Durapac HC-45C Bedienungsanleitung

ABSOLUTE EQUIPMENT PTY LTD –2/186 Granite Street, GEEBUNG QLD 4034 –Australia

sales@absoluteequipment.com.au –Phone: +61 7 3865 4006 –Fax: +61 7 3102 6288

Maximum Operating Pressure –700 bar

Instruction Manual

Self-Contained Hydraulic Cutter

Model –HC-45S

Instruction Manual

HC-45S SC Cutter - V1.1 www.durapac.com Page 2 of 10

This is a safety alert symbol. It is used to alert you to potential personal injury hazards.

Obey all safety messages that follow this symbol to avoid injury or death

1.0 Product Information

DURAPAC –Hydraulic cutters are engineered to meet Industrial Standards for Performance and

Safety. The HC-45S is a self-contained cutter with a spring return and a 180° rotating head. They are

compact, lightweight, easy to use and supplied in a heavy duty canvas carry bag. They feature

superior guillotine-type cutting, flip-top latch for easy insertion of cutting material and blades that

are easily replaceable.

The HC-45S cuts with ease though cable, round bar, wire rope, wire strand and more. It is a proven

performer in the electrical, railway, mining, manufacturing and construction industries.

Note –the cutting of piano wire is prohibited.

Figure 1 –HC-45S Subassembly

Special skill, knowledge and training may be required for a specific task and the product may not be

suitable for all jobs. The user must ultimately make the decision regarding suitability of the product

for any given task and assume the responsibility of safety for all in the work area. Contact a Durapac

representative if you are unsure of your hydraulic cutter’s suitability for a particular application.

2.0 Receiving Instructions

It is recommended prior to use that an inspection be done by qualified personnel and that any

missing or damaged parts, decals, warning/safety labels or signs are replaced with Durapac

authorised replacement parts only. Any hydraulic cutter that appears to be damaged in any way, is

worn, leaking or operates abnormally should be removed from service immediately until such time

as repairs can be made. Any hydraulic cutter that has been or suspected to have been subject to a

shock load should be removed from service immediately until inspected by a Durapac authorised

service centre. Owners and operators of this equipment should be aware that the use and

subsequent repair of this equipment may require specialised training and knowledge.

Instruction Manual

HC-45S SC Cutter - V1.1 www.durapac.com Page 3 of 10

3.0 Safety

Save these instructions. For your safety, read and understand the information contained within. The

owner and operator should have an understanding of this product and safe operating procedures

before attempting to use this product. Instructions and safety information should be conveyed in the

operator's native language before use of this product is authorised. Make certain that the operator

thoroughly understands the inherent dangers associated with the use and misuse of the product. If

any doubt exists as to the safe and proper use of this product as outlined in this factory authorised

manual, remove from service immediately.

DANGER:

To avoid personal injury keep hands and feet away from work area during operation

WARNING:

Always wear appropriate personal protective equipment (PPE) when operating

hydraulic equipment. The operator must take precaution against injury due to failure

of the tool or work piece(s)

IMPORTANT:

If at any stage, the safety related decals become hard to read, these must be replaced

Minimum age of the operator must be 18 years. The operator must have read and

understood all instructions, safety issues, cautions and warnings before starting to

operate the equipment. The operator is responsible for this activity towards other

persons

Hydraulic equipment must only be serviced by a qualified hydraulic technician. For

repair service, contact the Durapac authorised service centre in your area. To protect

your warranty, use only high quality hydraulic oil

CAUTION:

KEEP HYDRAULIC EQUIPMENT AWAY FROM FLAMES AND HEAT. Hydraulic fluid can

ignite and burn. Excessive heat will soften packings and seals, resulting in fluid leaks.

Heat also weakens hose materials and packings. For optimum performance do not

expose equipment to temperatures of 65°C (150°F) or higher. Protect all equipment

from weld spatter

No alteration should be made to this device

3.1 Hydraulic Cutters

Keep hands off the cutting head section while operating the product

This product is NOT an insulator. Proper equipment should be used to avoid electrical

shock

Do NOT keep this product in places with high temperatures, high humidity or direct

sunlight

Suggested working temperatures -10°C to 40°C

Instruction Manual

HC-45S SC Cutter - V1.1 www.durapac.com Page 4 of 10

Hydraulic fluid temperatures over 65°C might cause damage to components sealed

inside the product

FAILURE TO HEED THESE WARNINGS MAY RESULT IN PERSONAL INJURY AS WELL AS PROPERTY DAMAGE.

4.0 Installation

4.1 Familiarise yourself with the specifications and illustrations in this owner’s manual.

Know your hydraulic cutter, its limitations and how it operates before attempting to

use. Refer to the specification table below or if in doubt, contact a Durapac

representative.

