MK3000 Operating and Calibration Instructions
CONTENT 1. INTRODUCTION 3 1.1. GENERAL INFORMATION. 3 1.2. WORKING PRINCIPLE. 3 1.3. SECTION THROUGH CUTTER.. 4 1.4. SPECIFICATIONS.. 5 2. INSTRUCTIONS FOR USE 6 2.1. UNPACKING INSTALLATION.. 6 2.2. STARTING USE CUTTING. 7 2.3. SAFETY 8 3. MAINTENANCE. 9 3.1. MAINTENANCE.. 9 3.2. PRECAUTIONS DURING USE. 10 3.3. WARRANTY. 10 3.4. SPARE PARTS.. 11 4. CERTIFICATE OF CONFORMITY 13 MK3000 1/2001 2
1 INTRODUCTION 1.1. GENERAL INFORMATION You have just acquired the GATES MK3000 bench-mounted hose cutting machine and we congratulate you on your choice. This sturdy machine will give you long and satisfactory service. To this effect, it is important That you adhere to the enclosed instructions. The GATES MK3000 is designed to cut all types of hoses from GATES hose types 4M6K (M1T04) to 20G4K (BC1220). All the information concerning the operation, use and maintenance of the MK3000 can be found in this booklet. 1.2. WORKING PRINCIPLE CUTTING This cutter is designed to achieve a clean cut at right angles to the hose if spreading pins are correctly set. The method employed consists of bending the hose as it comes into contact with the circular blade, this will only be achieved if the adjustable pins are correctly positioned (see page 7). This avoids friction and ensures a clean, square cut to the hose without slowing the motor. ELECTRICAL SYSTEM The electrical system is comprised of an electric motor and its controls. A start button provides power to the motor, which is either a 230v single phase or 415v three phase brake motor, (see specification plate on cutter). A stop / emergency stop button is used to terminate the operation of the cutter. MK3000 1/2001 3
1.3. SECTION THROUGH CUTTER This section is comprised of (figure 1): - A steel blade (1) Ø 300 with sharp edge. This is rotated by an electric motor. - A longitudinal trolley (2) guided by dovetail slides. A shoe (3) at the forward end of the trolley moves the hose during cutting. It also serves as a protection when the trolley is at the end of travel during cutting. - A lever (4) controls trolley movement. - A threaded stop rod (5) for adjustment of trolley travel according to blade wear. - A return spring (6) for trolley. - Two rods (7) of variable spacing, inserted into the cutter table, which allow the bending according to the hose section. Separate the pins as the diameter of the hose being cut increases. HOSE Figure 1 : Working principle MK3000 1/2001 4
1.4. SPECIFICATIONS Motor: (3 Phase) - 380V - 50Hz 3kW 6.35A brake motor (1 Phase) - 220V 50Hz 2.2kW 13A Speed (3 Phase) - 3000 R.P.M. (1 Phase) 2800 R.P.M. Disk diameter: 300 mm x 25.4 mm x 3 mm Dimensions: H 340 L 650 W 500 Weight: 60 KGs Capacity: 1 ¼ Max Tools: 2 spreading pins Safety circuit breaker THREE PHASE SINGLE PHASE Figure 2 : Electrical circuit MK3000 1/2001 5
2. INSTRUCTIONS FOR USE 2.1. UNPACKING INSTALLATION Be careful, never lift the machine by the motor casing or the blade cover, open the cardboard and put webbing lifting straps under the machine and then use lifting gear. For ease of transport, the machine is delivered with handles removed. For best use, the machine should be fixed on a bench, the feet supplied with the machine will need to be removed so that the threaded holes can be utilised. Recommended height for operation: 900 mm. Work area should be clear to unwind hose in satisfactory conditions. Electrical connection must be carried out correctly. Check that the blade rotates in the direction indicated by the arrow on the casing. If it rotates incorrectly, reverse two phases. After positioning the two spreading pins, the machine is ready to operate. MK3000 1/2001 6
2.2. STARTING USE CUTTING Hose cutting is carried out by bending the hose on two spreading pins (adjustable according to hose diameter). Hose cutting must be conducted carefully; too much pressure will slow the motor and may cause damage to the blade. Ensure that pins are correctly positioned in order to bend the hose as it is cut. Hose spreading pin positioning table Compact 1 wire braid 1 + 2 wire braid. 4 Spiral + fabric braid 3 / 16 C C N/A ¼ C C N/A 5 / 16 C A N/A 3 / 8 C A A ½ A A A 5 / 8 A A B ¾ A B B 1 B B B 1 1 / 4 B B D KEEP YOUR HANDS CLEAR OF THE BLADE WHEN IT IS ROTATING MK3000 1/2001 7
