling vents clean and unobstructed
9.1.4 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 of frequent usage conditions.
Refer to document LAA-023 SERVICE PROCEDURE LAA-023 (Level 2 service technician) and LIK-056 SERVICE PROCEDURE
ION SPREADER ARM.
9.1.5 HANDLE LIGHT BATTERY REPLACEMENT
To replace the batteries for either of the independent lights located
at opposite ends of the handle, remove the corresponding lid
screws with a 3mm hex key. Insert one CR123A battery into each
of the battery holders. Use the hex key to tighten the lid screws
back into position.
Battery change; remove the screws and covers. Replacement
batteries; CR123 lithium ion battery (2 required).
Figure 9.1.5

©Copyright AMKUS Rescue Systems, Inc. 2016-2019 LAI-001 January 29, 2019 Rev03
19
10.3 TROUBLESHOOTING THE HYDRAULICS
FAULT POSSIBLE REASON POSSIBLE REMEDY PERFORMED BY
OUTWARD
STROKE DOES
NOT BEGIN
Control valve actuator damaged Replace 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
OUTWARD
STROKE
DISCONTINUOUS
Max. pressure valve fault Consult AMKUS
Service Department
M,O
10.2 TROUBLESHOOTING THE MOTOR
FAULT POSSIBLE REASON POSSIBLE REMEDY PERFORMED BY
MOTOR DOES
NOT START
Battery defective Replace O
Tool not turned on Press power button for
3 seconds
O
Battery not charged Charge battery O
FAULT POSSIBLE REASON POSSIBLE REMEDY PERFORMED BY
ELECTRIC
MOTOR
OVERHEATED
Battery overheated Wait for it to cool down O
Cooling vents
obstructed
Clean O
10.0 TROUBLESHOOTING
10.1 GENERAL
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 systems.
NOTICE ALL SERVICE MUST BE PERFORMED BY QUALIFIED SERVICE TECHNICIANS IN OBSERVANCE
OF SAFETY REGULATIONS.
Remedies marked by the letter M require the intervention of the Maintenance technician.
Remedies marked with the letter O can be performed by the Operator.

©Copyright AMKUS Rescue Systems, Inc. 2016-2019 LAI-001 January 29, 2019 Rev03
AMKUS RESCUE SYSTEMS
AMKUS.com
4201 Montdale Drive, Valparaiso, IN 46383-4098 USA
800-592-6587 • 219-548-5000
11.0 PARTS, SERVICE AND TECHNICAL INFORMATION
Parts, service, and technical information may be obtained from your local AMKUS dealer, or by contacting AMKUS Rescue Systems.
12.0 DECOMMISIONING
When decommissioning any AMKUS Rescue Systems Tool or power supply, local regulations shall be followed. For proper disposal
information, contact your local AMKUS Rescue Systems dealer.
13.0 INSPECTION, CLEANING, DECONTAMINATION, AND STORAGE
1. Always store the tool securely in a clean, dry space.
2. Relieve the pressure on the tools after use by backing off the end stop.
3. 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. 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 dealer or
AMKUS Rescue Systems for service.
6. Install battery and verify tool operation.
WARNING Any rescue tool failing any part of the checklist is unsafe for use and must have the problem
corrected before use or being placed back into service. Operating a rescue tool that has failed the
checklist is a misuse of this equipment. Contact your local dealer or AMKUS Rescue Systems.
Products manufactured in Italy and USA.