Operating & Safety Manual Pipe Cutter DN70, DN100 & DN150/ 3, 4 & 6 Pipe Cutter Ultra Flex DN70, DN100 & DN150/ 3, 4 & 6 I N S T R U C T I O N S These instruc ons are for your personal safety. Always ensure that you have read and understood these instruc ons before using any of the Pipe Cu er range. LMK Technologies, LLC 1 815 640 9302 www.lmktechnologies.com #1686 V.0 10/16 (16 10 576)
Table of Contents TOPIC PAGE/S SAFETY INFORMATION & SYMBOLS 3 AVAILABLE SIZES & POWER SOURCES 4 REQUIRED PARTS 5 ASSEMBLY & USE 7 MAINTENANCE & SPARE PARTS 15 PRACTICAL TIPS & SAFETY ADVICE 16 To watch prac cal demonstra on videos, or to download an electronic copy of these Instruc ons, please visit www.picotesolu ons.com. Please note that videos are not intended as a replacement or alterna ve to this opera ng and safety manual, but only as an addi onal learning tool. 2
SAFETY INFORMATION This sec on contains important safety informa on. Failure to comply could result in serious injury or death. Safety Symbols Safety symbols are used throughout this manual to draw a en on to poten al hazards. Danger risk of serious injury, follow instruc ons Danger risk of serious injury from rota ng parts Personal Protec ve Equipment (PPE) Always use Personal Protec ve Equipment when using the Pipe Cu er and Miller systems, including suitable overalls / protec ve clothing & footwear and the following: Always wear suitable eye protec on when using the Pipe Cu er to prevent epoxy or other dust from irrita ng your eyes. Always wear suitable ear protec on when using the Pipe Cu er and Miller systems to prevent any hearing loss. Always remember Always wear suitable cut resistant gloves when using the Pipe Cu er to prevent any hand injuries. Any open injuries or skin irrita ons should be covered at all mes to avoid contact with epoxy dust. Always wear a suitable ven la on mask when using the Pipe Cu er or Miller systems to prevent any epoxy resin dust being inhaled or consumed, which can cause occupa onal asthma or epoxy derma s as well as eye irrita on. Dust produced can be dangerous to your health, inflammable or explosive. Make sure the drain pipe has been opened and ven lated to stop any gases forming in the lateral drain where the work takes place. Before assembly, use, replacement of parts or maintenance, unplug the Picote milling machine or your hand drill from its power socket. Failure to comply may lead to serious injury including electric shock or injury from rota ng parts. 3
AVAILABLE SIZES & POWER SOURCES The Pipe Cu er is used to remove excess cured liner that has overshot during the lining process into the main line. Selec ng the correct Pipe Cu er for the job Choose your Pipe Cu er according to the size of the original host pipe. PIPE CUTTER SIZE OF PIPE Sha size BEND 90 BEND 45 mm/inches mm/inches Pipe Cu er DN70/3 70/3 8 / ⅓ YES YES Pipe Cu er DN100/4 100/4 12 / ½ YES YES Pipe Cu er DN150/6 150/6 12 / ½ YES YES Pipe Cu er Ultra Flex 100, 150, 200 4, 6, 8 12 / ½ YES YES CHOOSING YOUR POWER SOURCE The Pipe Cu er can be a ached to a Picote milling machine or to a hand drill, an excep on is the 8 Pipe Cu er which is to be used with the Maxi Miller. The DN100 & 150/4 & 6 Pipe Cu ers can be powered by the Midi or Maxi Miller. The DN70/3 Pipe Cu er can be powered by the Micro or Mini Miller. The DN200/8 Pipe Cu er can only be used with the Maxi Miller. 4
