User Manual - Metal Cutters
Contents
1. 6417010 x5 x5 x5 x5 X7 x6 x6 x6 X7 X7 Thickness X 16 Length mm BLADES REPLACEMENT PROCEDURE If the cutting edges of the blades are chipped cracked deformed or damaged in any way their cutting ability will be reduced Cutting under such conditions may cause further damage and result in personal injury The blades should be replaced as a set immediately if any damage is found M A WARNING vs Washer When replacing the blades ensure that the tool is disconnected Blade A i Blade B from the power supply to prevent accidental operation Bar Holder H Ensure that Blade A on the Bar Holder and Blade B on the Cutter Rod are fitted in their correct respective positions O 1 Undo the bolts and the washers that hold Blade A and Blade pE B a I 2 Remove dirt and clean the surfaces where the new blades Bolt are to be fitted Cutter rod 3 Fit Blade A to the Bar Holder and Blade B to the Cutter Rod Replace bolts and washers and tighten firmly Tighten torque for the bolts of Blades is 10Nem A WARNING The bolts that hold Blade A and Blade B should be tightened regularly If the bolts become loose the Blades may be damaged and may cause personal injury Blade Identification Blade B on Cutter Rod Spare blade Securing bolts should be firmly tightened Confirm periodically that the blade is tightened properly2. Blade A on Bar Holder Blade Size Use this table to identify the correct blades for your model CE A Fitted to Bar Holder B Fitted to Cutter Rod HBC 313 3 13 mm 9002010 20X 15 X 9 mm Bolt size 5mm 20 X 15 X 8 mm Bolt size 5mm HBC 613 a 3 13 mm 9002010 20X 15 X 9 mm Bolt size 5mm 20 X 15 X 8 mm Bolt size 5mm HBC 316 a 3 16 mm 9002410 22 X 17 X 9 mm Bolt size 5mm 22 X 17 X 9 mm Bolt size 5mm HBC 16R 3 16 mm 9002420 22 X 17 X 9 mm Bolt size 5mm 22 X 16 7 X 8 mm Bolt size 5mm Model HBC 816 3 16 mm 9002020 26 X 20 X 10 mm Bolt size 5mm 21 X 20 X 10 mm Bolt size 5mm HBC 19R 3 19 mm 9002030 28 X 20 X 11 5 mm Bolt size 5mm 26 X 20 X 10 mm Baolt size 5mm HBC 520 3 20 mm 9002030 28 X 20 X 11 5 mm Bolt size 5mm 26 X 20 X 10 mm Bolt size 5mm HBC 22 8 3 22mm 9002400 30 X 24 X 11 mm Bolt size 5mm HBC 225 4 25 mm 9002040 36 X 28 X 13 mm Bolt size 5mm HBC 232 4 32 mm 9002460 44 X 36 X 16 mm Bolt size 5mm 14 ADDING OIL This rebar cutter is electro hydraulic When shipped from the factory it was filled with oil Do not attempt to add oil as long as the tool performs well Over a period of time the oil level will gradually go down Eventually this will cause a noticeable dropping off in performance When this happens add oi
3. 620 N mm 63 kg mm 90 000 P S I 19 mm 6 Cutting Speed 2 5 seconds 3 0 seconds Standard Accessories Model Carrying case Hydrauli c oil 46 Hex wrenches 3 4 5 6 mm Double open end wernches 17 19 mm HBC 225 Double open end wernches 17 22 mm HBC 232 115V 230 V a c 50 60 Hz Single Phase 1 430W 1 430W Weight 22 0 Kg 37 6 Kg Dimensions L X W X H 480 X 138 X 269 mm 543 X 167 5 X 289 mm Cutting Capacity Tensile Strength Max Dia Tensile Strength Max Dia 620 N mm 63 kg mm 90 000 P S I 25 mm 8 620 N mm 63 kg mm 90 000 P S I 32 mm 10 Cutting Speed 4 0 seconds 7 0 seconds Standard Accessories Carrying case Hydrauli C oil 32 Hex wrenches 4 5 6 8 mm Hex wrenches 4 5 6 8 10 mm Double open end wernches 14 17 24 mm Double open end wernches 17 30 mm OPERATING PROCEDURE This tool is electro hydraulic rebar cutter to be designed to cut reinforcing bars Read understand and follow all safety instructions and operating procedures If you do not understand the instructions or if conditions are not correct for proper operations do not operate this tool Consult your supervisor or other responsible person A WARNING 1 Before operation confirm that the position of the operator relative t
