HYDROSCAND MaxiCut 5-60 User manual
USER MANUAL Edition 2-05
2012-10-23
Serial number:
MaxiCut 5-60
MaxiCut 5-60 USER MANUAL EDITION 2-05 2012-10-23
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Hydroscand was established 1969 in Stockholm, Sweden, by Björn Holmström.
The focus was, and still is, uid connectors, hoses and ttings.
About 30 years ago, Hydroscand started developing and manufacturing machines for its own
purpose. High quality and reliable performance in a demanding environment was the primary focus.
Downtime and unnecessary service is always more expensive than the small extra cost of a quality
product. That was the philosophy and still is for what became Hydroscand Machine AB in Säter, 20
years ago.
Today Hydroscand Group has a turnover of 190 million Euro and is present in many countries in
Europe, Asia and Africa. Hydroscand Machine has expanded it´s business to worldwide exports.
No matter where in the world you are, always know that: We stand by our machines.
CONTENTS
1. INTRODUCTION........................................ 4
2. GENERAL PRECAUTIONS ............................ 5
3. EQUIPMENT............................................. 6
3.1 WARRANTY....................................... 6
3.2 IMPORTANT...................................... 6
4. MACHINE................................................ 7
4.1 IDENTIFICATION .................................
4.2 DESCRIPTION ................................... 7
5. CONTROL PANEL....................................... 8
6. STARTING UP .......................................... 9
6.1 PRELIMINARY STEPS .......................... 9
6.2 OPERATOR POSITION.......................... 9
6.3 STARTING UP.................................... 9
7. HOSE CUTTING .......................................10
7.1 RUNNING IN THE CUTTING BLADE........10
7.2 DIFFERENT HOSE DIMENSIONS.............10
8. MAINTENANCE........................................11
8.1 REPLACING THE CUTTING BLADE .........11
8.2 AFTER EACH WORKING SHIFT .............11
8.3 REGULAR MAINTENANCE....................11
8.4 RESET THE MOTOR PROTECTION...........12
9. PICTURE................................................12
10. TECHNICAL DATA ...................................13
10.1 NOISE LEVEL..................................13
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1. Introduction
The purpose of this manual is to provide the necessary information for com-
petent, safe use of the hose cutting machine.
This information is the result of continuous, systematic data processing and
technical tests recorded and validated by the manufacturer, in accordance
with the internal procedures to ensure the safety of information: 2006/42/
EC.
The information below is intended EXCLUSIVELY for specialized users, capable of
interacting with the product with the utmost safety people, the machine and the
environment, interpreting basic diagnostics of problems and malfunctions and
performing simple checks and maintainance, in full compliance with the instruc-
tions given from the pages that follows and with current health and safety regu-
lations.
The manual does not examine in depth the topics of disassembly and extraordi-
nary maintainance, as these operations must always be carried out by our autho-
rized Technical Service.
To handle the machine properly, it is necessary to keep the manual in good condi-
tion for the future. Contact the nearest authorized technical service if you need
a new manual or more complete information.
Before each intervention to the machine or its packaging, read the instructions
in the following manual very carefully.
Every operator using the machine, MUST read the following instructions be-
fore operating.
Hydroscand Machine AB declines any responsability for damage to persons, things
or to the machine itself, arising fromits incorrect use, neglience and supercial
interpretations of safety concepts in this manual.
This instruction manual should serve for the duration of the cutting machine´s
operating life and be available for at least 10 (ten) years. We recommend to keep
it in a known and accessible place (possible together with other documents rela-
ted to the machine).
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2. General precautions
Always make sure in advance that the minimum safety, placement and operating
standards are respected, taking note of the environmental conditions, tempera-
ture, humidity, lighting, vibrations, suspended dust and the appropriateness of
the area to be occupied.
For unloading from pallet or moving of an unpacked machine, the lifting device
on the top must be used. Any other lifting device may cause damage to people,
property or the machine itself.
The cutting machine is constructed to operate indoors (workshops, industries
etc.) where there is no risk of explosion or re.