REQUIRED PARTS Your Pipe Cu er package will include four panels (all packages) and centralizers (DN100 & 150/4 & 6 packages only). You can use the Pipe Cu er panels with Smart Cu er hubs, hubs discs and sha. First, make sure you have all the required parts. Pipe Cu er DN70/3 List of required parts: 1. Two DN70/3 panels 1. 2. DN50/2 narrow hub 2W for 8mm/⅓ sha 3. Wedged hub disc (20mm / 2 screws) 4. 8mm/⅓ sha with outer casing 4. 5. 2. 1. 3. 5. 8mm/⅓ Sleeve with bearing for outer casing (recommended, shown in the photo) 6. Picote Miller Pipe Cu er DN100/4 List of required parts: 3. 1. Four DN100/4 panels 2. Centralizers (3 parts) 3. DN70/3 hub aluminum for 12mm/½ sha 4. 4. 1. 4. Small hub disc (35mm / 4 screws) 5. Tape 2. 2. 2. 6. 12mm/½ sha with outer casing 7. 12mm/½ Sleeve with bearing for outer casing (recommended) 6. 8. Picote Miller 5. 7. PLEASE NOTE: always check that the rota onal direc on is clockwise before placing the tool inside 5
Required parts con nued Your Pipe Cu er package will include four panels (all packages) and centralizers (DN100 & 150/4 & 6 packages only). You can use the Pipe Cu er panels with Smart Cu er hubs, hubs discs & sha. First, make sure you have all the required parts. 1. Pipe Cu er DN150/6 2. List of required parts: 1. Four DN150/6 panels 2. Centralizers (3 parts) 3. DN100/4 aluminum hub for 12mm/½ sha 3. 4. Large hub disc (40mm with 4 screws) 5. Tape 6. 12mm/½ sha with outer casing 7. 12mm/½ sleeve with bearing for outer casing (recommended) 4. Power source: Picote Miller 6. 5. 7. PLEASE NOTE: always check that the rota onal direc on is clockwise before placing the tool inside drain. 6
DN100 & 150/4 & 6 PIPE CUTTER ASSEMBLY & USE First, make sure you have all the required parts. Please see photo parts lists on previous pages. Please read safety informa on on page 3 before assembly and use. Pipe Cu er DN100/4 100x100mm/4x 4 panel 70mm/3 aluminum hub for 12mm/½ sha Small hub disc with screws Centralizers Pipe Cu er DN150/6 100x150mm/4x 6 panel 100mm/4 aluminum hub for 12mm/½ sha Large hub disc with screws Centralizers Step 1. The sha without outer casing should be the length of a hub slot. 7
Assembly & use (DN100 & 150/4 & 6 ) con nued Pipe Cu er DN100 & 150/4 & 6 Step 2. Posi on the biggest centralizer about 50cm/20 inches from the end of the outer casing (Pipe Cu er end). Use tape on the both sides of the centralizer to secure the centralizer at the right spot. PLEASE NOTE: always check that the rota onal direc on is clockwise before placing the tool inside drain. 8
Assembly & use (DN100 & 150/4 & 6 ) con nued Pipe Cu er DN100 & 150/4 & 6 Step 3. Posi on the second centralizer against the outer casing. Step 4. Posi on the centralizing bearing against the second centralizer. Step 5. Insert the hub on the sha against the centralizers. Tighten the screws with a hex key. Please see the Smart Cu er manual for more detailed informa on. 9
Assembly & use (DN100 & 150/4 & 6 ) con nued Pipe Cu er DN100 & 150/4 & 6 Step 6. For DN150/6 Pipe Cu er only: prepare the panel by pulling out the flaps on each panel as shown on the picture. This will decrease the risk of damaging the liner when pushing the cu er in or pulling it out. Step 7. Insert four Pipe Cu er panels into the Smart Cu er hub so that the blades point towards the liner when you run the cu er clockwise. Step 8. A ach the small hub disc (DN100/4 Pipe Cu er) or the large hub disc (DN150/6 Pipe Cu er) to the hub. Make sure the screws are ghtened securely. 10
Assembly & use (DN100 & 150/4 & 6 ) con nued Pipe Cu er DN100 & 150/4 & 6 Step 9. Your Pipe Cu er has been assembled. Step 10. Wrap the panels evenly around the hub so that the blades point outwards. Put the en re Pipe Cu er inside the pipe. Step 11. Now you can turn the power on. Set the rpm low (500rpm). Step 12. While you push the cu er to the right spot, you can facilitate the movement of the cu er by increasing the rpm slightly in the bends for a short period of me. However, be careful not to damage the liner. PLEASE NOTE: always check that the rota onal direc on is clockwise before placing the tool inside 11
