Manual: AMK-22 Cutter - AMKUS Rescue Systems · 2019. 8. 19. · Manual: AMK-22 Cutter DANGER...

©Copyright AMKUS Rescue Systems, Inc. 2016-2019 LAC-003 May 20, 2019 Rev05

AMKUS RESCUE SYSTEMSamkus.com

4201 Montdale Drive, Valparaiso, IN 46383-4098 USA800-592-6587 • 219-548-5000 • Fax 219-476-1669

Manual: AMK-22 Cutter

DANGERUnderstand 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-004.

EN13204 Designation: AC127F-20.9

Certifi ed Compliant toNFPA 1936, 2015 Edition

Shown with optionallighted handle


DANGERPERSONAL 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 AssociationP.O. Box 147, Lynnfi eld, MA 01940 • www.FEMSA.org

©Copyright Amkus Rescue Systems, Inc. 2016 LAA-001 April 15, 2016 Rev00

DANGERUnderstand 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 gasolinedriven), 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 SYSTEMSwww.amkus.com


©Copyright Amkus Rescue Systems, Inc. 2014-2016 LAA-004 December 8, 2016 Rev04

SAFETY DATA SHEETAccording to OSHA Hazard Communication

Standard, 29 CFR 1910.1200



SECTION 1. IDENTIFICATIONDIULF CILUARDYH 1VM SUKMAemaN tcudorP

Manufacturers of suppliers detailsAMKUS RESCUE SYSTEMS, INC.4201 Montdale DriveValparaiso, IN 46383-4098 USA

0005-845-912tseuqeR SDSCustomer ServiceEmergency telephone number

CERTMEHC 0039-424-008noitamrofnI llipSHealth InformationRecommend use of the chemical and restrictions on use

lio ciluardyHesU dednemmoceR

SECTION 2. HAZARDS IDENTIFICATION cation

Not a hazardous substance or mixtureGHS Label element

deriuqer lobmys drazah oNsmargotcip drazaHdrow 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 statementsPrevention: No precautionary phrases.Response: No precautionary phrases.Storage: No precautionary phrases.Disposal: No precautionary phrases.

cationProlonged 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 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 information for AMKUS 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-004 for AMKUS MV1 Hydraulic Fluid is available at AMKUS.com and CHEMTREC.com


Table Of Contents

1.0 MEANING OF SAFETY SIGNAL WORDS ................................................................. 42.0 SPECIFICATIONS ...................................................................................................... 4 2.1 PART IDENTIFICATION........................................................................................ 53.0 PROTECTIVE CLOTHING ......................................................................................... 54.0 TRAINING ................................................................................................................... 55.0 SET-UP PROCEDURE ............................................................................................... 66.0 GETTING STARTED ................................................................................................... 7 6.1 ROTATING THE HANDLE .................................................................................. 7 6.2 CONTROL VALVE ACTUATOR .......................................................................... 77.0 OPERATING INSTRUCTIONS ................................................................................... 88.0 SAFETY GUARDS ...................................................................................................... 99.0 ROUTINE MAINTENANCE ....................................................................................... 10 9.1 ROUTINE MAINTENANCE FOR HOSES 9.2 ROUTINE MAINTENANCE FOR COUPLINGS 9.3 ROUTINE MAINTENANCE FOR CENTER BOLT 9.4 MAINTENANCE RECORDS 9.5 HANDLE LIGHT BATTERY REPLACEMENT10.0 TROUBLESHOOTING ...............................................................................................1111.0 PARTS, SERVICE, AND TECHNICAL INFORMATION ............................................ 1212.0 DECOMMISSIONING ............................................................................................... 1213.0 INSPECTION, CLEANING, AND STORAGE ............................................................ 12


1.0 MEANING OF SAFETY SIGNAL WORDSA 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:

DANGERDANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury.

WARNINGWARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury.

CAUTIONCAUTION indicates a potentially hazardous situation which, if not avoided, could result in minor or moderate injury.

NOTICENOTICE is used to address practices not related to physical injury.

2.0 SPECIFICATIONSPart # AMK-22

MECHANICAL SPECIFICATIONSLength 24.7 in. (627.4 mm)Width 7.5 in. (190.5 mm)Depth 8.9 in. (226.1 mm)

Weight (ready to use)(Ready-to-use with standard couplings

and non-lighted handle)

46.0 lbs. (20.9 kg)

Cutter Opening Distance 5.0 in. (127 mm)Cutter Opening Time 5 secondsCutter Closing Time 6 seconds

Rated Input Pressure 10,500 psi (724 bar)Cutter Rating NFPA 1936 A7 / B6 / C7 / D7 / E8

Fluid Type AMKUS MV1 Mineral Base Hydraulic FluidSafety 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° deg C) contact Amkus Rescue Systems for recommendation.)

A7

B6

C7

D7

E8


4.0 TRAINING

WARNINGAMKUS equipment should only be operated by trained personnel that follow all safety precautions. Failure to do so could result in serious injury or death.

This product is designed for use 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 acknowledged as being educationally sound by the local authority having jurisdiction over such training. This document contains basic operating and maintenance instructions only.