4. HBC 16R O Bar Holder Cutter Rod This lever isn t used for HBC 613 See How to use Switch for HBC 613 on P11 for the details Lever Lock Button Note Do not push this button during operation as Cutter Rod will lock and won t return HBC 613 816 Safety Warning Decal Trigger Switch Hydraulic Pump Case Blade B Hydraulic Cylinder Bar Holder Cutter Rod HBC 520 19R 22 225 232 Blade A Bar Holder Hydraulic Cylinder Cutter Rod Blade B SPECIFICATIONS B Specifications Model HBC 313 HBC 613 HBC 316 115 V 230 V a c 50 60 Hz Single Phase 580 W 710 W 580 W Weight 5 4 Kg 7 3 Kg 5 8 Kg Dimensions L X W X H 362 X 205 X 106 5 mm 447 X 151 X 110 mm 378 X 205 X 108 mm Cutting Capacity Tensile Strength Max Dia Tensile Strength Max Dia Tensile Strength Max Dia 490 N mm 50 kg mm 71 000 P S I 13 mm 4 490 N mm 50 kg mm 71 000 P S I 13 mm 4 490 N mm 50 kg mm 71 000 P S I 16 mm 5 620 N mm 63 kg mm 90 000 P S I 10 mm 3 620 N mm 63 kg mm 90 000 P S I 10 mm 3 620 N mm 63 kg mm 90 000 P S I 13 mm 4 Cutting Speed 1 5 seconds 1 5 seconds 2 0 seconds Standard Accessories Model Carrying
5. bearings damaged or broken Replace bearings NOTE The internal components of the pump and piston area have very close tolerances and are sensitive to damage from dust dirt contamination of the hydraulic fluid or improper handling The disassembly of the pump housing requires special tools and training and should only be attempted by qualified repair personnel that have been properly trained and have the right tools The improper servicing of electrical components can lead to conditions that could cause serious injury The pump piston components and all electrical parts should be serviced only by authorized repair shop dealer or distributor Ogura 2661 Hongo Ebina City Kanagawa pref Japan 243 0417 TEL 046 238 1285 FAX 046 238 4188 Ogura amp Co Lid IOJIN 8503400 0810
6. case Hydraulic oil 46 Hex wrenches 3 4 5 mm Double open end wrenches 14 17 mm HBC 816 HBC 16R HBC 19R 115V 230 Va c 50 60 Hz Single Phase 1 010 W 580 W 700 W Weight 8 8 Kg 6 2 Kg 11 4 Kg Dimensions L X W X H 492 X 165 X 120 mm 410 X 205 X 180 mm 401 X 126 X 226 mm Cutting Capacity Tensile Strength Max Dia Tensile Strength Max Dia Tensile Strength Max Dia 620 N mm 63 kg mm 90 000 P S I 16 mm 5 440 N mm 45 kg mm 63 000 P S I 16 mm 5 620 N mm 63 kg mm 90 000 P S I 13 mm 4 620 N mm 63 kg mm 90 000 P S I 19 mm 6 Cutting Speed 1 5 seconds 2 0 seconds 2 5 seconds Standard Accessories Carrying case Hydraulic oil 46 Hex wrenches 3 4 5 mm Hex wrenches 3 4 5 6 mm Double open end wrenches 14 17 mm Double open end wrenches 17 19 mm Model HBC 520 Specifications HBC 22 115V 230 V a c 50 60 Hz Single Phase 1 330 W 700W Weight 12 2 Kg 14 2 Kg Dimensions L X W X H 396 X 112 X 220 mm 414 X 112 X 238 mm Cutting Capacity Tensile Strength Max Dia Tensile Strength Max Dia 620 N mm 560 N mm 57 kg mm 81 000 P S I 22 mm 7 63 kg mm 90 000 P S I 20 mm 6
7. debris and clean Cutter Rod has not returned completely due to damage to the Cutter Rod Replace Cutter Rod Cutter Rod has not returned completely due to loose or damaged Cutter Rod Blade Tighten Blade bolts Replace Cutter Rod Blade Cutter Rod has not returned completely due to weak Return Spring Replace Return Spring Insufficient power to cut rebar Insufficient oil Top up oil Refer to Adding Oil Return Valve not properly seated or seating damaged Clean tip of Return Valve and seating Remove any scratches from seating Return Valve damaged Replace Incorrect clearance between Cylinder and Piston Replace Piston Note different size pistons available Check Valve not properly seated or seating damaged Clean Check Valve and seating Replace Urethane Packing damaged or broken Replace Oil Leveller Bladder damaged or broken Replace Cutter Rod Bar Holder O Ring damaged Rod Bar Holder surface grooved Replace Back Up Ring and O ring Replace Cutter Rod Bar Holder Cylinder Bar Holder O Ring damaged Replace O ring Cylinder Pump Case Gasket damaged Replace Bar Cutter Cylinder Pump Case flange bolts loose Tighten bolts Motor not working Motor slow or erratic Voltage incorrect Correct Carbon brushes worn Replace Armature damaged or open circuit Replace Armature
