Interpump Hydralok HCL Mobile User manual
HCL Mobile
Hose Cutter
Machines manufactured by Hydralok, Bristol, UK
Machine enquiries, sales, after sales service :
Interpump Hydraulics (UK) Ltd t/a IMM Hydraulics (UK) : Kidderminster
P a g e | 2r1
Contents
Warranty Conditions...............................................................................................................................3
Information Relating to Cutting Blades ..................................................................................................4
Guidelines for Correct Cutting ............................................................................................................ 4
Blade Wear..........................................................................................................................................4
Replacement Blades............................................................................................................................4
EC Declaration of Conformity ................................................................................................................. 5
Safety Regulations...................................................................................................................................6
Machine Manual .....................................................................................................................................7
Technical / Dimensional Data .............................................................................................................7
Unpacking from Transport ..................................................................................................................7
Preliminary Checks..............................................................................................................................7
Routine Maintenance .........................................................................................................................7
Machine Description ...........................................................................................................................8
Installation ..........................................................................................................................................8
Operating Instructions ........................................................................................................................8
Maintenance and Service....................................................................................................................9
Noise Emissions...................................................................................................................................9
Appendix 1 –Mounting Information ....................................................................................................10
Appendix 2 –Wiring Schematic ............................................................................................................ 11
Appendix 3 –Machine Diagram............................................................................................................12
Appendix 4 –Blade Replacement Instructions .....................................................................................14
Machines manufactured by Hydralok, Bristol, UK
Machine enquiries, sales, after sales service :
Interpump Hydraulics (UK) Ltd t/a IMM Hydraulics (UK) : Kidderminster
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Warranty Conditions
Note! All machines undergo strict testing prior to shipment.
The user manual must be read and understood in full prior to use of the machine.
1. All machines are warranted against any defects for a period of SIX MONTHS starting from
the date of delivery to the customer. The company reserves the right to require a copy of
the sales invoice or proof of purchase.
2. Defects must be verified, therefore each defective item must be returned to our address
with SHIPPING CHARGES PREPAID IN FULL. We will return the item with CARRIAGE
FORWADED. ALL DELIVERIES TO OUR COMPANY WITH CARRIAGE FORWARD WILL BE
RETURNED TO THE SENDER.
3. The machine warranty covers replacement or repair of any component found to be
defective due to manufacturing or assembly.
4. Replacement parts and repairs carried out during this six month period do not extend the
duration of the machine warranty.
5. The warranty does not cover damage caused by deterioration form use, or damage caused
by improper or negligent machine maintenance.
6. The warranty does not cover damage due to improper use, or misuse. The warranty does
not cover damage caused by use outside of compliance with this machine operation
manual.
7. The warranty is not valid in case of any unauthorised machine modification.
8. This machine manual is to be considered as a certificate of warranty, valid only for the
machine to which it pertains, commencing on the date indicated on the freight bill.
9. The cutting blade is covered by a specific set of guidelines, detailed overleaf.
Machines manufactured by Hydralok, Bristol, UK
Machine enquiries, sales, after sales service :
Interpump Hydraulics (UK) Ltd t/a IMM Hydraulics (UK) : Kidderminster
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Information Relating to Cutting Blades
Guidelines for Correct Cutting
Initially, a new blade should be broken in. This is achieved by using the blade very carefully for 15-20
cutting operations on a hose size which does not demand the full capability of the machine.
It is essential that the hose is forces to bend away from the blade using the provided hose support
pillars. It is also essential that the bend is symmetrical about the cutting edge.
When cutting a hose the hose must not be ‘slammed’ or forced unnecessarily against the blade as
this can cause blade fracturing or cracking, leading to premature blade failure. An elevated cutting
speed will have an inversely proportional effect on the quality of the cut, and of the life of the blade.
Avoid twisting the hose during the cutting operation as this can impact the quality of the cut.
Blade Wear
Each blade is subject to high forces during normal operation and will show signs of wear over time. It
is not possible to guarantee a blade for a number of cuts or a duration of time as this is entirely
subjective and all blades will experience a different duty cycle.
