KEEL CUTTER N450 Operation Manual NAKANO CUTTER LIMITED

KEEL CUTTER N450 Operation Manual NAKANO CUTTER LIMITED

Thank you for choosing our Keel Cutter. This operation manual offers procedures and precautions for safety use. Please read and understand this manual before use. (Incorrect use may cause injury.) Please carry the manual with you or store it carefully so it is available when needed. Descriptions in this manual may be changed without prior notice.

1 Prohibitions and precautions 1 2 3 4 5 Keel Cutter N450 3 Necessary parts and accessories Procedures for cutting pipe Hydraulic type specifications 3 4 6 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 Table of contents Specifications 6 Supplied accessories 6 Optional accessories 7 Optional accessories (blades) 7 Name of main components 8 Guide ring 9 Guide ring components 9 Attaching guide ring 10 Attaching rotary plates 11 Attaching spray unit 12 Checking V-belts and chains 13 Blades 14 Checking before attaching machine on the pipe 15 Attaching machine on pipe 16 Attaching guiding unit 17 Attaching driven shaft assy and hook shaft assy 18 Setting hydraulic motor 18 Connecting hydraulic hose and motor 19 Checking before starting hydraulic unit 20 Starting hydraulic unit 22 Spraying water 23 Starting machine 24 Removing machine 26

6 Maintenance of cutter machine 27 7 8 Pipe stands Water tanks 28 30 9 Genuine blades 32 10 11 12 13 Maintenance 33 Blades and applicable pipes 34 Extension chains 35 Minimum working clearance for Keel Cutters 35

1 Prohibitions and precautions Prohibitions Do not let personnel operate the cutter if they don't understand the instructions in this operation manual. Do not touch the blade when it's rotating. Sparks may come out from the blade when it's cutting. Do not use the cutter in places with danger of explosion (where flammable gas may be generated or exist). Precautions Wear safety goggles during operation to protect eyes from cut off dust. During operation and immediately after shutdown, the machine and the blade are hot and may cause burns. Inspect the machine before use. Clean and grease the machine after use. Do not wear loose clothing like ties which may get caught in the machine. 1 KEEL CUTTER N450

Please use genuine Keel Cutters parts. Non-genuine parts may cause failures or early wear in the product. Damages or failures caused by non-genuine parts may not be covered by warranty. Safety instructions given in this operation manual do not represent all circumstances which may occur. Great caution must be taken and sufficient safety instructions must be given to operators and maintenance workers. Store the original package box of the machine, blade etc. for use when sending them back for repair or sharpening. Warning symbols used in this manual: DANGER Indicates a high level risk to the operator and bystanders, if the instruction is not followed. WARNING Indicates a hazard which, if not avoided, may result in injury to the operator and bystanders. CAUTION Indicates a precaution which may affect durability of the product and work efficiency. Caution Hot Gives additional technical information. KEEL CUTTER N450 2

2 Keel Cutter N450 N450 was developed to cut ductile iron pipes automatically with high accuracy. Hydraulic driving type Having hydraulic unit 04E as power source, the product includes a blade lowering unit for accurate cutting and a guiding unit for securing guide ring. By adding one extention chain, the cutter can cut pipes up to φ733mm. Stable operation is provided with cutting speed 100mm/min. 3 Necessary parts and accessories The following parts and accessories are necessary for cutting pipes (not for construction work). Keel Cutter N450 machine main body Hydraulic unit 04E Blade, cutter holder and cutter holding plate Optional parts and accessories (see the list below) Main optional parts (1) Guide Rings *necessary A guide ring is attached to the pipe to keep the cutter on track. Select the right guide ring according to the nominal pipe diameter. (2) Pipe Stands (H or L) *to be used if necessary Pipe stands are used for holding the pipe when it is cut on the ground. (3) Water tank, 7 or 12 liters *necessary Used for spraying water to the blade and cooling it during cutting. (4) Wedges *to be used if necessary For preventing the cutting blade from getting caught in the pipe 3 KEEL CUTTER N450

4 Procedures for cutting pipe Checking necessary parts See the previous section (P3) STEP 1 STEP 2 Attaching blade Attach a blade to the machine (P14) STEP 3 Attaching guide ring (1) Select a guide ring of the same diameter as the pipe. (2) Check where to attach the guide ring (P9) (3) Attach the guide ring (P10) Setting up machine (P15) Adjust guiding unit (P17) STEP 4 STEP 5 Connecting cutter and hydraulic unit Check the hydraulic unit before starting (P18) KEEL CUTTER N450 4

