Amkus ion AMK-iC550 User manual

©Copyright Amkus Rescue Systems, Inc. 2016-2017 LAI-001 August 31, 2017 Rev01
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-028 for hydraulic fl uid. Instructions for safe operation of DeWALT lithium ion
batteries and chargers are included with DeWALT packaging. Obtain safety information at
www.amkus.com/resources/information
Manual: Battery Powered
Electro-hydraulic Rescue Tools
AMKUS RESCUE SYSTEMS
www.amkus.com 4201 Montdale Drive, Valparaiso, IN 46383-4098 USA
800-592-6587 • 219-548-5000 • Fax [phone]
CUTTER Model: AMK-iC550
SPREADER Model: AMK-iS240, AMK-iS280
COMBI TOOL Model: AMK-iCT516
RAM Model: AMK-iTR230
BATTERY 36 VDC 4Ah LITHIUM ION, DeWALT® DCB360 Part#: AMK-IBATT
CHARGER DeWALT® DC9000 1 Hour Charger, 110 VAC Part#: AMK-ICHRG
HYDRAULIC SYSTEM Self-contained, 10,150 PSI (700 bar) high-speed single stage pump
HYDRAULIC FLUID AMKUS MV2 (Mineral Oil base) part#: KF0006
Safety Data Sheet (SDS) for AMKUS MV2 Hydraulic Fluid is available at AMKUS.com and
CHEMTREC.com

©Copyright Amkus Rescue Systems, Inc. 2016-2017 LAI-001 August 31, 2017 Rev01
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. 2016-2017 LAI-001 August 31, 2017 Rev01
3
©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]
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.
©Copyright Amkus Rescue Systems, Inc. 2015-2016 LAA-028 December 15, 2016 Rev01
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
DIULF CILUARDYH 2VM 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
llipS
noitamrofnI htlaeH
Recommend use of the chemical and restrictions on use
lio ciluardyHesU dednemmoceR
SECTION 2. HAZARDS IDENTIFICATION
GHS Classi¿ cation
Not a hazardous substance or mixture
GHS Label element
deriuqer lobmys drazah oNsmargotcip drazaH
drow langis oNdrow langiS
:SDRAZAH LACISYHPstnemetatS drazaH
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.
Other hazards which do not result in classi¿ 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.
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) LAA-028 for AMKUS MV2
Hydraulic Fluid is available at AMKUS.com and
CHEMTREC.com

©Copyright Amkus Rescue Systems, Inc. 2016-2017 LAI-001 August 31, 2017 Rev01
4
Table Of Contents
1.0 MEANING OF SAFETY SIGNALWORDS.....................................................................................................................................5
2.0 SPECIFICATIONS..........................................................................................................................................................................5
2.1 GENERALSPECIFICATIONS
2.2 CUTTER SPECIFICATIONS
2.3 SPREADER SPECIFICATIONS
2.4 COMBI TOOL SPECIFICATIONS
2.5 TELESCOPIC RAM SPECIFICATIONS
3.0 DESCRIPTION...............................................................................................................................................................................7
3.1 TOOLCOMPONENTS
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 INSTALLTHE BATTERY
5.3 POWER SWITCH ON/OFF
5.4 ROTATING HANDLE
5.4.1 HANDLE LIGHTS
5.5 CONTROLVALVEACTUATOR
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
7.0ACCESSORIES............................................................................................................................................................................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 GREASE THE CENTER PIN
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 INSPECTION, CLEANING, DECONTAMINATION,AND STORAGE ......................................................................Back Cover
12.0 PARTS, SERVICEAND TECHNICALINFORMATION.............................................................................................Back Cover

©Copyright Amkus Rescue Systems, Inc. 2016-2017 LAI-001 August 31, 2017 Rev01
5
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#: AMK-IBATT
Model - DeWALT DCB360
Nominal voltage [ Volts DC] 36
Battery capacity [ Ah ] 4.0
Dimensions; Length X Width X Height Inches ( mm ) 6.2 X 3.6 X 3.3 (158 X 92 X 84)
Weight LB ( kg ) 2.87 (1.3)
CHARGER SPECIFICATIONS Part#: AMK-ICHRG
Model; DeWALT DC9000
Input power [ Volts AC] 120
Output [ Volts DC ] 36
Charge current [ mA ] 0-3000
Dimensions; Length X Width X Height Inches ( mm ) 8.5 x 6.1 x 3.5
(216 x 155 x 89)
Charge Time (minutes) 60
OPERATING LIMITS
Guaranteed no-load LwA sound level
(CEI EN 60745-1 and CEI EN 60745-2-8) [ dB ]
95
No-load operator Lpa
(CEI EN 60745-1 and CEI EN 60745-2-8) [ dB ]
79
Vibrations (CEI EN 60745-1 and EN ISO 5349) (m/s²) 2.56
Operating temperature range Degrees F (C) -25 to 140 (-32 to 60)
ELECTRIC DRIVE SPECIFICATIONS
Input voltage [ Volts ] 36
Rated input current; minimum / maximum [ Amps ] 2.75 / 4.75
HYDRAULIC SPECIFICATIONS
Fluid Type; AMKUS MV2 Hydraulic Fluid (part number) KF0006
Maximum operating pressure PSI ( bar ) 10,150 (700)

