Amkus ITR500 - User Manual

©Copyright AMKUS Rescue Systems 2020-2021 1 LAI-004 July 20, 2021 Rev01
AMKUS RESCUE SYSTEMS
AMKUS.com
4201 Montdale Drive, Valparaiso, IN 46383-4098 USA
800-592-6587 · 219-548-5000
G-Force
INSTRUCTIONS FOR SAFE OPERATION AND MAINTENANCE
ION
®
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. 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.
CUTTER Model: IC700
SPREADER Model: IS281
TELESCOPING RAM Model: ITR500
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 System for recommendation)
IC700 IS281 ITR500

Summary

Instructions for Safe Operation and Maintenance

Meaning of Safety Signal Words

Safety

General Description

Various Models and Terms

Identifies and illustrates key components of the AMKUS ION rescue tools.

Safety Markings

Shows examples of safety labels and markings found on the tools.

Specifications

General Specifications

Details battery, charger, and electric drive specifications.

Cutter Specifications

Provides mechanical specifications for the IC700 Cutter.

Spreader Specifications

Provides mechanical specifications for the IS281 Spreader.

Telescoping Ram Specifications

Provides mechanical specifications for the ITR500 Ram.

Safety Considerations

Protective Clothing

Emphasizes operator responsibility for appropriate protective clothing.

Training

Stresses the necessity of proper training for victim extrication.

Operating Considerations

Discusses tool use for intermittent operation and cooling.

Set-Up Procedure

Charge the Battery

Instructs to read manufacturer documentation for battery and charger use.

Install the Battery

Details safe procedure for installing the battery into the tool.

Power Button On;Off

Explains how to power the tool on and off using the power button.

Rotating Handle

Describes the 360° swiveling handle and its tension adjustment.

Operation

Battery Charge Status

Guides on checking battery charge status via indicator lights.

When to Change the Battery

Provides criteria for replacing the battery based on performance.

Storage Recommendations

Offers advice on optimal storage conditions for tools and batteries.

Status LED

Explains the meaning of different LED colors and error codes.

Cutting

Details the procedure and safety precautions for cutting operations.

Spreading; Squeezing; Lifting

Outlines the process and safety measures for spreading, squeezing, and lifting.

Telescoping Ram Operation

Explains the two-stage operation and safe use of the telescoping ram.

Accessories

Extended Reach Spreader Tips (ERT)

Describes the removable spreader tips and their interchangeability.

Chain Use

Provides safety guidelines and procedures for using transport chains.

Safety Guards

Inspection and Maintenance

Routine Maintenance

Outlines regular maintenance checks for blades, hydraulics, and motor.

Check the Blades

Details how to inspect and maintain cutter blades, including torque specs.

Hydraulic Maintenance

States that the pressure relief valve is not user adjustable.

Motor Maintenance

Advises keeping motor cooling vents clean and unobstructed.

Lubrication

Recommends lubrication with white lithium grease for moving parts.

Handle Light Battery Replacement

Provides instructions for replacing batteries in the handle lights.

Troubleshooting

General

General advice on removing malfunctioning tools and service responsibilities.

Troubleshooting the Motor

Offers solutions for motor-related issues like not starting or overheating.

Troubleshooting the Hydraulics

Provides troubleshooting steps for hydraulic problems like stroke issues.

Parts, Service, and Technical Information

Decommissioning

Inspection, Cleaning, Decontamination, and Storage

Overview

1. Function Description
2. Important Technical Specifications
3. Charger Specifications (ICHRG120 / DCB118)
4. Operating Limits
5. Electric Drive Specifications
6. Hydraulic Specifications
7. Cutter Specifications (IC700)
8. Spreader Specifications (IS281)
9. Telescoping Ram Specifications (ITR500)
10. Usage Features
11. Maintenance Features

The AMKUS ION® Battery Powered Electro-hydraulic Rescue Tools are a line of self-contained hydraulic rescue tools designed for extrication and emergency response. These tools operate using a brushless direct current (DC) motor powered by a 60 Volt battery, driving a high-pressure pump that actuates the arms or blades of the tool.

Function Description:

The AMKUS ION tools are designed to perform cutting, spreading, squeezing, pulling, and lifting operations. The control valve actuator regulates the hydraulic flow rate and power delivered to the tool. Rotating the actuator to the end stops provides maximum hydraulic flow and power. A deadman safety feature returns the control valve actuator to the OFF (neutral) position when released, stopping blade or arm movement and holding position and load. Electronics within the tool prevent electrical overload during operation.

Important Technical Specifications:

Battery Specifications (20V/60V MAX FLEXVOLT):*

• 6.0 Ah Battery (DCB606 / IBATTFV-6):
  • Dimensions: 4.9 x 3.3 x 3.6 inches (124 x 84 x 91 mm)
  • Weight: 2.25 lb (1.0 kg)
• 9.0 Ah Battery (DCB609 / IBATTFV-9):
  • Dimensions: 5.4 x 3.8 x 3.6 inches (137 x 97 x 91 mm)
  • Weight: 3.2 lb (1.45 kg)
• 12.0 Ah Battery (DCB612 / IBATTFV-12):
  • Dimensions: 5.4 x 3.8 x 3.6 (137 x 97 x 91 mm)
  • Weight: 3.2 lb (1.45 kg) The FLEXVOLT battery pack intelligently changes voltage to power 60V MAX, 120V MAX, and existing 20V MAX tools and chargers.