3.0 PROTECTIVE CLOTHING

WARNINGAlways wear protective clothing. Failure to do so could result in serious injury or death.

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.

2.1 PART IDENTIFICATION

Tool Connection Hose

Handle

Control Valve Actuator

Manifold

Center Bolt Drive Link Pin(under Guard)

Cutter Blades

Guard


5.0 SET-UP PROCEDUREAMKUS manufactures equipment of superior craftsmanship and quality. Amkus backs new products with a standard warranty published on the AMKUS website, amkus.com

NOTICEOnly use AMKUS tools with AMKUS equipment. Mixing AMKUS tools with another manufacturer’s equipment may cause operational problems, equipment failure, or denial of warranty claims.

NOTICEOnly use AMKUS mineral-base hydraulic fluid in AMKUS equipment. Using another manufacturer’s hydraulic fluid in AMKUS equipment may cause operational problems, equipment failure, or denial of warranty claims.

Normally, AMKUS dealers prepare and service equipment prior to delivery. If, however, you decide to place the equipment into service yourself, please review the following instructions carefully.1. Remove equipment from the packing cartons and carefully inspect for damage. Damage occurring during shipment should be

reported immediately to the carrier.2. Gather and review all safety and use documentation prior to operating any rescue tool.3. Connect the tool connection hoses to the hose lines from the AMKUS hydraulic power unit.

a. Standard Couplings: Please note that the male and female couplings on the hose lines leading from the power unit should be connected to the corresponding male and female couplings on the tool connection hoses. To connect the couplings, twist the sleeve on the female coupling so that the notch in the sleeve lines up with the pin. Push the sleeve back so the pin fi ts into the notch. While holding the sleeve back, push the male coupling into the female coupling. Release the sleeve; it will spring forward into place. Twist the sleeve 1/4 turn so that the pin no longer lines up with the notch. Pull on the couplings to check that they are securely connected.

b1. Mono Couplings: Please note that the female coupling on the hose lines leading from the power unit should be connected to the corresponding male coupling on the tool connection hoses. To connect the couplings, place the male coupling into the female coupling. Rotate clockwise until you feel the coupling latch. Pull on the couplings to check that they are securely connected.

b2. In most cases, the Mono Couplings can be connected and disconnected while the hose line is under fl ow. It is usually not necessary to place the directional control of the power unit in the neutral position before connecting and disconnecting. However, certain circumstances such as back pressure in the return line and/or cold temperatures, may make connecting and disconnecting under fl ow extremely diffi cult or impossible. If you are unable to connect and disconnect while the line is under fl ow, place the directional control valve of the power unit in the neutral position and then disconnect or connect.


6.0 GETTING STARTED

WARNINGDo not connect tools in series. Connecting tools in series could cause operational problems, equipment failure, or catastrophic failure of the equipment resulting in serious injury or death.

Start the power unit (refer to power unit and engine manuals). Following the instructions in the power unit manual, operate the selector valve to charge the hose line to which the tool is connected. Pick up the tool, noticing that the design of the AMK-22 Cutter makes it natural to grip the handle with one hand and the control valve handgrip with the other.

6.1 ROTATING THE HANDLEThe rotating handle can be operated from any one of eight equally spaced detent positions. Ergonomic hand positioning makes cutting easier and safer even in awkward situations. A tension lock lever sets how much drag holds the handle position. To change handle position; unlock the tension and rotate the handle to the desired place. The tension lock lever follows a “U” shaped track between “locked” and “unlocked” positions as shown on the label. If the handle encounters an obstruction during cutting then the handle just moves to the next position.

Figure 6.1ALocked Position

Figure 6.1BUnlocked Position

6.2 CONTROL VALVE ACTUATORThe 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. 6.2b). The movement of the tool will stop and hold its position and load. The control valve actuator has three positions (see fi g. 6.2A, 6.2B & 6.2C)

Figure 6.2ACLOSE: Twist handle to left, from above.

Figure 6.2BOFF: (Neutral position):

The control valve actuator returns to the center

Figure 6.2COPEN: Twist handle to right, from above.


7.0 OPERATING INSTRUCTIONSRotating 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 7.3a

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.Please note the minimum safe bend radius of the hoses is 4 inches (101.6 mm).

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.

NOTICECutting 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 POSITIONINGFigure7.3b

INCORRECT POSITIONINGBlades start to flex sideways

Figure 7.3c


8.0 SAFETY GUARDS

WARNINGOperating 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 AMKUS Rescue Tools)

Tools with moving blades or arms have a guard over the moving parts. Do not operate rescue tools with guards missing.

Guard

Figure 8.0


9.0 ROUTINE MAINTENANCE

WARNINGAvoid contact with escaping hydraulic fl uid under pressure. If hydraulic fl uid punctures skin, seek medical treatment immediately. Contact with escaping hydraulic fl uid under pressure could result in serous injury or death.

Inspect all hose, hose fittings and couplings for leakage and damage (see routine maintenance for hoses and couplings).