4.2 Check oil level in reservoir before operating cutter.

4.3 Remove air from the system –Air can accumulate in the hydraulic system during the

initial setup or after prolonged use, causing the cylinder to respond slowly or in an

unstable manner. Should removal of air from the hydraulic cutter be required, please

follow the steps in 6.3 –Bleeding Air from the System in the Maintenance Section.

5.0 Operation

IMPORTANT:

The maximum cutting capacity of this tool includes the thickness of the cable covering.

Keep this in mind when selecting the appropriate cable to use. If in doubt, use another

tool to cut away the cable covering before commencing cutting with this tool

Only attempt to cut cables which fit the tool specifications. No other materials are to

be cut

5.1 Before Operation

5.1.1 Make sure all parts of the product are clean, without rust or loose parts.

5.1.2 Check that no leakage occurs while the tool is resting or while the product is

being tested without cables.

5.2 Operation

Stop operating immediately in the case of any abnormalities

5.2.1 Release the hydraulic fluid pressure and retract the piston before opening

the tool head. To release the pressure; pull out the moving handle and

rotate it clockwise. Push down the moving handle. Once the piston returns

to its starting position the product is ready to operate.

6x7

(mm)

6x12

(mm)

6x19

(mm)

1x7

(mm)

1x19

(mm)

22 25 25 20 16 45 45 45 16 20 700 145 10.0 50.0 7.0

Oil

Required

(cc)

Max.

Output

(ton)

Cylinder

Stroke

(mm)

Weight

(kg)

Copper

Cable

(mm)

Aluminium

Cable

(mm)

ACSR

(mm)

Guy Wire

Max.

Pressure

(bar)

Wire Rope

Soft

Steel Bar

(mm)

Reinforcing

Rod (mm)

Instruction Manual

HC-45S SC Cutter - V1.1 www.durapac.com Page 5 of 10

Figure 2 –Release Pressure

5.2.2 Remove the tool head lock pin and pull back the upper blade to open the

cutting head.

5.2.3 Place the cable between the blades at the desired cutting point. Close the

cutter head and secure the latch pin.

Figure 3 –Latch Pin Position

5.2.4 Position the cable at the centre of the fixed blade. Improper positioning of

the cable on the edge might cause damage to the blade or deform the tool.

Figure 4 –Centre cable

5.2.5 Pump the moving handle back and forth to advance the piston and sliding

blade forward.

5.2.6 Keep pumping the moving handle until the cable is cut.

5.2.7 Turn the moving handle clockwise and press down the release lever by

pushing down the moving handle. The tool will return to its starting position.

5.2.8 Repeat steps 5.2.3 –5.2.7 until the cutting operation is complete.

Instruction Manual

HC-45S SC Cutter - V1.1 www.durapac.com Page 6 of 10

5.3 After Operation

5.3.1 Clean the product and blades.

6.0 Maintenance

IMPORTANT:

Check oil level regularly and make sure the reservoir is full

Use only good quality hydraulic fluid. Do NOT use brake fluid, transmission fluid,

turbine oil, motor oil, alcohol, glycerine etc. Use of anything other than good quality

hydraulic oil will void warranty and damage the cutter. We recommend Durapac

Hydraulic Oil or equivalent

Equipment must only be serviced by a qualified hydraulic technician. For repair service,

contact your local Durapac authorised service centre

Tools with worn or damaged blades may cause property damage or even personal

injury

The hydraulic relief valve pressure should only be adjusted by a Durapac

representative

Maintenance is required when wear or leakage is noticed. Periodically inspect all

components to detect any problem that may require service and maintenance.

Keep the tool head free of dirt and metal chips. Use a lubricant to clean the tool when

necessary.

Routine application of rust preventative oil to the product is needed. Avoid bringing the tool

into contact with water or solvents.

6.1 Blade Replacement

6.1.1 Fixed Blade Replacement

6.1.1.1 Open the tool head and pull back the fixed blade. Remove the four

small screws to unfasten the blade.

6.1.1.2 Position the new blade, reassemble the small screws.

6.1.1.3 Ensure that all components are tight and that the blade opens and

closes smoothly.

6.1.2 Moving Blade Replacement

6.1.2.1 Advance the lower blade until the connecting pin is visible on the

main piston.

6.1.2.2 With the tool head open, remove the connecting pin to unfasten the

blade.

6.1.2.3 Insert the new blade and reassemble the connecting pin to secure

the blade in place.

6.1.2.4 Ensure that all components are tight and the blade moves back and

forth smoothly.

Instruction Manual

HC-45S SC Cutter - V1.1 www.durapac.com Page 7 of 10

6.2 Adding Hydraulic Fluid

6.2.1 Position the tool upside-down in a vice with the pump handle in the open

position.