STEP 6 Starting hydraulic unit (P20) Read operation manual of the hydraulic unit beforehand. STEP 7 Lowering blade and running machine (P24) STEP 8 Removing machine from pipe (P26) 5 KEEL CUTTER N450

5 Hydraulic type specifications 1 Specifications Cutter machine Applicable pipe type Cut depth Cut speed Dimensions Weight Oil to be used Ductile iron, cast iron, steel, Hume concrete pipe 19.9mm(when diamond blade 125x3 S is used) 32.4mm(when diamond blade 150x3 S is used) 100mm /min (H)220mm x (W)517mm x (L)330mm (when guiding unit and blade lowering unit are attached) Approx. 16kg Idemitsu PromenteSJ/CF-4 10W-30 or equivalent Hydraulic drive unit Speed 620rpm (Hydraulic motor M26) Max. pressure 10Mpa Discharge rate 16l /min Dimensions (H)655mm x 388mm x 540mm Weight Approx. 90kg Hydraulic oil to be used 25l (Super Hydro 32A (Idemitsu) or equivalent) 2 Supplied accessories Cutter machine 1 Keel cutter N450 hydraulic drive type main body 1 (including guiding unit and screw type blade lowering unit) 2 Extention chains 1 3 Driven shaft assy (with single pulley) 1 4 Hook shaft assy 1 5 V-belt SB-25(A100) 2 6 Cutter holder for cutting (A27) 1 7 Cutter holding (A28) 1 8 Ratchet handle (A104) 1 9 Crank handle (K159) 1 10 Safety goggles (A111) 1 11 Single head spanner 24mm (A101) 1 12 Hex key #5 (A102) 1 13 Hex key #6 long (A103) 1 14 Straw broom (A112) 1 15 Single head spanner 13mm (A721) 1 16 Operation manual 1 KEEL CUTTER N450 6

Hydraulic unit 1 Hydraulic unit 04E 1 (including hydraulic motor M26, hydraulic hose 10m with coupler x 2) 2 Tool (plug wrench) 1 3 Optional accessories Guide Rings φ 93 ~φ 733mm According to pipe outer diameter Water Tanks Water Tank 7l Water Tank 12l for pipe φ 528mm (OD) for pipe φ 528mm or above (OD) Pipe Stands (3 or 4 pcs to be used) (L) with aluminum wheel (H) with aluminum wheel (H) with rubber wheel for pipe φ 118-1554mm (OD) for pipe φ 93-733mm (OD) for pipe φ 93-733mm (OD) Extension chains Extension chains Wedges (2 pcs) Wedges For preventing diamond blade from getting caught in the pipe 4 Optional accessories (blades) Diamond Blades 125 3S Cut depth: approx. 19.9mm (new blade) 150 3S Cut depth: approx. 32.4mm (new blade) HS Tipped Saw Blade 125 4.2 For steel pipe 7 KEEL CUTTER N450

5 Name of main components KEEL CUTTER N450 8

6 Guide ring Check the cutting position and guide ring position 7 Guide ring components Tightening screw Nut M12 (K267) Plain washer M12 (D022) Caulking pin (K266) Hex socket head bolt M8 35(K264) Roll pin φ8 2 4( K 2 6 9) Supporting part (K270) 9 KEEL CUTTER N450

8 Attaching guide ring 1 Open the guide ring and attach it around the pipe Before a taching the guide ring, m ove up the hex bolts M8x35 so they don't touch the pipe. 2 Fit the tightening screw in the slot and fasten the nut 3 Temporarily fasten the M8x35 bolts evenly A tach the guide ring at a right angle to the pipe 4 Check the position If the guide ring is displaced,adjustit by hiting with plastic ham mer(do not use an iron ham mer). 5 Fasten the bolts evenly on the circumference Ensure the guide ring doesn't get displaced while fastening the bolts. KEEL CUTTER N450 10

9 Attaching rotary plates If the diamond blade on the cutter touches the pipe, adjustment with rotaty plates is necessary so the blade doesn't touch the pipe. When using the blade 125 3S: Pipe OD φ93-117mm: [A] Pipe OD φ118-168mm: [X] Pipe OD φ169-219mm: [B] When using the blade 150 3S: Pipe OD φ169-219mm: [X] Pipe OD φ220-270mm: [B] 1 Remove the hex bolts Remove the hex bolts from the arm. Hex socket head bolt M8x25 (A085) 2 Markings and female thread There are two rotary plates inside the arm. There are markings [A] [B] [X] on the rotary plates and female thread (M8) by each marking. A X B Check if the rotary plates are warped or distorted. If they are, the blade may touch the pipe. 3 Fasten the hex bolts Align the hole in the arm and the female thread (with the right diameter), and insert the bolt (M8 x 25) from the arm side to fasten (to be fastened by two bolts). 11 KEEL CUTTER N450