2.3. SAFETY - Keep your hands clear of the blade when it is rotating. - Before starting, check the electric connection. - It is imperative you check the motor rotation (a incorrect direction of rotation will cause the unscrewing of the nut which secures the blade to the motor shaft). - The hose must be set securely between the guide shoe and the 2 correctly positioned pins. - Never cut at an angle; if the blade deviates from its axis or vibrates, stop cutting immediately and then start again a little further along the hose. - Do not remove the blade or motor cover. - Do not remove covers while the machine is connected to a power supply. - Switch off the machine after use. - The blade and machine is designed for cutting Gates Hydraulics hoses only, GATES cannot be held responsible for use with other materials. - Contact your GATES sales office for further information. St. Neots Meyzieu MK3000 1/2001 8
3. MAINTENANCE 3.1. MAINTENANCE This sturdy-built machine requires little maintenance if used in the conditions prescribed by this booklet. Set up a blade sharpening service to re-sharpen the blade after operation of the cutter is impaired and indicates the blade edge has been dulled. The slightest crack in the blade indicates that the machine has been used in abnormal conditions (cropping of different materials or blade overheating for example) and that the blade requires immediate replacement. To renew worn parts (blade), switch off the machine and remove the casing to gain access. Care should be exercised when performing this operation Light oiling on dovetailed guides will maintain smooth trolley movement. Figure 3 : Bending MK3000 1/2001 9
3.2. PRECAUTIONS DURING USE - A hose requires to be curved as much as possible to avoid blocking the motor. It is necessary to use the pins provided (please refer to the table on Page 5 and Figure 3, page 7). - It is necessary to exert pressure perpendicular to the blade, if not the blade could be distorted. An angled cut is also extremely dangerous. - It is recommended to relieve pressure of the lever on the hose when motor slows down. - The trolley is equipped with a locking pin to prevent involuntary movement and hence the blade edge being revealed. - This machine is equipped with a safety circuit breaker which will automatically return to stop if power drops (load loss, power cut) in order to avoid involuntary restarting. - From time to time check that rubber deposits do not clog the outlet pipe. Such negligence could cause a fire because the cutting can cause sparks. The hose must be cropped perfectly perpendicular. An angled cut should be systematically rejected as the fitting cannot be correctly mounted. 3.3. WARRANTY GATES machines are guaranteed against defects and faulty workmanship for a period of one year from date of purchase. During the period of warranty, GATES will repair (or replace as necessary) free of charge all faulty parts, provided the machine is returned to the works. This warranty will not apply in the case of accidental damage, misuse or if the machine has been subjected to repairs or modifications by persons other than GATES. GATES cannot be held responsible for any damage or injury direct, indirect or consequential to the use of its machines, nor after express or implicit termination of warranty. This warranty replaces all other warranties including implicit warranties. MK3000 1/2001 10
3.4. SPARE PARTS The user may carry out repairs himself (after expiry of the warranty period) and, to this end, the following table and view will help to locate and order the required spare part. All orders must state description, product No. and quantity required. Example: Description : BLADE Product No.7482-19868 Quantity : 1 Item No. Product No. DESCRIPTION QUANTITY 1 7482-19867 7482-19861 Brake Motor Three Phase 380v Motor Single Phase 220V 1 1 2 7482-19868 Blade 1 3 7482-19863 Hose spreading pin 2 N/A 7482-19866 Optional dust extraction adapter (not shown) 1 Table of the composition of MK3000 MK3000 1/2001 11
Figure 4 : Composition of MK3000 MK3000 1/2001 12
CERTIFICATE OF CONFORMITY Relating to equipment which is subject to automatic certification The Manufacturer, the undersigned : Hereby declares that the new equipment described below: MK3000 Serial No. Complies with the regulations regarding health and safety at work, as applicable, and with the EC European Norm. Authorised G.R. Keast, Director of Technical Date: March 1 st 2000 Gates Hydraulics Ltd. Gates Hydraulique S.A. Gates Europe N.V. Station Road B.P. 14 Dr. Carlierlaan 30 St. Neots, Huntingdom F-69881 Meyzieu Cedex B-9320 Erembodegem Cambs., PE 191XA France Belgium UK Tel: (+44) (0) 1480 22 50 00 Tel: (+33) (0) 4 72 45 12 12 Tel: (+32) (0)53 76 27 11 Fax: (+44) (0) 1480 22 53 50 Fax: (+33) (0) 4 72 02 81 08 Fax: (+32) (0)53 76 29 22 www.gates.com/europe MK3000 1/2001 13