8. Oovura F FCTRO HYDRAULIC REBAR CUTTER Model HBC313 613 316 816 16R IDR 520 22 225 232 Instruction Manual Before installing and operating this machine read understand and follow all instructions and operating procedures Keep these instructions with the machine TABLE OF CONTENTS IMPORTANT SAFETY INSTRUCTIONS ee eee eee eter reer tee teee tastes zaaceaaa 3 PARTS NAMES tic ettet eq m be ni iti eerie ed 6 SPEGIFICATIONS zeza dete an die etd e i e aie ee ed 7 OPERATING PROCEDURE imt ife ede ede eee 9 BLADES REPLACEMENT PROCEDURE sese enneennrenenen ens 12 CARBON BRUSHES REPLACEMENT PROCEDURE eee 13 ADDING Oll ei ERES en utis 14 TROUBLE SHOOTING eege ete AE eem 15 Meaning of caution and warning indications Caution Indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury This is also used to alert against unsafe practices associated with events that could lead to personal injury Warning Indicates a potentially hazardous situation which if not avoided will result in death or serious injury Ogura amp Co Ltd shall not be responsible for any incidental damages or personal injuries resulting from negligence of Warnings and Safety Instructions contained in the Instruction Manual A WARNING Read understand and follow all safety instructions and operating procedures If you do not understand the i
9. e starting operation 17 Avoid Unexpected Operation Do not carry plugged in tool with finger on switch Be sure switch is off before plugging in 18 Use Outdoor Extension Cord For Outside When tool is used outdoors use only extension cord intended for use outdoors and so marked 19 Stay Alert When using electric tools Read and follow operating procedures in this instruction manual Consider safety of others Operate tool with care Watch what you are doing Use common sense Do not operate tool when you are tired A GENERAL POWER TOOL SAFETY WARNINGS 20 Check For Damaged Parts Before using the tool carefully check all parts for damage including guards to ensure that they will operate correctly and perform their intended function Check for any misalignment or binding of moving parts damaged or broken parts and mountings and any other conditions that may affect its operation Do not use tool if electric plug or cord is damaged Do not use tool if it was dropped or damaged in any way A guard or other part that is damaged should be properly repaired or replaced by an authorized service centre unless otherwise indicated in this manual Do not use tool if switch does not turn it on and off Have damaged or defective switch replaced by an authorized service centre 21 Only Use Specified Accessories and Attachments Use only the accessories and attachments described in this manual and t
10. he Ogura catalogue Use of other accessories or attachments may result in an accident or injury 22 Service at Factory Authorized Repair Centre Only Service this electric appliance in accordance with the relevant safety regulations Repairs to electric appliances should only be done by a qualified person Repairs by others may endanger the user Contact your dealer to arrange servicing 23 To throw a way the waste in illegal manner is strictly prohibited Follow the local regulations AXELECTRO HYDRAULIC REBAR CUTTER SAFETY WARNINGS Cut pieces may fly off during cutting Confirm the safety of surroundings before cutting e Keep fingers and face away from the cutting area Cut pieces may fly off and cause injury to the operator e Material is ejected at end of cut Be sure that ejected slug cannot fall and cause injury Consider the safety of others when cutting e Never cut rebar when the piece to be cut off is less than 200 mm in length Smaller pieces have a tendency to fly off and may cause injury to the operator and the surroundings e Replace any broken worn deformed cracked or damaged parts immediately with Ogura identical replacement parts Damaged or broken parts may cause further damage to the tool as well as serious injury to personnel Tool should be connected only to a power supply of the same voltage as indicated on the product label and can only be operated on single phase AC supply f extensi