6.2.2 Unscrew the main handle from the body and then remove the oil reservoir

cap.

6.2.3 Use a small funnel to fill the reservoir to the top of the oil filler hole.

6.2.4 Bleed air from the system (below)

6.2.5 Close the rubber reservoir, insert the filler cap and reassemble the main

handle.

6.3 Bleeding Air from the System

6.3.1 Repeat Steps 6.2.1 to 6.2.3 (above), if required.

6.3.2 Pump the moving handle a few times to advance the cylinder.

6.3.3 Press the release lever to release the pressure in the hydraulic circuit until the

cylinder is fully retracted and the oil has returned completely into the

reservoir.

6.3.4 Repeat the process several times to ensure that all air bubbles are removed.

6.3.5 Recheck oil level after removing air.

6.4 Changing Hydraulic Fluid

For best results, change fluid once a year or every 300 hours of use

6.4.1 Repeat Steps 6.2.1 to 6.2.2 (above).

6.4.2 Pour used fluid into a sealable container.

6.4.3 Repeat Steps 6.2.3 to 6.2.5 (above).

6.4.4 Dispose of fluid in accordance with local regulations.

6.5 Storage

6.5.1 Check to ensure that all pieces are in good working condition.

6.5.2 Apply rust preventive oil to the product and blades before returning to the

carrying case.

Instruction Manual

HC-45S SC Cutter - V1.1 www.durapac.com Page 8 of 10

7.0 Troubleshooting

Problem

Cause

Solution

Cable cannot be cut

Worn or damaged blades

Replace blades

Cables are over specification

Use tool that is appropriate

for cutting requirements

Internal leakage

Send to a Durapac

authorised service centre

for repair

Handle is jammed or unable to

rotate to release pressure

Foreign objects preventing

movement

Clean the moving handle to

remove impediments

Cylinder is loaded at end of

stroke

Pressure can be released by

pressing down the release

lever manually

Torsional spring is damaged

Send to a Durapac

authorised service centre

for repair

Sliding blade is jammed or

unable to retract after

operation

Worn or damaged blades

Replace blades

Blade guide pieces are blocked

with impediments

Use an airgun to remove

impediments

Use lubricant to clean the

tool

Lower blade does not advance

or advances slowly

Air in the hydraulic system

Refer to 6.3 –Bleeding Air

from the System

Instruction Manual

HC-45S SC Cutter - V1.1 www.durapac.com Page 9 of 10

8.0 Parts Breakdown and List

Instruction Manual

HC-45S SC Cutter - V1.1 www.durapac.com Page 10 of 10

Item Description Qty Item Description Qty

1 Blade guide 1 44 O-ring 1

2 Fixing blade 1 45 Compression spring 1

3 Blade guide 1 46 Ball 3

4 Screw 4 47 Ball seat 1

5 Chain 1 48 O-ring 2

6 Hook 1 49 Back-up ring 2

7 Locating plate 2 50 Valve screw 1

8 Moving blade 1 51 O-ring 1

9 Dust seal 1 52 Ball 1

10 Cylinder cover 1 53 Screw 1

11 Spring washer 1 54 Solid filter 1

12 Hex. nut 1 55 Oil screen 1

13 Screw 2 56 Push-in fastener 1

14 Blade guide 1 57 Extension tube 1

15 Ball 2 58 Spring pin 1

16 Compression spring 1 59 O-ring 1

17 Screw 1 60 Valve screw 1

18 Arresting lever 1 61 Compression spring 2

19 Buckle 1 62 Screw 1

20 Screw 1 63 O-ring 1

21 Spring pin 1 64 Valve screw 1

22 Hinge pin 1 65 Oil reservoir 1

23 Compression spring 1 66 Magnetic bar 1

24 Locating screw 1 67 Filler cap 1

25 Main piston 1 69 Fibre glass pipe 1

26 Back-up ring 1 70 Handle grip 1

27 O-ring 1 71 Insulation cap 1

28 Valve screw 2 72 Cap 1

29 Compression spring 2 73 Spring pin 1

30 Ball 2 74 Hinge pin 1

31 Cylinder body 1 75 Bushing 4

32 Compression spring 1 76 Crescent 2

34 Pump piston 1 77 Arresting pin 1

35 Back-up ring 1 78 Conical pin 1

36 O-ring 1 79 Torsional spring 1

37 O-ring 1 80 Guide bolt 1

38 Back-up ring 1 81 Release pin 1

39 Locating screw 1 82 Fibre glass pipe 1

40 Release valve stem 1 83 Spring pin 1

41 O-ring 1 84 Handle grip 1

42 Relief valve set 1 85 Washer 1

43 Compression spring 1

Serial number and model need to be quoted when ordering parts.

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