Service Procedure:
ION OIL FILL PROCEDURE
LEVEL 3 TOOL REPAIR
WARNING
Understand manual before use. Servicing AMKUS Rescue Tools 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 the documents pictured below. Obtain safety information at www.
amkus.com/resources/information
An AMKUS Level 3 Certification is required to complete the Level 3 repairs involved in this and other Level 3 Manuals.
Only AMKUS Level 3 Certified personnel are authorized to perform the complete contents of this and other manuals.
AMKUS Level 3 certification is only offered at AMKUS Rescue Systems Headquarters to authorized AMKUS Dealers.
All certifications must be renewed every 3 years. If your certification has expired, you are no longer authorized to
perform Level 3 repairs and must be re-certified at AMKUS Rescue Systems Headquarters. Failure to renew or maintain
your AMKUS Level 3 Certification could result in voiding any and all warranty coverage if AMKUS Level 3 maintenance
is still performed.
AMKUS RESCUE SYSTEMS
www.amkus.com
©Copyright Amkus Rescue Systems, Inc. 2017
4201 Montdale Drive, Valparaiso, IN 46383-4098 USA
800-592-6587 • 219-548-5000 • Fax 219-476-1669
LIK-055 October 10, 2018 Rev00
Table Of Contents
1.0 ADDITIONAL MANUALS .............................................................................................................. 3
2.0 MEANING OF SAFETY SIGNAL WORDS .................................................................................... 4
3.0 BEFORE SERVICING ANY AMKUS RESCUE TOOL .................................................................. 4
4.0 PURPOSE..................................................................................................................................... 5
5.0 PROCEDURE................................................................................................................................. 5
5.1 MAJOR FLUID FILL
5.2 FLUID TOP OFF
6.0 INSPECTION, CLEANING, DECONTAMINATION, AND STORAGE ..........................Back Cover
7.0 PARTS, SERVICE AND TECHNICAL INFORMATION .................................................Back Cover
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
©Copyright Amkus Rescue Systems, Inc. 2017
Fire and Emergency Manufacturers and Service Association
P.O. Box 147, Lynnfield, MA 01940 • www.FEMSA.org
2
LIK-055 October 10, 2018 Rev00
1.0 ADDITIONAL MANUALS
Manual: Battery Powered
Electro-hydraulic Rescue Tools
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 Àuid. 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
CUTTER
SPREADER
COMBI TOOL
RAM
BATTERY
CHARGER
HYDRAULIC SYSTEM
HYDRAULIC FLUID
Model: AMK-iC550
Model: AMK-iS240
Model: AMK-iCT516
Model: AMK-iTR230
36 VDC 4Ah LITHIUM ION, DeWALT® DCB360 Part#: AMK-IBATT
DeWALT® DC9000 1 Hour Charger, 110 VAC Part#: AMK-ICHRG
Self-contained, 10,150 PSI (700 bar) high-speed single stage pump
AMKUS MV2 (Mineral Oil base) part#: KF0006
Safety Data Sheet (SDS) for AMKUS MV2 Hydraulic Fluid is available at AMKUS.com and
CHEMTREC.com
4201 Montdale Drive, Valparaiso, IN 46383-4098 USA
800-592-6587 • 219-548-5000 • Fax 219-476-1669
AMKUS RESCUE SYSTEMS
www.amkus.com
©Copyright Amkus Rescue Systems, Inc. 2016
LAI-001 January 23, 2017 Rev00
MANUAL: ION Electro-Hydraulic Battery Operated Rescue Tools
LAI-001
SAFETY DATA SHEET
SAFETY MANUAL for AMKUS
RESCUE SYSTEMS
According to OSHA Hazard Communication
Standard, 29 CFR 1910.1200
SECTION 1. IDENTIFICATION
Product Name
DANGER
AMKUS MV2 HYDRAULIC FLUID
Manufacturers of suppliers details
AMKUS RESCUE SYSTEMS, INC.
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.
4201 Montdale Drive
Valparaiso, IN 46383-4098 USA
SDS Request
219-548-5000
Customer Service
This manual is intended for use with manuals published by manufacturers of prime movers (engines, electric motors, and pumps)
used in AMKUS power units.
Emergency telephone number
Spill Information
800-424-9300 CHEMTREC
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.
Health Information
Recommend use of the chemical and restrictions on use
Recommended Use
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/
Hydraulic oil
SECTION 2. HAZARDS IDENTIFICATION
*+6&ODVVL¿cation
Not a hazardous substance or mixture
GHS Label element
Hazard pictograms
No hazard symbol required
Signal word
No signal word
Hazard Statements
PHYSICAL HAZARDS:
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.
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 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.