11. l pressure and allow the Cutter Rod to return Retighten the Return Valve once the Cutter Rod is fully returned and before starting the next operation Return Valve Switch operation for HBC 613 This Lever not used on HBC 613 When operating fully depress the Trigger Switch Note Do not operate with the Trigger Switch only partly depressed CARBON BRUSHES REPLACEMENT PROCEDURE When the carbon brushes become less than 6mm the motor force deteriorates because of low rectification Carbon brushes need to be replaced 1 Remove the carbon brush cap of the motor outer frame using the standard screwdriver 2 Replace the carbon brushes with new ones 3 Put back the caps 6mm Carbon Brush Size Model Part Number Size HBC 313 o 3 o 13 mm 6071060 Thickness X 12 Length mm HBC 613 o 3 o 13 mm 6402170 HBC 316 o 3 o 16 mm 6071060 Thickness X 12 Length mm HBC 16R a 3 16 mm 6071060 Thickness X 17 Length mm Thickness X 12 Length mm HBC 816 o 3 o 16 mm 6400580 Thickness X 17 Length mm HBC 19R a 3 19 mm 6071070 5 Thickness X 17 Length mm HBC 520 o 3 o 20 mm 6415720 5 Thickness X 18 Length mm HBC 22 6 3 22 mm 6071070 5 Thickness X 17 Length mm HBC 225 9 4 25 mm 6417010 Thickness X 16 Length mm HBC 232 8 4 32 mm
12. l as follows Place some rebar between the Blades and pull the Trigger Switch Release the Trigger Switch just before the cut is completed to stop the tool Unplug the tool so that the Blades cannot be moved accidentally Remove the Bolt M10 X 15 which caps the oil filler hole Add the oil being careful not to allow any oil to spill into the motor Replace the Bolt M10 X 15 and tighten securely Plug the tool in and complete the cutting operation Repeat the above procedure several times until the oil level remains correct o RO DP N O A CAUTION Only pure hydraulic oil as recommended by Ogura amp Company Ltd should be used in this tool For HBC 25N and HBC 32 use Super Hyrando 32 Nippon Oil Corporation or equivalent spec anti wear Hydraulic Oil ISO Viscosity Grade 32 For all other models use Ogura supplied hydraulic oil Super Hyrando 46 Nippon Oil Corporation or equivalent spec anti wear Hydraulic Oil ISO Viscosity Grade 46 Do not use other oils as these may cause damage to the seals and other internal machine parts TROUBLE SHOOTING A WARNING Unplug tool from the power source before troubleshooting PROBLEM CAUSE SOLUTION Cutter Rod will not extend Insufficient oil Top up oil Refer to Adding Oil Cutter Rod has not returned completely due to build up of debris between Cutter Rod and Bar Holder Manually push back Cutter Rod Remove
13. l cause seizure of the motor overheating smoke and fire Use Right Tool Do not force small tool or attachment to do the job of a heavy duty tool Do not use tool for purpose not intended Dress Properly Do not wear loose clothing or jewellery as they can be caught in moving parts Rubber gloves and non skid footwear are recommended when working outdoors Wear protective hair covering to contain long hair 10 Always Wear Safety Glasses or Goggles 11 Do Not Abuse Power Cord Never carry tool by its power cord or pull on the cord to disconnect it Keep cord away from heat oil and sharp edges 12 Secure Work Use clamps or a vice to hold the work This frees both hands to properly hold control and operate the tool Failure to properly secure the work may result in injury 13 Do Not Overreach Keep proper footing and balance at all times 14 Maintain Tools Carefully Keep tools sharp and clean for better and safer performance Follow instructions for lubricating and changing accessories Inspect tool power cord periodically and if damaged have repaired by authorized service facility Keep handles dry clean and free from oil and grease 15 Disconnect Tools From Power Source When not in use before servicing and when changing accessories such as blades and cutters 16 Remove Keys and Wrenches Form habit of checking to see that keys and wrenches are removed from tool befor
