Amkus AMK-22 User manual

©Copyright AMKUS Rescue Systems, Inc. 2016-2019 LAC-003 May 20, 2019 Rev05
AMKUS RESCUE SYSTEMS
amkus.com
4201 Montdale Drive, Valparaiso, IN 46383-4098 USA
800-592-6587 • 219-548-5000 • Fax [phone]
Manual: AMK-22 Cutter
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-004.
EN13204 Designation: AC127F-20.9
Certifi ed Compliant to
NFPA 1936, 2015 Edition
Shown with optional
lighted handle

©Copyright AMKUS Rescue Systems, Inc. 2016-2019 LAC-003 May 20, 2019 Rev05
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 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]
©Copyright Amkus Rescue Systems, Inc. 2014-2016 LAA-004 December 8, 2016 Rev04
SAFETY DATA SHEET
According to OSHA Hazard Communication
Standard, 29 CFR 1910.1200
AMKUS RESCUE SYSTEMS
amkus.com
4201 Montdale Drive, Valparaiso, IN 46383-4098 USA
800-592-6587 • 219-548-5000 • Fax [phone]
SECTION 1. IDENTIFICATION
DIULF CILUARDYH 1VM 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 0039-424-008noitamrofn
I llipS
Health Information
Recommend use of the chemical and restrictions on use
lio ciluardyHesU dednemmoceR
SECTION 2. HAZARDS IDENTIFICATION
*+6&ODVVL¿ 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.
2WKHUKD]DUGVZKLFKGRQRWUHVXOWLQFODVVL¿ 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 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

©Copyright AMKUS Rescue Systems, Inc. 2016-2019 LAC-003 May 20, 2019 Rev05
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Table Of Contents
1.0 MEANING OF SAFETY SIGNAL WORDS ................................................................. 4
2.0 SPECIFICATIONS ...................................................................................................... 4
2.1 PART IDENTIFICATION........................................................................................ 5
3.0 PROTECTIVE CLOTHING ......................................................................................... 5
4.0 TRAINING...................................................................................................................5
5.0 SET-UP PROCEDURE ............................................................................................... 6
6.0 GETTING STARTED................................................................................................... 7
6.1 ROTATING THE HANDLE.................................................................................. 7
6.2 CONTROL VALVE ACTUATOR.......................................................................... 7
7.0 OPERATING INSTRUCTIONS ................................................................................... 8
8.0 SAFETY GUARDS...................................................................................................... 9
9.0 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 REPLACEMENT
10.0 TROUBLESHOOTING...............................................................................................11
11.0 PARTS, SERVICE, AND TECHNICAL INFORMATION ............................................ 12
12.0 DECOMMISSIONING ............................................................................................... 12
13.0 INSPECTION, CLEANING, AND STORAGE............................................................ 12

©Copyright AMKUS Rescue Systems, Inc. 2016-2019 LAC-003 May 20, 2019 Rev05
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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
Part # AMK-22
MECHANICAL SPECIFICATIONS
Length 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 seconds
Cutter 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 Fluid
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° deg C) contact Amkus Rescue Systems for recommendation.)
A7
B6
C7
D7
E8

©Copyright AMKUS Rescue Systems, Inc. 2016-2019 LAC-003 May 20, 2019 Rev05
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4.0 TRAINING
WARNING AMKUS 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
WARNING Always 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 Actuato
r
Manifold
Center Bolt Drive Link Pin
(under Guard)
Cutter Blades
Guard

©Copyright AMKUS Rescue Systems, Inc. 2016-2019 LAC-003 May 20, 2019 Rev05
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5.0 SET-UP PROCEDURE
AMKUS manufactures equipment of superior craftsmanship and quality. Amkus backs new products with a standard warranty
published on the AMKUS website, amkus.com
NOTICE Only 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.
NOTICE Only 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.

©Copyright AMKUS Rescue Systems, Inc. 2016-2019 LAC-003 May 20, 2019 Rev05
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6.0 GETTING STARTED
WARNING Do 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 HANDLE
The 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 6.1A
Locked Position
Figure 6.1B
Unlocked Position
6.2 CONTROL VALVE ACTUATOR
The 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 6.2A
CLOSE: Twist handle to left, from above.
Figure 6.2B
OFF: (Neutral position):
The control valve actuator
returns to the center
Figure 6.2C
OPEN: Twist handle to right, from above.

©Copyright AMKUS Rescue Systems, Inc. 2016-2019 LAC-003 May 20, 2019 Rev05
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7.0 OPERATING INSTRUCTIONS
Rotating 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.
NOTICE Cutting 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 POSITIONING
Figure7.3b
INCORRECT POSITIONING
Blades start to flex sideways
Figure 7.3c

©Copyright AMKUS Rescue Systems, Inc. 2016-2019 LAC-003 May 20, 2019 Rev05
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8.0 SAFETY GUARDS
WARNING Operating 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

©Copyright AMKUS Rescue Systems, Inc. 2016-2019 LAC-003 May 20, 2019 Rev05
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9.0 ROUTINE MAINTENANCE
WARNING Avoid 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 3
Clean 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).