Assembly & use (DN100 & 150/4 & 6 ) con nued Pipe Cu er DN100 & 150/4 & 6 Step 13. Verify the right spot where to posi on the Pipe Cu er blade with a CCTV camera. Turn the power on for a moment and double check that the Pipe Cu er is in the right spot. If the spot is right, hold on to the sha ghtly so that the Pipe Cu er does not shi or move. Step 14. Change the rpm to 1000 2000 (max 3000rpm). Hold on ghtly to the sha so the Pipe Cu er does not move. Turn the power source on with full speed as men oned before. Follow the cu ng process with a CCTV camera. The blades should point outwards. As soon as the cut is finished turn the power off immediately. DN100/4 Pipe Cu er DN150/6 Pipe Cu er Step 15. Change the rpm back to 500. Turn the power on and let the cu er turn around for a moment in the main before pulling it back inside the lateral pipe. Verify with a CCTV camera that the blades are posi oned upwards. If they are not, push the Pipe Cu er back to the main and start step 11 over again. Do not pull back the Pipe Cu er from the main unless the cu er is turning at low speed. If the cu er is not running at a low rpm while pulling it back, the Pipe Cu er panels will spring open into the main. It will then be difficult to pull it back into the lateral. Running the Pipe Cu er at low rpm will help to collapse the panels back around the hub for easy removal. Step 16. Pull the Pipe Cu er out of the pipe the same way you put it in. 12
DN70/3 PIPE CUTTER ASSEMBLY & USE First, make sure you have all the required parts. Please see photo parts lists on previous pages. Please read safety informa on on page 3 before assembly and use. Pipe Cu er DN70/3 blade 50x75mm/2x 3 panel 50mm/2 narrow hub for 8mm/⅓ sha with 2 panels Small wedged hub disc Step 1. Insert two 3 panels into the narrow Smart Cu er hub so that the blades point towards the liner when you run the cu er clockwise. Step 2. A ach the small wedged hub disc to the hub. Make sure both screws are ghtened securely. Step 3. Add a 8mm/⅓ sleeve bearing for the outer casing on the casing. Step 4. A ach the Pipe Cu er to the sha. Please see the Smart Cu er manual for more detailed informa on. PLEASE NOTE: always check that the rota onal direc on is clockwise before placing the tool inside drain. 13
Assembly & use (DN70/3 ) con nued Pipe Cu er DN70/3 Step 5. Wrap the panels evenly around the hub so that the blades point outwards. Step 6. Put the en re Pipe Cu er inside the pipe. Step 7. Now turn your power source on. Set the rpm low (500rpm). Step 8. While you push the cu er to the right spot, you can facilitate the movement of the cu er by increasing the rpm slightly in the bends for a short period of me. However, be careful not to damage the liner. Step 9. Verify the right spot where to posi on the Pipe Cu er blade with a CCTV camera. Turn the power on for a moment and double check that the Pipe Cu er is in right spot. If the spot is right, hold on to the sha ghtly so that the Pipe Cu er does not shi or move. Step 10. Change the rpm to 1000 2000 (max 3000rpm). Hold on ghtly to the sha so the Pipe Cu er does not move. Turn the power source on with full speed men oned before. Follow the cu ng process with a CCTV camera. As soon as the cut is finished turn the power off immediately. Step 11. Change the rpm back to 500. Turn the power on and let the cu er turn around for a moment in the main before pulling it back inside the lateral pipe. Verify with a CCTV camera that the blades are posi oned upwards. If they are not, push the Pipe Cu er back to the main and start step 11 over again. Step 12. Pull the Pipe Cu er out of the pipe the same you put it in. PLEASE NOTE: always check that the rota onal direc on is clockwise before placing the tool inside drain. 14
