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ION® Battery Powered Electro-Hydraulic Rescue Tools

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ION® Battery Powered Electro-Hydraulic Rescue Tools G-Force ION® Battery Powered Electro-hydraulic Rescue Tools Understand manual before use. Operating AMKUS Rescue Systems without understanding the DANGER 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 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. INSTRUCTIONS FOR SAFE OPERATION AND MAINTENANCE Certified Compliant to NFPA 1936 CUTTER Model: iC550 SPREADER Model: iS240, iS240-L, iS280, iS280-L COMBI TOOL Model: iCT516 RAM Model: iTR230 BATTERY DeWALT® Lithium Ion DCB606 (AMKUS 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 (for equipment stored and operated in environments below 32°F (0°C) contact AMKUS Rescue System for recommendation) AMKUS RESCUE SYSTEMS 4201 Montdale Drive, Valparaiso, IN 46383-4098 USA AMKUS.com 800-592-6587 · 219-548-5000 ©Copyright AMKUS Rescue Systems 2016-2020 1 LAI-001 November 5, 2020 Rev06 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. Fire¿ 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 Fire¿ 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, Lynn¿ eld, MA 01940 • www.FEMSA.org 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: ©Copyright Task Force Tips LLC 2016-2020 2 LAI-001 November 5, 2020 Rev06 SUPPORTING MATERIALS The following documents contain supporting safety and operating information pertaining to the equipment described in this manual. SAFETY DATA SHEET According to OSHA Hazard Communication Standard, 29 CFR 1910.1200 SECTION 1. IDENTIFICATION Product Name AMKUS MV0 HYDRAULIC FLUID Manufacturers of suppliers details AMKUS RESCUE SYSTEMS, INC. 4201 Montdale Drive Valparaiso, IN 46383-4098 USA SDS Request 219-548-5000 Customer Service Emergency telephone number Spill Information 800-424-9300 CHEMTREC Health Information Recommend use of the chemical and restrictions on use Recommended Use Hydraulic oil SECTION 2. HAZARDS IDENTIFICATION *+6&ODVVL¿ cation Aspiration hazard Category 1 GHS Label element Hazard pictograms Signal word Danger Hazard Statements PHYSICAL HAZARDS: 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. 2WKHUKD]DUGVZKLFKGRQRWUHVXOWLQFODVVL¿ 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. AMKUS RESCUE SYSTEMS 4201 Montdale Drive, Valparaiso, IN 46383-4098 USA AMKUS.com 800-592-6587 • 219-548-5000 • Fax 219-476-1669 ©Copyright AMKUS Rescue Systems, Inc. 2019 LAA-040 January 28, 2019 Rev00 Safety Data Sheet (SDS) DeWalt Charger Original Packaging DeWalt Battery Original Packaging AMKUS MV1 HYDRAULIC FLUID ION Cutter/Combi Annual SERVICE PROCEDURE: Service Procedure. LEVEL 2 ION Spreader Arm Service It is RECOMMENDED that this service procedure be performed by Amkus Trained Service people. An AMKUS Level 2 Certi¿ cation is required to complete the Level 2 repairs involved in this and other Level 2 Procedures. Only AMKUS Level 2 Certi¿ ed personnel are authorized to perform the complete contents of this and other procedures. A technician 1.0 PURPOSE can be certi¿ ed by any Level 3 Certi¿ ed Technician but Level 2 cannot teach or certify any individuals. Any Service/Maintenance Technicians that service AMKUS Equipment are required to have at least Level 2 Training. All certi¿ cations must be renewed 1.1 This service procedure outlines the process of removal and replacement of the ION Spreader arms.. every 3 years. If your certi¿ cation has expired, you are no longer authorized to perform Level 2 repairs and must be re-certi¿ ed. Failure to renew or maintain your AMKUS Level 2 Certi¿ cation could result in voiding any and all warranty if AMKUS Level 2 2.0 PROCESS maintenance is still performed. If your Certi¿ cation has expired, you are no longer authorized to perform Level 2 repairs and 2.1 DISASSEMBLY must be recerti¿ ed. 1.0 PURPOSE 1.1 This service procedure outlines the process to perform annual maintenance of the ION Cutter/Combi blades 2.0 PROCESS 2.1 Operate the tool so that the blades are half way in between open and closed. 2.2 3RZHURႇ the tool and remove the battery. 2.1.1 Actuate the tool so that the arms are at the 3RZHURႇ the tool and remove the battery. end of their stroke. Be sure the arms have 2.1.3 Remove the pinch point guard by removing (3) some play. 2.5 mm Screws. 2.3 Use a 2.5 mm hex key to loosen and remove (2) 2.4 Pull back the Boot to expose the links. set screws retaining the top and bottom of the boot. 2.1.4 Apply heat to the Pivot Point Retaining Nut 2.1.5 Remove the link pin retaining rings. for 45-60 seconds and remove using a 30mm wrench and a 10mm hex key. 2.5 Place the unit in a vise, gripping on the blades 2.6 Apply heat to the center bolt for 20-30 seconds 2.1.6 Slide link pins and pivot pins out and remove the arm. using soft jaws or rags to prevent damage. (opposite side of the zerk ¿ tting) 2.1.7 Clean and inspect the pivot pins, pivot pin nut, and link pins for damage (corrosion, marring, or fractures). 2.7 Use a 2” 6 point socket to break the center bolt loose. Replace if necessary. 2.1.8 Clean excess debris and grease from the rack and arms. 4201 Montdale Drive, Valparaiso, IN 46383-4098 USA AMKUS RESCUE SYSTEMS 4201 Montdale Drive, Valparaiso, IN 46383-4098 USA amkus.com 800-592-6587 • 219-548-5000 • Fax 219-476-1669 AMKUS RESCUE SYSTEMS amkus.com 800-592-6587 • 219-548-5000 • Fax 219-476-1669 ©Copyright AMKUS Rescue Systems, Inc. 2016-2019 LAA-023 August 14, 2019 Rev02 ©Copyright Amkus Rescue Systems, Inc. 2016-2018 LIK-056 August 6, 2018 Rev02 LAA-023 ION Combi/Cutter Annual LIK-056 ION Spreader Arm Service Service Procedure LEVEL 2 Procedure ©Copyright AMKUS Rescue Systems 2016-2020 3 LAI-001 November 5, 2020 Rev06 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 4.5 TELESCOPIC RAM 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 CUTTING 7.5 SPREADING / SQUEEZING / LIFTING 7.6 TELESCOPING RAM OPERATION 8.0 ACCESSORIES 8.1 RAM EXTENSIONS 8.2 EXTENDED REACH SPREADER TIPS (ERT) 8.3 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 ©Copyright AMKUS Rescue Systems 2016-2020 4 LAI-001 November 5, 2020 Rev06 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.
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