4201 Montdale Drive, Valparaiso, IN 46383-4098 USA
800-592-6587 • 219-548-5000 • Fax 219-476-1669
AMKUS RESCUE SYSTEMS
www.amkus.com
©Copyright Amkus Rescue Systems, Inc. 2015-2016
AMKUS RESCUE SYSTEMS
MADE IN USA • www.amkus.com
LAA-028 December 15, 2016 Rev01
4201 Montdale Drive, Valparaiso, IN 46383-4098 USA
800-592-6587 • 630-515-1800 • Fax 219-476-1669
©Copyright Amkus Rescue Systems, Inc. 2016
LAA-001 April 15, 2016 Rev00
Safety Data Sheet AMKUS MV2 Hydraulic Fluid
Safety Manual For AMKUS Rescue Systems
LAA-028
LAA-001
©Copyright Amkus Rescue Systems, Inc. 2017
3
LIK-055 October 10, 2018 Rev00
2.0 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 standard Z535.4-2011, 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, may result in minor
or moderate injury.
NOTICE
NOTICE is used to address practices not related to physical injury.
3.0 BEFORE SERVICING ANY AMKUS RESCUE TOOL
WARNING
Servicing rescue equipment creates injury risk not found during normal product use;
· Guards removed for service create pinch points. Avoid injury during service by keeping hands
and fingers away from movable mechanisms when cycling the tool under pressure. Replace
guards before returning tools to service.
· Pressure stored within a hydraulic cylinder against an end stop can be suddenly released
during service by disassembly of hydraulic components. Release pressure by moving piston
slightly from the end stop before service. Release pressure by turning the control valve in
which the piston moves slightly away from the end stop before servicing any components.
· Energizing electrical connections and wiring exposed during service creates ignition and shock
hazards.
· Do not attempt to open a battery case. There are no user serviceable components inside the
battery.
· Always wear safety glasses when servicing, or testing Amkus rescue equipment.
Obtain Level 3 service technician training before servicing Amkus rescue equipment.
©Copyright Amkus Rescue Systems, Inc. 2017
4
LIK-055 October 10, 2018 Rev00
4.0 PURPOSE
4.1 This service procedure outlines the process of filling and topping off the ION tools with hydraulic fluid.
5.0 PROCEDURE
5.1 MAJOR FLUID FILL
5.1.1 Position the tool so that the fluid reservoir is at its highest point while also ensuring that the tool is level.
5.1.2 Ensure the piston is all the way extended but not under pressure.
5.1.3 Remove the (6) screws from the reservoir cover and remove cover.
5.1.4 Gently pry under the lip of the bladder, with your fingers, to remove it. Sharp tools may damage the
bladder.
5.1.5 Once removed, inspect the bladder for any damage (cracks, holes or splits). Replace if damaged.
5.1.6 Clean the bladder and the reservoir cover’s mating surfaces of all debris.
©Copyright Amkus Rescue Systems, Inc. 2017
5
LIK-055 October 10, 2018 Rev00
5.1.7 Slowly add oil to the reservoir, allowing air to escape.
5.1.8 Place the cover over reservoir and cycle the tool to fill the cylinder’s chamber without building pressure.
Add oil as needed.
5.1.9 With the piston fully extended, there should only be a film of fluid covering the bottom of the reservoir.
5.1.10 Retract the piston allowing the fluid to fill the reservoir, allow time for air bubbles to dissipate.
5.1.11 Once the air bubbles have dissipated from the fluid, cycle the tool to ensure there is no air in the tool.
If air bubbles appear again repeat steps 2.2.10-2.2.11
5.2.12 With the piston fully extended reinstall the bladder and reservoir cover. (The fluid will overflow from the
reservoir and force air from the system.)
©Copyright Amkus Rescue Systems, Inc. 2017
6
LIK-055 October 10, 2018 Rev00
5.2 FLUID TOP OFF
2.2.1 Position the tool so that the oil bolt is at its highest point, while ensuring that the tool is level.
2.2.2 With piston fully extended, but not under pressure, remove the oil bolt using a 5mm hex key.
NOTICE
5.1.3
DO NOT OPERATE THE TOOL WITH THIS BOLT OUT!
Using a syringe, slowly add AMKUS MV2 Hydraulic Oil to the tool. Be sure to allow air in the unit time to
escape during top off. This may take some patience.
5.2.4 Reinstall the oil bolt into the tool. Cycle tool 3-5 times from full open to full close.
5.1.5 Repeat steps 2.1.1-2.1.4 as necessary until the tool will not take any more oil.
5.1.6 After the tool is full, cycle the tool to ensure that pressure builds in both directions of operation.
©Copyright Amkus Rescue Systems, Inc. 2017
7
LIK-055 October 10, 2018 Rev00
6.0 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. IE: biological, chemical,
radioactive. The authority having jurisdiction may follow internal decontamination guidelines or request technical
advice 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.
7.0 PARTS, SERVICE AND TECHNICAL INFORMATION
Parts, service and technical information may be obtained from your local AMKUS dealer, or by contacting AMKUS
Rescue Systems.
AMKUS RESCUE SYSTEMS
www.amkus.com
©Copyright Amkus Rescue Systems, Inc. 2017
4201 Montdale Drive, Valparaiso, IN 46383-4098 USA
800-592-6587 • 219-548-5000 • Fax 219-476-1669
LIK-055 October 10, 2018 Rev00
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