⓾ Attaching spray unit It is necessary to spray water on diamond blades. 1 Spray unit (a set of 7 components) from the water tank (optional) is necessary. 2 Attach the spray unit Attach the unit to the hole in the blade cover as shown below. Adjust the assembly so that the spray port faces the diamond blade. KEEL CUTTER N450 12

⓫ Checking V-belts and chains Check the V-belts Check that 2 x V-belt SB-25 are fitted in the cutter machine. If they are not, fit the V-belts as shown below. 1 Remove the blade cover Remove the two hex bolts (M6x10) fixing the blade cover using hex wrench (5mm). 2 Fit the V-belts Fit the V-belts SB-25 on the drive pulleys. 3 Attach the blade cover Attach the blade cover with two hex bolts (M6x10). Check the chains Select the right chains according to the pipe diameter. Pipe diameter Chains to be used φ93~φ220mm Chain (machine side) φ221~φ476mm Chain (machine side) + extension chain φ477~φ733mm Chain (machine side) + extension chain x 2 13 KEEL CUTTER N450

⓬ Blades Selecting a blade Select either from diamond blade 125 x 3S or 150 x 3S. Blade and related components necessary for cutting Part No. Description Q'ty 1 A27 Cutter holder 1 2 Diamond blade 125 3S or 150 3S 1 3 A28 Cutter holding plate 1 4 A93 Hex nut M16 1 Attaching the blade Check the rotational direction and order of fitting the related parts, then attach the blade securely with supplied ratchet handle and single head spanner 24mm. KEEL CUTTER N450 14

Caution Direction of blade rotation Cutting blade (diamond blade) has a specified rotational direction. The direction is marked on the blade as shown below. If the blade is attached for the wrong direction, not only the blade doesn't cut, but it will be destroyed and cause troubles. Ensure the nut is securely fastened to fix the blade. It is very dangerous if it gets loose during rotation, ⓭ Checking before attaching machine on the pipe Ensure the following two points before attaching the machine on the pipe. Check thatthe blade lowering unit(screw type)is elevated. The part showing "UP" and "Down"(arrows) should stay at the top of the screw. If it's lowered, the blade may touch the pipe. 15 KEEL CUTTER N450

Slightly loosen the nut on the outer roller shaft of the guiding unit with wrench (24mm). If the nut is tightened, the guiding unit may not fit on the guide ring. ⓮ Attaching machine on pipe Clean the pipe you are going to cut. If it is oily, the cutter may be slipped. Hold the guide ring between rollers of the guiding unit. Check that the V-belt fit in the groove of the drive pulley (on both sides). Check that the blade doesn't touch the pipe. If it does, move up the blade before starting the machine. KEEL CUTTER N450 16

⓯ Attaching guiding unit 1 Push the inner side guide rollers (on the machine side) against the guide ring. 2 Tighten the adjusting bolt (M8) with spanner (13mm) until the outer guide roller contacts the guide ring. 3 Fix the nut of the outer roller shaft, then fix the M8 adjusting bolt with nut. 4 Loosen the wing bolt and lower the bracing attachment until its two rollers touch the pipe, then tighten the wing bolt securely. 17 KEEL CUTTER N450

⓰ Attaching driven shaft assy and hook shaft assy 1 Set the driven shaft assy and hook assy. Adjust the long screw with a sufficient tightening margin. 2 Connect the chains Connect the chains on the hook of the driven shaft assy. 3 Tighten the belts Fit the ratchet handle to the end of the long screw and slightly tighten the belts with the wrench. ⓱ Setting hydraulic motor 1 Hydraulic motor (M-26) Use the hydraulic motor included in the hydraulic unit 04E. KEEL CUTTER N450 18

2 Attach the motor Check that a key is fitted on the motor shaft. Align the key to the keyway to attach the motor. A82 Key 5x5x19 3 Tighten the bolt Fix the motor securely by tightening the bolt (hex socket head, M8x25) using hex wrench #6. ⓲ Connecting hydraulic hose snd motor 1 Connect the hydraulic hose and the hydraulic motor Clean the coupling part before connecting the hose and motor. 2 Connect couplers After connecting the couplers, slide the outer part of the female coupler to prevent the couplers from being disconnected. 19 KEEL CUTTER N450