Charger Specifications (ICHRG120 / DCB118):

• Input Power: 120 VAC
• Output: 20 VDC
• Charge Current: 8 A
• Dimensions: 7.6 x 4.7 x 3.3 inches (193 x 120 x 84 mm)
• Charge Time: 60 minutes

Operating Limits:

• Operating Temperature Range: -25 to 140 °F (-32 to 60 °C)

Electric Drive Specifications:

• Motor Type: Brushless
• Input Voltage: 60 VDC
• Rated Input Current: 27 Amps

Hydraulic Specifications:

• Fluid Type: AMKUS MV1 Hydraulic Fluid (Mineral Oil base, Part# KF0001)
• Maximum Operating Pressure: 10,500 psi (724 bar)

Cutter Specifications (IC700):

• Dimensions: 32.9 x 8.7 x 11.6 inches (856 x 221 x 294 mm)
• Weight (excluding battery): 54.3 lb (24.6 kg)
• Weight (ready to use): 56.6 lb (25.6 kg)
• Cutter Opening: 5.8 inches (147 mm)
• Cutter Rating NFPA 1936: A7/B8/C7/D9/E9/F4

Spreader Specifications (IS281):

• Dimensions: 35.9 x 11.1 x 11.6 inches (912 x 282 x 294 mm)
• Weight (excluding battery): 53.9 lb (24.4 kg)
• Weight (ready to use): 56.3 lb (25.5 kg)
• Max Spreading Distance: 28.2 inches (716 mm)
• Max Spreader Opening (w/optional ERT tips): 35.4 inches (899 mm)
• Highest Spreading Force (HSF): 16,430 lb (73.1 kN)
• Lowest Spreading Force (LSF): 11,850 lb (52.7 kN)
• Max Spreading Force: 23,850 lb (106.1 kN)
• Highest Pulling Force (HPF): 12,860 lb (57.2 kN)
• Lowest Pulling Force (LPF): 9,200 lb (40.9 kN)

Telescoping Ram Specifications (ITR500):

• Dimensions (Retracted): 21.9 x 11.5 x 10.9 inches (556 x 292 x 277 mm)
• Dimensions (Extended): 50.5 x 11.5 x 10.9 inches (1283 x 292 x 277 mm)
• Weight (excluding battery): 54.30 lb (24.63 kg)
• Weight (ready to use): 56.55 lb (25.65 kg)
• Stroke Piston 1: 15 inches (381 mm)
• Stroke Piston 2: 13.55 inches (344 mm)
• Stroke Overall: 25.55 inches (649 mm)
• Highest Spreading Force (HSF)- Piston 1: 46,500 lb (206.8 kN)
• Lowest Spreading Force (LSF)- Piston 2: 21,750 lb (96.7 kN)

Usage Features:

• Power Button: A silver power button activates and deactivates the tool. The tool automatically powers off after 20 minutes of inactivity.
• Rotating Handle: ION Cutter and Combi Tools feature a 360° swiveling handle with adjustable tension, allowing for flexible positioning.
• Handle Lights: Dual handle lights operate in either an on/off mode or an optional mode with three intensity levels, providing illumination during use.
• Battery Charge Status: Users can check the battery charge status using indicator lights on the battery by pushing a status button. The Status LED on the tool also communicates battery status and tool conditions (e.g., good, low, fault, or error conditions like temperature extremes or motor issues).
• Spreader Tips: ION spreaders use removable tips, including Gator Tip, ERT (Extended Reach Tips), Combination Gator Tip and ERT, and Combination Offset ERT, which are interchangeable.
• Chain Use: Chain kits are available for spreaders for pulling operations, with a chain rating of 3/8" grade 70 Transport chain and a working load limit of 6600 lbs (29.94 kN). Transport chain is NOT rated for overhead lifting.
• Safety Guards: Tools with moving blades have a guard over the moving parts, secured with screws, which can be removed for maintenance.

Maintenance Features:

• Routine Maintenance:
  • Blades: Regularly check cutter blades, spreader arms, and ram pistons for wear or damage. Replace worn, cracked, or gouged blades. Check torque on cutter and combination tool pivot bolts monthly (140 ft-lb / 190 N-m).
  • Hydraulic Maintenance: The pressure relief valve is not user adjustable.
  • Motor Maintenance: Keep motor cooling vents clean and unobstructed to prevent overheating.
  • 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.
• Handle Light Battery Replacement: The handle lights are powered by 2 AA batteries, which can be replaced by removing lid screws with a 3 mm hex key.
• Overheating Prevention: AMKUS tools are designed for intermittent use. If the tool's exterior becomes too hot (above 120°F / 49°C) or hydraulic oil temperature reaches 158°F (70°C), the tool's efficiency drops, and it should be stopped to cool down. Keep motor cooling vent holes unobstructed.
• Cleaning: Remove the battery prior to cleaning. After use, clean off any accumulated oil, grease, dirt, or corrosive substances with a damp cloth and soapy water.
• Storage: Store electric tools in a clean, cool, dry place, away from direct sunlight and excess heat or cold. For long storage, fully charged battery packs should be stored in a cool, dry place out of the tool and charger. If exposed to water, remove the battery and allow both to dry before storage or use.
• Inspection: After each use, inspect the tool, controls, and battery for damage, leakage, and excessive wear. Any damaged or inoperable equipment should be removed from service immediately. Annual tool maintenance is required regardless of hours of use.
• Decontamination: If the tool becomes contaminated, follow decontamination guidelines provided by the Authority Having Jurisdiction.
• Service: All service must be performed by qualified service technicians. Malfunctioning or damaged tools should be immediately removed from service and referred to an AMKUS dealer or AMKUS Rescue Systems.

Amkus ITR500 Specifications

General

Brand	Amkus
Model	ITR500
Category	Power Tool
Language	English