The warranty of the cutting blade is extended only to defects in geometry and manufacturing, and
does not cover excessive wear or failure due to improper or abusive use.
Replacement Blades
The cutting blade is the only consumable element of the HCL mobile cutter, and is the only element
which will be readily available for spares.
It is recommended that only cutting blades obtained from the original machine supplier be used with
the machine.
Machines manufactured by Hydralok, Bristol, UK
Machine enquiries, sales, after sales service :
Interpump Hydraulics (UK) Ltd t/a IMM Hydraulics (UK) : Kidderminster
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Safety Regulations
Always work in safe conditions and with the necessary personal protective equipment (PPE) and
space around the machine. Ensure that the machine is secured onto a stable flat work surface, and
bolted down using a minimum of two bolts set at opposing corners through the holes provided.
1. DO NOT USE any of the equipment before fully reading and understanding the machine
manual.
2. DANGER! If improperly used the machine can be dangerous and may cause injury. Heed all
warning notices and do not touch operational or moving elements of the machine, especially
during operation.
3. WARNING! It is absolutely essential that all working operations are carried out by a SINGLE
OPERATIVE at any one time.
4. This manual must be presented to the machine operative, and it must be ensured that the
machine operative must fully read and understand the manual, and his/her responsibilities
with regard to machine operation.
5. Machine guards should NEVER be modified, tampered with or removed. Doing so will void
any remaining warranty
6. (Where applicable) A fully trained and competent electrician must connect the machine to
an appropriate power supply.
7. Always wear protective GLOVES, SAFETY GLASSES and APPROPRIATE CLOTHING. Ensure
LONG HAIR is TIED BACK to prevent entanglement.
8. (Where applicable) Isolate the machine from the power supply before removing any covers,
or attempting any maintenance. A trained and competent electrician must be present for all
works on electrical elements and components of the machine.
9. Only ORIGINAL spare parts may be used for the maintenance of the machine.
Machines manufactured by Hydralok, Bristol, UK
Machine enquiries, sales, after sales service :
Interpump Hydraulics (UK) Ltd t/a IMM Hydraulics (UK) : Kidderminster
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Machine Manual
Technical / Dimensional Data
Category
HCL mobile Cutter
Capacity
1¼” 4-wire, 1½” 2-wire braided hydraulic hose
Machine Dimensions (mm)
467 x 387 x 486 (approx.)
Net Weight (Kg)
23
Voltage
12v / 24v DC
Noise Level
(Not Exceeding) 75dB(A)
Unpacking from Transport
The machine will be shipped bolted on opposing corners to a wooden pallet. The bolts should be
removed and the machine lifted onto the work surface using suitable lifting equipment and
guidelines.
Preliminary Checks
Ensure that the intended work surface is pre-drilled with mounting holes to bolt the machine down.
Dimensions for mounting holes can be found in Appendix 1 –Mounting Information.
Ensure that there is a suitable power source nearby and that the power supply line is fitted with a
differential safety breaker and overload cut-out.
The machine does not have any integrated lighting, so ensure that the machine is positioned in an
area with ample lighting and that the working area is suitably illuminated.
Routine Maintenance
Ensure that moving parts are always lightly greased and free of dust and debris.
(Where applicable) Check that limit and safety switches are operational, and that safety switches
and emergency stop buttons are in good working order.
Machines manufactured by Hydralok, Bristol, UK
Machine enquiries, sales, after sales service :
Interpump Hydraulics (UK) Ltd t/a IMM Hydraulics (UK) : Kidderminster
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Machine Description
A bench mounted, electrically powered rotating circular, toothed knife. Cutting operation is
powered by hand. The machine is intended to be used for cutting steel wire reinforced rubber
hydraulic hose or similar.
Installation
The machine must be fixed to a firm, and level work surface, bolted down by a minimum of two
bolts located in opposing corners of the machine. Mounting information can be found in Appendix 1
–Mounting Information.
Connections should be made to an appropriate 12v / 24v DC electrical supply by a qualified
electrician. Standard wire colour coding is applied where the RED wire terminal must be connected
to the positive/live supply terminal, and the BLACK wire must be connected to the negative/neutral
supply terminal. For electrical schematic see Appendix 2 –Wiring Schematic.