14. nstructions or if conditions are not correct for proper operation DO NOT OPERATE THE MACHINE Consult your supervisor or other responsible person WARNING LABELS RELATED SAFETY Flying debris and loud noise hazards Wear ear and eye protection Hazardous voltage Disconnect all power before working on this equipment Failure to observe this instruction will result in death or serious injury Moving blade Keep hands clear while machine is operating Turn power off before servicing SAVE THESE INSTRUCTIONS AAGENERAL POWER TOOL SAFETY WARNINGS Before Operating Tool Read Instruction Manual Keep Work Area Clean Cluttered areas and benches invite injuries Consider Work Area Environment Do not expose tool to rain Do not use tool in damp or wet locations Keep work area well lit Do not use tool in presence of flammable liquids or gases Guard Against Electric Shock Prevent body contact with grounded surfaces e g pipes ranges refrigerator enclosures etc Keep Children Away Do not allow children or unauthorised personnel to handle tool or extension cord All visitors should be kept away from work area Store Idle Tools When not in use tools should be stored in a dry and secure place out of reach of children Do Not Force Tool It will do the job better and safer at the rate for which it was intended Do not force tool to work beyond its ability Excessive load wil
15. o the tool and the surrounding area is safe for operation Put on safety glasses and wear Hold Bolt Stopper protective clothing Refer to the tool specifications in this manual and do not cut rebar of size or hardness that exceeds the cutting capacity of the tool Do not cut material other than rebar Please ask the manufacturer if you want to cut other materials HBC 16R Cutting Procedure 1 Position the rebar to be cut so that it is fully between the blades as shown in the figure on the left l A WARNING If the rebar to be cut is not positioned fully between the blades the blades will be damaged the rebar will be ejected violently and may cause serious personal injury Rebar X Blades Q 2 Adjust the Hold Bolt according to the diameter of the rebar to be cut so that the rebar is at 90 degrees to the blades as shown in the figure on the left Tighten the lock nut The Hold Bolt supports the rebar and keeps it per pendicular to the blades when cutting A WARNING When cutting rebar adjust the Hold Bolt according to the thickness diameter of the rebar to be cut so that the rebar is at 90 degrees to the blades as shown in the figure on the left Without this adjustment the cut piece may fly off and cause serious injury to the operator or bystanders 3 Confirm that the power supply is 115 V 230 V single phase Insert the plug into the power outlet and c
16. on cord is used the wire size should be equal to or greater than that specified below Use only 3 wire extension cord that has a 3 pin earthed plug and 3 pin earthed socket that matches the plug on the tool Replace or repair a damaged cord Always adjust the Hold Bolt to the diameter of the rebar and retighten Hold Nut before cutting e Confirm the Hold Nut is tightened properly before cutting starts ACAUTION Power source with a breaker is recommended to avoid the electric shock Follow Local Noise Level Regulations Operate tools within a soundproofed enclosure if necessary Check Before Operation The tool is manufactured for the purpose of cutting reinforcing bars Do not use the tool for a purpose it was not intended for Only use Ogura genuine blades Replace parts when and as directed in this instruction manual Confirm that all bolts and screws are tightened properly before operation begins Operate Tool With Proper Voltage The tool should be connected only to a power supply of the same voltage as indicated on the product label If connected to a higher voltage the motor will over speed and eventually burn out If connected to a lower voltage the motor will be damaged and eventually break up Pay Attention When Operating e Keep proper footing and balance at all times e Stop operation immediately when the tool is out of order or makes abnormal sound during use e During tool operation keep hands and face away f