Do not combine the machine with other equippment unless you have an approval
from the manufacturer. If other equippment are installed on the machine, or if the
machine is combined with other equippment it’s necessary to make a risk analysis
and a CE approval for the whole foundation.
Before cutting the rst hose, make sure that the cutting blade rotates in the cor-
rect direction (see rotation arrow) and that the hose is placed steady towards the
adjustable cutting support. Also make sure that the hose is held steady so that
there will be no risk for injuries or damages. Do not put your hands in the cutting
blade working area.
Do not remove the information plates on the cutting machine. Make sure they are
readable and that you are sure about their meaning. Should they deteriorate, re-
place them immediately by contacting an authorized Technical Service.
The use of spares that do not respond to the specications listed below, changes
or manipulations - however slight- shall exempt Hydroscand Machine AB from any
responsability regarding the proper use and functioning of the cutting machine
and safety of peole and/or property.
It is strictly forbidden to tamper with safety equipment and/or devices.
NOTE !
Any maintenance operations, except for those specically described on the pages
of this manual, must be carried out by skilled personnel co-ordinated by authori-
zed Technical Service. Dispose of processing waste in compliance with current
regulations.
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3. Equipment
Our stationary hose cutting machine is supplied ready to use packed on a pallet.
The machine is supplied with an electric cable but without plug and main switch.
It’s the customers responsibility to install the power supply according to present
national regulations. The manufacturer recommends a lockable main switch bet-
ween the machine and the mains. MaxiCut 5-60 OT is prepared with a smoke eva-
cuation connection and if a smoke evacuation is connected the manufacturer re-
commends to install a spark lter to prevent hazards.
NOTE !
The packing material must be disposed according to current environmental
protecting regulation.
The machine is supplied initially with:
• Cutting blade HSM 400x4x50 Toothed part No: 9009-01-05
• 2 pcs of hose supports (for 3/16”-1” hose)
• Locking tool for changing cutting blade • Instruction manual
• Certicate regarding agreement according to CE-standards
3.1 Warranty
The cutting machine is guaranteed for one (1) year following the date of purchase;
the warranty is valid only if all of the instructions listed on the warranty certi-
cate and in this manual are fully complied with.
NOTE !
When unpacking the cutting machine, make sure that the machine is in perfect
condition and that the package contains the parts described. Hydroscand Mach-
ine AB does not respond for errors or missing parts not reported to Hydros-
cand Machine AB following eight (8) days after shipment.
3.2 Important
The hose cutting machine is designed, manufactured and protected for cutting 1-,
2- and 4-layers hydraulic hose with dimension from 3/16” up to 2”.
Any other use is excluded by Hydroscand Macine AB, who shall be exempt from
any liability for damage to people, property or the machine itself, caused by im-
proper use. Do not leave the cutting machine idle running for longer periods,
without cutting anything.
Do not cut solid steel, wood or other unknown material, that can cause da-
mage to people, property or the machine itself.
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4. Machine
4.1 Identication
The information for identifying the machine is found on the plates, located out-
side of the cutting machine. This essentially includes:
• Manufacturer • Serial number • Year of manufacture • Voltage (V)
• Hertz (Hz) • Amperes (A) • Weight
The CE- approval plate is located at the back of the machine, on the top to the
right.
NOTE !
It is strictly forbidden to remove or damage the plate. Should this happend,
always contact an authorized Techical Service only.
For any information and/or technical explanations regarding the cutting machine,
always indicate:
• Model • Serial number • Edition and preparation date of the instruction manual
4.2 Description
The stationary hose cutting machine consists of one unit, equipped with a pneu-
matic cylinder, which is manouvered by a foot pedal and ap doors that are press-
sed down by the hose during the cutting process. The unit is also equipped with
a connection for a smoke evacuator (option), and as standard a toothed cutting
blade assembled on the machine.
The machine is equipped with an air pressure regulator and lter. Do not start the
machine before the air pressure has reached min. 5 bar.
The hose cutting machine must only be used for hydraulic hoses compatible with
the specications below. Follow the environmental conditions and limitations
recommended by Hydroscand Machine AB and current health and safety regula-
tions.