A separate 160 - 180 amp battery coupled to a split charger is recommended. Alternatively a 110 -
120 amp battery can be used for light duty. To ensure a maximum 12 volt DC supply is delivered to
the machine, a minimum cable size of 25 mm square with a maximum length of four meters can be
fitted. A suitable isolator and overload protection device should be fitted to the voltage supply line.
Prior to operation, ensure that the blade is free to rotate without fouling on any of the guards and
that the guards are operating correctly and covering the cutting blade completely.
Operating Instructions
To move the hose support pillars (object 4 of Appendix 3 –Machine Diagram), unscrew the clamping
handle 1-2 rotations, slide the pillar to position, and re-tighten the clamping handle. Set the hose
support pillars an equal distance apart from the blade, so that when the handle (1) is pushed down
the hose is put under reasonable bending strain to relieve pressure on the sides of the blade during
the cutting operation.
Place the hose into the cutting jaws (6) so that the hose bends out towards the user and is
supported by the hose support pillars (4). Ensure that the cutting mark is directly between the hose
cutting jaws (6). Switch on the machine using the green portion of the control button (3) and push
the handle downwards SLOWLY. Allow the blade to cut through the hose at a controlled rate
without excessive slowing of the blade. When the hose is cut, allow the handle to return to a fully up
position where the blade is fully covered and switch off the machine using the red portion of the
control button (3).
Machines manufactured by Hydralok, Bristol, UK
Machine enquiries, sales, after sales service :
Interpump Hydraulics (UK) Ltd t/a IMM Hydraulics (UK) : Kidderminster
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Maintenance and Service
Regular inspection and routine cleaning of the machine, focussing especially on the guards
(Appendix 3 - 7 & 8). Under no circumstances should the machine be used if the guards have been
damaged or removed.
The cutting blade should be inspected regularly for signs of wear or damage. DANGER! The machine
must not be run if the blade shows signs of damage or stress cracking as projectiles may cause
serious injury as the blade rotates at very high speeds.
To replace the blade, follow the instructions in Appendix 4 –Blade Replacement Instructions.
Noise Emissions
Readings taken of this model of machine, mounted on a wooden work bench in the working position
at a distance of 1.1m above floor level was 75dB(A).
Machines manufactured by Hydralok, Bristol, UK
Machine enquiries, sales, after sales service :
Interpump Hydraulics (UK) Ltd t/a IMM Hydraulics (UK) : Kidderminster
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Appendix 4 –Blade Replacement Instructions
The following instructions detail how to change the cutting blade of the HCL mobile Cutter.
DANGER! Cutting blades are extremely sharp and must be handled with extreme care at all times to
avoid injury.
Remove four M6 dome head bolts from the front guard (two each side) and the M4 bolt at the top
of the front guard, as shown above. And remove the front guard by sliding it forwards as shown
below.
Machines manufactured by Hydralok, Bristol, UK
Machine enquiries, sales, after sales service :
Interpump Hydraulics (UK) Ltd t/a IMM Hydraulics (UK) : Kidderminster
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Remove the two M6 socket cap bolts from the pivot block as shown above. Note! that the tension
within the handle spring will attempt to work against this operation during undoing. Pivot the
handle, and pivot linkages, the cutting jaws, and the pivot block up above the rear cover as shown
below.
Machines manufactured by Hydralok, Bristol, UK
Machine enquiries, sales, after sales service :
Interpump Hydraulics (UK) Ltd t/a IMM Hydraulics (UK) : Kidderminster
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Remove the M6 clamp plate bolts (x2) by locating a bar or hex key into the torsion restraint holes in
the blade boss, shown above. Once both bolts have been removed the clamp plate can be removed
and the blade can be carefully removed and replaced as shown below ensuring that the teeth are
pointing in the correct direction. Once the new blade is installed these steps can be repeated in
reverse to reinstate all of the machine components. Ensure that thread locker is applied to the blade
clamp bolts on reassembly to prevent loosening over time.
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