3 Move the clutch to "Stop" position. Be sure the clutch is at the stop position when starting the engine. ⓳ Checking before starting hydraulic unit 1 2 Check the hydraulic oil Check the oil level with the oil level stick. The oil level should be above the line in the middle of the oil-level stick. Add hydraulic oil If necessary, remove the cap from the tank and add hydraulic oil. "Idemitsu Super Hydro 32A" or equivalent oil should be used. Oil inlet Ensure no contaminants get in when adding hydraulic oil. A black rubber packing is fitted inside the oil cap to prevent oil leakage during transportation. Make sure to remove the packing before using the machine. Rubber packing Flower shape cap (with the packing) KEEL CUTTER N450 20

The hydraulic unit must be placed in the flattest place possible. (maximum inclination angle: 10 degrees) 3 Check the fuel tank Add gasoline if necessary. 4 Check if the air cleaner is clean Clean it if necessary. Maintenance Every 50 hours Every 200 hours Every 300 hours Engine oil change Air cleaner cleaning Fuel strainer cleaning Spark plug cleaning Hydraulic oil change Hydraulic oil tank cleaning For the first time, change at 25 hours. Add engine oil if necessary. Idemitsu's "Pro-mente SJ/CF-4 10W-30" or equivalent oil should be used. Drain the gasoline completely if the engine is not used for a long time. Thoroughly read Engine Operation Manual before using the engine. Engine oil inlet 21 KEEL CUTTER N450

⓴ Starting hydraulic unit 1 Move the switch lever to "OFF" position 2 Move the clutch to "Stop" position 3 Turn on the engine switch of the hydraulic unit 4 Open the cock lever Check the gasoline. 5 Start the engine Confirm the safety before starting the engine 6 Warm-up operation Keep the switch lever of the hydraulic unit to "OFF", then perform warm-up operation for several minutes. Especially in winter, perform warm-up operation about 10 miniutes to improve the flow of hydraulic oil. KEEL CUTTER N450 22

7 Move the switch lever to "ON" The blade starts to rotate immediately after you move the switch lever to "ON". Confirm safety before moving the lever to "ON" and warn operators and bystanders. When you are going to switch on the lever, be sure the blade doesn't touch the pipe. 8 Break-in operation (be sure to perform this) Move the clutch to "Run" position and run the machine 200mm or more without lowering the blade. By performing break-in operation, you can prevent the cutter from being driven off its track and suppress overload during cutting. The V-belts are loosened after break-in operation, so retighten them after the break-in operation. The clutch mechanism is for running or stopping the machine on the pipe. It's not for rotating the blade. 21 Spraying water 1 Open the cock lever and spray water on the blade 23 KEEL CUTTER N450

22 Starting machine 1 Lower the blade Attach the crank handle to the blade lowering screw, then turn the handle counterclockwise to lower the blade and cut through the pipe wall. 2 Check the depth Check the depth with "Roller Bumper" which is attached on the arm side of the blade cover. You can rotate the roller bumper with your hand until it comes to the proper depth position. When the roller bumper is at the proper position, it touches the pipe and cannot be rotated any more. Tighten the wing bolt on the blade lowering unit. Turn the roller bumper with bare hand. Do not touch the blade. Wear safety goggles during cutting to protect eyes from cut off dust. Do not lower the blade quickly, which will scatter fragments of pipe and cause machine troubles. Ensure the blade cover is closed when the blade is rotating. KEEL CUTTER N450 24

3 Move the clutch to "Run" position and run the cutter around the pipe In case of cutting buried pipe, the diamond blade may get caught in the cut pipe as the cutting comes to the end, causing damage to the blade. To prevent this, drive in wedges before and after the blade. 4 Complete the cut After the cutting is done, move the clutch to "Stop" position to stop the run, then lift up the blade by turning the crank handle. 5 Move the switch lever to "OFF" 6 Slow down and stop the engine 25 KEEL CUTTER N450

23 Removing machine 1 Disconnect the couplers Slide the outer part of the female coupler to disconnect the couplers. 2 Remove the driven shaft and hook shaft assy Turn the long screw of the hook shaft assy clockwise using crank handle, and remove the hook shaft assy from the V-belts (SB-25). 3 Remove the guiding unit from the guide ring Loosen the bolts and nuts in reverse order to remove the guiding unit. 4 Remove the machine from the pipe 5 Remove the guide ring KEEL CUTTER N450 26