NOTE !
The descriptions includes the use for which the machine has been designed,
built and protected. Any other use or failure to comply with the technical
parameters listed below, may constitute a hazard to people and/or property.
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5. Control panels
1. Emergency stop button
2. Start and stop
3. Hold for counter
Keep the button pressed down as long as you do not wish to count the cuttings.
E.g when clean cutting, press the button and keep it pressed down during the
whole cutting process.
4. Digital counter with reset
The counter is being reset by pressing the button to the left on the counter.
5. Switch for cutting speed
This switch is intended for regulation of cutting speed, e.g. when cutting a 1
1/4”-2” dimensioned hose, the speed shall be reduced to no. 1 speed.
6. Cutting stroke adjustment knob
With this knob it’s possible to adjust the cutting stroke, from starting position
with full speed to a variable distance to the point where you want the set cutting
speed (point 5) to begin. The intention with this function is to save time when
cutting hoses with small OD.
7. Regulator and gauge for air pressure
Default working pressure 6 bar.
1
3
5
4
2
7
7
6
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6. Starting - up
6.1 Preliminary steps
Important!
It is essential to determine size measurements and placement in advance in
order to ensure safe placement, running and emergency actions within the
surrounding environment. These conditions should be respected beginning
with the preliminary stages, before cutting begins.
• Place the machine on a steady and at foundation.
• Check that the cutting blade can rotate freely.
• Check that the cutting blade is tightened.
NOTE !
Before plugging-in the machine, make sure that the line voltage corresponds
to the voltage indicated on the machine.
6.2 Operator position
The placement of the machine in relation to the operator´s position must make it
possible to observe the result of the operation and maintain safety conditions.
During this stage, make sure that the start/stop button and safety switch not are
blocked and that there is sufcient visibility and lightning on the machine, the
surrounding area and base.
Warning !
Keep hands clear off the cutting blade area!
Always open the safety hatch and pull the hose with your hand well outside ope-
ning and then push the hose into opening of the machine, then close the hatch.
Never put your hands thru the cutting blade working area.
6.3 Starting - up
Always use safety glasses and ear protection when working with the machine.
Release the safety switch by turning the button clockwise. Select your cutting
speed. Press the START-button. The foot pedal will start the cutting sequence.
Caution!
Check the direction of rotation (the upper edge of the cutting blade shall rotate
towards the back part of the cutting machine). If the machine starts to vibrate
heavily, stop the machine immediately and check the reason for the vibrations.
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7. Hose cutting
7.1 Running in the cutting blade
New cutting blades must be used with reduced speed for the feeding at about
100-200 cut. When the running-in has been done the cut can be performed at
normal speed. As a basic rule the blade should never be overheated. If excessive
smoke or heat is generated or if the motor stalls the cut sequence must be inter-
rupted immediately and the cause found.
7.2 Different hose dimensions
Important !
When cutting...
... hoses of dimension 3/16”- 1/2” must the cutting supports always be used and
put in the two inner holes. Min. cutting length 150 mm. Cutting speed no. 2 or 3
can be used for these dimensions.
... hoses of dimension 5/8”- 1”must the cutting supports always be used and put
in the two outer holes. Min. cutting length 250 mm. Cutting speed no. 1 or 2 can
be used for these dimensions.
... hoses of dimension 1 1/4”- 2”, layers shall the cutting supports NOT be used.
Min. cutting length 300 mm. The cutting speed has to be switch to no.1.
Note !
Before cutting hoses of dim. 1 1/4” - 2” a cutting test has to be performed
without a hose as below:
1. Switch the cutting speed to no.1 speed.
2. Set the cutting stroke adjustment knob to zero.
3. Press the pedal and visually check that pusher have a slow movement down-
wards. As factory default a complete stroke take about 9 seconds. The speed may
have to be reduced more if mostly tough hoses are cut.
If excessive smoke or heat is generated or if the motor stalls when cutting the
hose adjust the speed to optimize the cut. Contact Hydroscand Machine AB for
further information about adjusting the speed.