Using a torque wrench, tighten the socket head cap screws which hold the control valve to the valve manifold and the valve manifold to the hydraulic cylinder plug to 180 in/lbs (20.3 Nm). DO NOT OVERTIGHTEN! These screws are installed securely at the factory but may loosen because of vibration while being transported on moving vehicles. Approximately once a year, or more often if necessary, remove the cutter blades for cleaning and inspection. Removal of the blades is most easily accomplished by closing the blades until the retaining rings on the drive link pins are easily accessible.

Loosen the center bolt nut. (Photo 1) After removing the nut, push the center bolt out, being careful not to damage the threads. Next, remove the retaining ring (Photo 2) from the drive link pin for each blade and push each drive link pin out. Remove the blades and friction plates from the body (Photo 3).

Photo 1 Photo 2 Photo 3Clean and inspect each blade, friction plate, drive link pin, and the center bolt for signs of damage or excessive wear. Damaged or worn parts may need to be replaced. Also, clean inside the body, being sure to remove all grease and dirt.Lubricate each blade inside the center bolt hole, the drive link pin hole, and on the surfaces where it will contact the other blade, the friction plate, and the drive link. Use a general purpose white lithium grease such as Lubriplate® No. 630-AA.Position the “ear” of the blade in the drive link. Lubricate and insert the drive link pin through the drive link and the blade. Please note that the head of the drive link pin should fit into the counterbore in the drive link. Install a new retaining ring into the groove of the drive link pin. Repeat these steps for the remaining blade.Lubricate the shaft of the center bolt. Insert the friction plate nearest the back of the cutter. Rotate the blade into position and insert the center bolt through the back half of the body, friction plate, and blade. Insert the remaining friction plate. Rotate the remaining blade into position and push the center bolt in completely. Be careful to line up the shape of the head of the center bolt with the corresponding shape in the body. Install the hex nut onto the center bolt. Using a torque wrench, tighten the nut to 120 ft/lbs (163 Nm) (Photo 1).


9.4 MAINTENANCE RECORDSIt is the responsibility of the user to keep maintenance records for each component of the rescue system. Maintenance shall be performed in accordance with the recommendations as outlined in this manual.

9.5 HANDLE LIGHT BATTERY REPLACEMENTLighted handles are optional equipment. 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.

Figure 9.5

9.1 ROUTINE MAINTENANCE FOR HOSESAfter each use, wipe clean hydraulic hoses with a light cleaning solvent such as Simple Green®. Inspect hydraulic hoses for damage to the outer rubber cover. Damage exposing the wire braided reinforcement subjects the wire to corrosion and may weaken the hydraulic hose. Remove damaged hydraulic hoses from service. Replace damaged hydraulic hoses immediately.

9.2 ROUTINE MAINTENANCE FOR COUPLINGSKeep hose couplings free of dirt and contaminants. Even with care, residual oils on the moving parts gradually accumulate dirt and grit making hose connections difficult. To clean hose couplings, immerse in, or scrub with, an automotive type aerosol solvent degreaser. Apply a light spray lube (automotive, lock, or gun type) to keep the collars moving easily. The rubber dust caps provided with the tools should be cleaned periodically. Be aware, the hose couplings may be clean, yet the dust caps accumulate dirt during use. Do not cover a clean hose coupling with a dirty dust cap.

9.3 ROUTINE MAINTENANCE FOR CENTER BOLTEvery three months, or more often if necessary, torque the center bolt nut to 120 ft/lbs (163Nm).

10.0 TROUBLESHOOTINGAny problem not resolved by these suggestions may require you to contact your local dealer or AMKUS Rescue Systems for further guidance.

PROBLEM SOLUTIONBlades do not move Check that hoses are properly connected.

Check hydraulic fl uid level in power unit reservoir.Check that the power unit is running.Check that the line is charged.

Rescue tool lacks power or speed Check hydraulic fl uid level in power unit reservoir.

Fluid leaks at fi ttings or hoses Check tightness of hose fi ttings.Replace damaged hoses.




11.0 PARTS, SERVICE, AND TECHNICAL INFORMATIONParts, service, and technical information may be obtained from your local AMKUS dealer, or by contacting AMKUS Rescue Systems.

12.0 DECOMMISSIONINGWhen 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, AND STORAGE1. Always store the tool securely in a clean dry space.2. Never store tools or power unit hoses under pressure. Always relieve the pressure on hoses and tools after use. BEFORE BEING PLACED BACK IN SERVICE, rescue tools must be inspected to this checklist;1. Check to see that important tool markings are legible.

Contact your local dealer or AMKUS Rescue Systems for replacement labels.2. Wipe tool, hoses, fi ttings and couplings clean (see routine maintenance for hoses and couplings).3. Inspect the rescue tool, hoses, fi ttings and couplings after each use for damage, leakage and excessive wear.4. 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.5. 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.

WARNINGAny 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.

Manual: AMK-22 Cutter - AMKUS Rescue Systems · 2019. 8. 19. · Manual: AMK-22 Cutter DANGER...

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Transcript of Manual: AMK-22 Cutter - AMKUS Rescue Systems · 2019. 8. 19. · Manual: AMK-22 Cutter DANGER...