6 Maintenance of cutter machine 1 Lubricate the sliding parts: Roller bumper (A25) Hook roller (A45) Chain roller (A43) Chain shaft roller (A44) Driven pulley (A32) 2 When the roller bumper is dirty and doesn't rotate. Remove the blade cover (see page 13), clean and lubricate the roller bumper, then attach them back on the machine. If the rollers get stuck by rust or cut off dust, or the chain plate is deformed, the cutter may slip or not run straight, or the cut line may not meet the starting point. It is recommended to overhaul the cutter machine and hydraulic unit about every 2 years. 27 KEEL CUTTER N450

7 Pipe stands 1 How to use pipe stands Pipe stands are used when the pipe iscuton the ground. Using 3 pipe stands Use one each stand at both ends of the pipe,and use one stand under the cut.after the pipe is cut,two pieces of cutpipe wilsiton the middle stand. Using 4 pipe stands Use one each stand at both ends of the pipe, and one each at both sides of the cut (the stands should not get in the way of attaching the machine and cutting the pipe). Use the pipe stands at a flat place. Do not use them on a slope. KEEL CUTTER N450 28

2 Types of stand and applicable diameter Applicable pipe diameter Pipe stand (H) Pipe stand (L) Position of wheels Pipe stand (H) Diameter φ93~φ733mm φ118~φ1554mm Eitherrubberoraluminum wheels may be used in(h)type. Pipe stand (L) Important Caution Fit the wheels at the right place so that pipe is firmly supported. Unstable pipe may cause accidents. Gently put the pipe on the pipe stands so the wheels won't come off. 29 KEEL CUTTER N450

8 Water tanks Water tank 7l Water tank 12l Applicable pipe diameter ~φ528mm φ528mm~ 1 Attach the spray unit (a set of 7 components) to the blade cover (see page 12) 2 Fill the tank Loosen the handle, remove the lid and fill the tank with tap water. After filling the tank, firmly attach the lid. Important Caution If the lid is loose, you cannot pressurize enough. Also it will cause danger if the lid comes off during pressurization. 3 Connect the coupler on the hose to the water feed assembly. KEEL CUTTER N450 30

4 Pressurization Pressurize the tank by moving the handle up and down, and stop the pressurization when the safety valve is green. If pressurization exceeds 5kg/ cm2, the safety valve turns red and depressurize the tank. If you push down the handle to the lowest position and turn it left (counterclockwise), the handle remains at the down position. 5 Spray water Spray the diamond blade or tipped saw blade. Diamond blade 6 Maintenance The couplers may stick in cut off dust. Wash them and spray antirust agent after use. 31 KEEL CUTTER N450

9 Genuine blades 1 Diamond blades Our diamond blades were specially developped for cutting castiron pipes. They are different from competitors in every aspect, such as ingredients and hardness of the diamond. Cutting tests were repeatedly performed to design the blades, and they are manufactured to deliver the best mechanical performance. 2 Check the blade Check if it has missing tips, it is worn out or its base is deformed. If the pipe is hard, run the machine around the pipe twice. If that's still not enough, run the machine three times. Non-genuine blades Blades made by competitors provide different cutting conditions. Use of non-genuine blades with our machine may overload the machine and the hydraulic unit and cause machine trouble. Please use genuine blades. Failures may not be covered by warranty if non-genuine blade has been used. KEEL CUTTER N450 32

10 Maintenance 1 V-belts If cut off dust remains on the belt after use, its durability will be deteriorated. Replace the belt if: It is torn or frayed. It goes below the edge of the pulley wheel when it is tightened. (If the machine is run with the belt staying below the edge of the pulley wheel, the belt will touch the bottom of the pulley wheel and the drive force will not be transmitted.) 2 Blade lowering unit (screw type) Lubricate the screw and the rotating part to make the unit move up and down smoothly. Stiff movement may cause damage to the parts. Screw Rotating part 33 KEEL CUTTER N450

11 Blades and applicable pipes Diamond blade Tipped Saw Blade Spray water Ductile iron pipe Necessary Cast iron pipe Necessary Hume pipe Necessary Electric pole Necessary Concrete pile Necessary (needs extra) Steel pipe Necessary Polyvinyl chloride pipe Necessary If a tipped saw blade is used for cutting ductile iron pipe, it's not possible to cut concrete part of the pipe. Cutting steel pipes 1Special size guide ring may be necessary depending on the pipe diameter. 2The machine may not be able to cut some steel pipes (depending on the diameter and wall thickness of the pipe). KEEL CUTTER N450 34

12 Extension chains (mm) Extension chain 13 Minimum working clearance for Keel Cutters Model L1 L2 L3 (mm) N2600 250~300 610~760 80~230 N600LRCU 250 470 58 N450 with hydraulic unit 200 470 52 35 KEEL CUTTER N450