Instruction Manual - Specialised Force

Instruction Manual
Self-Contained Hydraulic Cutter
Model – HC-85S
Maximum Operating Pressure – 700 bar
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
Instruction Manual
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-85S is a self-contained cutter with a spring return, a 180° rotating head and
incorporates a two stage pump. 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-85S cuts with ease though copper, aluminium and CCP cable. It is a proven performer in the
electrical, railway, mining, manufacturing and construction industries.
Note – this tool is not designed to cut wire rope, soft steel bars, reinforcement bars or piano wire.
Figure 1 – HC-85S 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.
HC-85S SC Cutter - V1.0
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Instruction Manual
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
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Instruction Manual
 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.
Model
Number
Copper Aluminium CCP
Max.
Oil
Max. Cylinder
Weight
Cable
Cable
Cable Pressure Required Output Stroke
(kg)
(mm)
(mm)
(mm) (bar)
(cc)
(ton) (mm)
HC-85S
85
85
85
700
168
5.6
90.8
9.0
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
HC-85S SC Cutter - V1.0
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 (see Figure 2). Once the
piston returns to its starting position the product is ready to operate.
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Instruction Manual
Figure 2 – Release Pressure
5.2.2
Press the spring loaded cutter head latch 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 ensure the spring loaded cutter head latch is fully engaged.
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 3 – 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
(see Figure 2).
5.2.8
Repeat steps 5.2.3 – 5.2.7 until the cutting operation is complete.
5.3 After Operation
Clean the product and blades.
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Instruction Manual
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.
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Instruction Manual
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 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.
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Instruction Manual
7.0 Troubleshooting
Problem
Cable cannot be cut
Handle is jammed or unable to
rotate to release pressure
Sliding blade is jammed or
unable to retract after
operation
Cause
Worn or damaged blades
Cables are over specification


Internal leakage

Foreign objects preventing
movement
Cylinder is loaded at end of
stroke


Pressure can be released by
pressing down the release
lever manually
Torsional spring is damaged

Worn or damaged blades
Blade guide pieces are blocked
with impediments


Send to a Durapac
authorised service centre
for repair
Replace blades
Use an airgun to remove
impediments
Use lubricant to clean the
tool
Refer to 6.3 – Bleeding Air
from the System

Lower blade does not advance
or advances slowly
HC-85S SC Cutter - V1.0
Air in the hydraulic system
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
Solution
Replace blades
Use tool that is appropriate
for cutting requirements
Send to a Durapac
authorised service centre
for repair
Clean the moving handle to
remove impediments
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Instruction Manual
8.0 Parts Breakdown and List
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Instruction Manual
Item
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
Description
Fixed blade
Spring pin
Bolt
Latch
Bushing
Nut
Stud bolt
Blade guide
Blade guide
Compression spring
Arresting pin
Hinge pin
Support plate
Crescent
Moving blade
Arresting pin
Locating screw
Roller
Spring
Spring pin
Stud bolt
Screw
O-ring
Pin
Cylinder cover
Cylinder
Screw
Washer
Main piston
Back-up ring
O-ring
Spring connector
Cylinder spring
Spring connector
O-ring
Insulation cap
Crescent
Bushing
Cap
Torsional spring
Guide bolt
Release pin
Spring pin
Hinge pin
Spring pin
Conical pin
Qty
1
1
1
1
1
11
2
1
1
1
1
2
2
2
1
2
1
1
2
1
3
1
1
3
1
1
1
1
1
1
1
1
1
1
1
1
2
4
1
1
1
1
1
1
1
1
Item
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
Description
Arresting pin
Tube
Handle grip
Handle grip
Valve screw
Compression spring
Ball
Compression spring
Screw
Ball
O-ring
Back-up ring
O-ring
Dust seal
Pumping piston
Compression spring
Release valve stem
O-ring
Locating screw
Cylinder
Compression spring
Valve screw
Back-up ring
O-ring
Ball
Relief valve set
O-ring
Ball seat
Valve screw
Compression spring
Valve screw
Screw
Ball
Screw
O-ring
Solid filter
Oil screen
Push in fastener
Handle grip
O-ring
Oil reservoir
Magnetic bar
Filler cap
Stop collar
Washer
Pin
Qty
1
1
1
1
2
2
2
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
3
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Serial and model numbers need to be quoted when ordering parts.
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Page 10 of 10
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