17. onnect the plug to ground does not apply to HBC 613 816 and 520 If your power outlet has no earth first install a ground adapter on the tool side before inserting the plug excluding HBC 613 816 and 520 10 More than 200 mm Operating procedure A WARNING HBC 16R Do not cut rebar when the piece to be cut off is less than 200 mm in length Cutting shorter length may cause the rebar to fly off during cut and may result in serious personal injury A WARNING Do not cut rebar when it is not properly supported by the Hold Bolt or if the Hold Bolt is not properly adjusted When cutting hold the rebar on the Hold Bolt side as shown in the figure on the left If not the cut piece may fly off and cause serious injury to the operator or bystanders A WARNING Replace damaged chipped broken cracked or deformed blades immediately The blade will not cut true and may fracture or break causing serious personal injury 4 Pull the Trigger Switch to start cutting operation The Cutter Rod will move forward to cut the rebar Keep the Switch depressed until the Cutter Rod stops at the end of its stroke 5 Release the switch when the cut is completed and the Cutter Rod has reached the end of its stroke The Cutter Rod will then return automatically to its starting position The Cutter Rod will not return if the s
18. rom the blades all moving parts and the scrap ejection section Carbon brushes should be replaced every 200 hours or when the length of the brush is reduced to 6 mm Protect Tool e Handle tool carefully If it is dropped or struck it could be damaged The motor air vents should be open and unobstructed as they provide cooling for the motor Keep the air vents clear of dust dirt and debris or the motor will over heat and be damaged Maintain Tool e Keep tool clean to stay in best condition Always wipe off dirt and oil from the motor switch and handles e Use only Ogura genuine parts for replacement e Check the tool regularly so that it can be used safely and effectively e Stop operation immediately and contact your dealer if the tool is making abnormal sounds or is out of order in any way Do not disassemble the tool as the internal components are sensitive to damage from dust dirt contamination of the hydraulic fluid or improper handling e This is a hydraulic tool powered by electricity When the temperature is low the oil will thicken and tool may not work properly Idle tool for a few minutes before use Ear protection Typical A weighted sound pressure level 96 dB A Typical A weighted sound power level 75 dB A CAUTION Wear ear protection The typical weighted root mean square acceleration Value is not more than 2 5m S Contact your dealer for service and check up PARTS NAMES HBC 313 316 16R
19. troke is not completed Similarly the Cutter Rod will not be able to move forward again until after it returns completely to its starting position Pull the switch to start the next cut only after the Cutter Rod completely returns to its starting position and stops A WARNING When cutting rebar of a high tensile strength the cut piece may fly off and cause serious injury to the operator Wear safety glasses and confirm that the surrounding area is safe before starting operation Operating procedure A WARNING Keep your hands and face away from the blades the moving parts and the cutting area during operation Unplug the machine immediately after use and when the electric supply is cut off Note Keep the air hole in the end of the Bar Holder clear of dirt and debris The air hole controls the internal pressure and should not be obstructed The Motor Body can be rotated though 360 degrees in either direction during operation This feature is particularly useful when working in awkward or narrow areas as it allows the operator to position the tool in the best position for easy operation E Return Valve Operation HBC 520 22 225 and 232 The funtion of the Return Valve is to allow the Cutter Rod to return to the starting position if it is unable to complete a cut or becomes jammed Using supplied hex wrench loosen Return Valve about half a turn in anticlockwise direction This will release the oi
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