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8. Maintenance
8.1 Replacing the cutting blade
Warning !
Always use protective gloves when changing the cutting blade.
• Turn off and disconnect the power supply to the machine. Lock switches if pos-
sible.
• Wait until the machine has stopped completely.
• Open the lid on the left side of the chassie.
• Lift up the safety hatch, open the front cover to access the cutting blade.
• Lock the motor shaft by inserting the locking tool in the drilled hole behind the
cutting blade.
• Loosen the hexagon headed screw by using a 10 mm hexagon wrench.
• The cutting blade is now loose. Dismantle the old blade.
• Mount the new blade and screw the adapter plate tightly with the centre bolt.
Moment of torsion is 47 Nm.
• A new cutting blade must initially be run according to chapter 7.1.
• Start the cutting machine and check that no vibrations occur.
8.2 After each working shift
• Turn off the machine, disconnect the power supply.
• Open the waste box, remove cutting residue.
8.3 Regular maintenance
At service and maintenance there should be a warning sign ”Service in progress”
placed by the machine. Before service or maintenance the power and air supply has
to be disconnected. The main switch has to be switched off, locked and a warning
sign ”Service in progress” has to be placed at the connection to the mains.
Make sure that the cutting blade has stopped completely before any service starts.
• Make sure that the cutting blade is in good condition, that no cracks have occured.
• Clean the machine and remove cutting residue to avoid risk of re.
• Empty the water separator, placed on the machine side.
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1
9
10
11
4
5
3
6
7
8
2
13
12
Adjustable feet Waste box
Footpedal
Hatch to cutting blade
Safety hatch
Hatch to electric system
Emergency stop
ON - OFF
Connection for smoke evacuation
system dia. 100 mm hole (Option)
Valve cutting speed
Valve cutting speed
Regulator for air
pressure
Pressure gauge
Lifting eye
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8.4 Reset the motor protection switch
• Open the electric box hatch. Warning! Electrical power, do not touch
wire/terminals.
• Push the blue reset button on the switch.
• Close the hatch and restart the machine.
• If the machine fails to start, contact an electrician.
8.4 Reset the motor protection switch
• Open the electric box hatch. Warning! Electrical power, do not touch
wire/terminals.
• Push the blue reset button on the switch.
• Close the hatch and restart the machine.
• If the machine fails to start, contact an electrician.
TECHNICAL DATA
Hose dimension 1-2-4-layers........................... 3/16 - 2”
Max outside hose diameter .................................80 mm
Motor ...............................................................5,5 kW
Voltage...................................... 230/400 V/16 A/50 Hz
Velocit y ........................................................2850 rpm
Diameter (blade) external.................................400 mm
Diameter (blade) internal ...................................50 mm
Air pressure...................................................... 6,0 bar
Counter.................................................... 0 - 9999 pcs
Smoke evacuation system .................................100 mm
Noise Level Idle speed..................................... 66,5dBA
Noise Level Cutting........................................ 85,3 dBA
Colour.....................................................Black/Orange
DIMENSIONS
Length/Depth/Height ...................... 700x600x1300 mm
Weight..............................................................140 kg
DESIGNATION: PART NUMBER:
MaxiCut 5-60 400V 3-phase .............. 9009-00-00-2003S
MaxiCut 5-60 230V 3-phase .............. 9009-00-01-2003S
SPARE PARTS: PART NUMBER:
Cutting blade HSM 400x4x50 Smooth........... 9009-01-04
Cutting blade HSM 400x4x50 Toothed.......... 9009-01-05
10 Technical data
10.1 Noise Level
Test result of measuring noise level on MaxiCut 5-60 OT. This result is to be consi-
dered as a guiding reference value and it is not performed under any ISO standard
regulations or similar. The test is made at two different steps, rst at idle speed
and second when cutting a ½” 2-layered hydraulic hose.
The measuring device was placed 1700mm above oor level and about 700mm in
front of machine centre, pointing down at approximately 45 degrees.
Result:
Idle speed : 66,5 dBA
Cutting : 85,3 dBA
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Table of contents
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