©Copyright Amkus Rescue Systems, Inc. 2016-2017 LAI-001 August 31, 2017 Rev01
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2.2 CUTTER SPECIFICATIONS
Part#: AMK-iC550
MECHANICAL SPECIFICATIONS
Dimensions; Length X Width X Height Inches ( mm ) 29.2 X 6.9 X 8.6 (741 X 175 X 218)
Weight (excl. battery) LB (kg) 44.4 (20.1)
Cutter Opening inches (mm) 5.9 (150)
Cutter Rating A6 / B6 / C7 / D7 / E7
2.3 SPREADER SPECIFICATIONS
Part#: AMK-iS240
MECHANICAL SPECIFICATIONS
Length 30.1 X 11.1 X 8.8 (764 X 282 X 223)
Weight (excl. battery) LB (kg) 46.2 (21)
Max Spreading Distance inches (mm) 24.0 (609)
Max Spreading Distance (with optional ERT tips) inches (mm) 32.0 (813)
Part#: AMK-iS280
MECHANICAL SPECIFICATIONS
Length 32.1 X 7.0 X 8.8 (815 X 177 X 223)
Weight (excl. battery) LB (kg) 49.1 (22.3)
Max Spreading Distance inches (mm) 28.0 (711)
Max Spreading Distance (with optional ERT tips) inches (mm) 36.0 (914)
2.4 COMBI TOOL SPECIFICATIONS
Part#: AMK-iCT516
MECHANICAL SPECIFICATIONS
Length 28.9 X 6.9 X 8.6 (734 X 175 X 218)
Weight (excl. battery) LB (kg) 47.1 (21.4)
Max Spreading Distance inches (mm) 15.6 (396)
Cutter Opening inches (mm) 7.3 (185)
Cutter Rating A6 / B6 / C6 / D7 / E7
2.5 TELESCOPIC RAM SPECIFICATIONS
Part#: AMK- iTR230
MECHANICAL SPECIFICATIONS
Dimensions; Length X Width X Height Inches ( mm ) 17.0 X 7.9 X 11.4 (432 X 200 X 290)
Weight (excl. battery) LB (kg) 36.1 (16.4)
Length Retracted inches (mm) 11.4 (290)
Length Extended inches (mm) 22.6 (574)
Extensions 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. 2016-2017 LAI-001 August 31, 2017 Rev01
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3.0 DESCRIPTION
3.1 TOOL COMPONENTS
AMKUS ION tools have a 36 Volt direct current motor which drives a hydraulic pump. Pressurized oil moves a piston to operate the
tool.
Cutter Blades
Grip
Control Valve Actuator Battery
Guard
Lighted Handle
Oil Cap
Power Button
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: 12/2016
MODEL: AMK—IC550
SYSTEM PRESSURE:
10,150 PSI (700 BAR)
FLUID TYPE: AMKUS MV2
36VDC, lmin 2.75, lmax 4.75

©Copyright Amkus Rescue Systems, Inc. 2016-2017 LAI-001 August 31, 2017 Rev01
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
This product is designed to be used by emergency services personnel to facilitate the extrication of victims from entrapment. Its
use should be limited to trained personnel only. 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 deg 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 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 tips.
• After use, clean off any accumulated oil, grease, dirt, or corrosive substances.
• Use a damp cloth and soapy water to clean components.
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 three-light charge indicator that blinks
according to the state of the charge of the battery pack.
• Charging is complete when three red lights remain ON
• The battery is fully charged and may be used, or left in
the charger
Figure 5.1

©Copyright Amkus Rescue Systems, Inc. 2016-2017 LAI-001 August 31, 2017 Rev01
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 ON/OFF
Press and hold the red power button for 3 seconds. The green lights on the button will fl ash 3 times. Release the button when the
lights stay lit. Press and hold the red switch for 2 seconds 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. 2016-2017 LAI-001 August 31, 2017 Rev01
10
5.4.1 HANDLE LIGHTS
AMKUS dual handle lights have 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 burn 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 OFF of
fi gure 5.5 when released. The movement of the tool will stop and hold its position and load. The control valve actuator controls the
motor and hydraulic pump. Battery protection software is installed in the battery to avoid overload from users attempting to re-start
the pump when the tool is against stroke ends. The control valve actuator has three positions (see fi g. 5.5)
CLOSE:
counter clockwise rotation
closes the tool
OFF (Neutral postion):
The control valve actuator returns to
the center with motor stopped
OPEN:
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.