PIPE CUTTER ULTRA FLEX DN100, 150 & 200/4, 6 & 8 The Ultra Flex models come fully assembled. The Ultra Flex Pipe Cu er centers itself even if the lateral pipe connec ng to the main has a bend or bends in it just before the loca on where the cured liner will be cut off. The centralizing white brushes hold the Pipe Cu er head centered during the cu ng process allowing a fast and accurate cut. Please read safety informa on on page 3 before assembly and use. Pipe Cu er Ultra Flex DN200/8 with 6 panels (Use DN150/6 panels with a six panel Smart Cu er hub). DN100/4 & DN150/6 models have four panels each A ach to the sha The sha without outer casing should be the length of a sha connector slot. Insert the sha into the slot. Your Pipe Cu er is now ready. The Pipe Cu er Ultra Flex DN100/4 and DN150/6 can be a ached to a Picote milling machine (Midi or Maxi Miller) or to a hand drill. The DN200/8 Pipe Cu er is to be used with the Maxi Miller. 15
MAINTENANCE CARING FOR THE FLEXIBLE SHAFT The flexible sha is pre treated with paraffin oil and the casing replaced prior to shipping. Always inspect the condi on and apply oil between the flexible sha and its outer casing when required. If necessary remove the sha from its casing to treat. When the casing has been replaced, rotate manually for even coverage. PIPE CUTTER PANELS Keep the panels clean. If a panel is worn or has a crack, it should be changed. For the best outcome, it is recommended that all the panels are changed at the same me. FASTENER SCREWS If you are unable to ghten the fastener screws properly, due to worn out hex socket heads, replace the fastener screws immediately. Otherwise, a panel can detach from the hub during the cu ng process and fall into the pipe. SPARE PARTS Pipe Cu er panels The Pipe Cu er panel packages include four panels. The DN100/4 and DN150/6 packages also include the required centralizer parts. The DN200/8 Pipe Cu er requires six 150/6 panels with a 6 panel Smart Cu er hub. 1250000070 Pipe Cu er DN70/3 panel package 1250000100 Pipe Cu er DN100/4 panel package, inc. Centralizers 1250000150 Pipe Cu er DN150/6 panel package, inc. Centralizers 1250100100 SPARE PART: Pipe Cu er Centralizer package DN100/4 1250150150 SPARE PART: Pipe Cu er Centralizer package Dn150/6 9125000200 SPARE PART: Pipe Cu er DN200/8 spare panels (6) 16
PRACTICAL TIPS & SAFETY ADVICE Here are some useful ps on how to get the most out of your Picote system. Always use the recommended tools for maintenance to avoid personal injury. SHAFT ROUNDER The sha rounder smooth's the end of the flexible sha, preven ng the user from being cut by the otherwise sharp metal edge. ATTACHING A SHAFT SOCKET Feed the sha through the socket to the end and securely fasten. The outer casing should reach all the way to the base of the sha socket to protect the sha. CUTTING THE FLEXIBLE SHAFT Always inspect the flexible sha before each use. If there are poten al weak points or the sha is damaged, cut off the damaged length using an angle grinder. This should be done outside in a clear area as there will be sparks generated by the process. ADDING A VISUAL MARKER FOR SAFETY A ach a visual marker (tape) to the outer casing of the flexible sha. Place it around half a meter from the end point of the sha. The mark will indicate the chain s loca on and prevent possible injuries when the Pipe Cu er is removed from the drain, including injury by rota ng parts. 17