Operating & Safety Manual

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Always ensure that you have read and understood these instructions before using any of the Pipe Cutter

1 Operating & Safety Manual Pipe Cutter DN70, 100 & 150 Pipe Cutter Ultra Flex DN100, 150 & 200 I N S T R U C T I O N S These instructions are for your personal safety. Always ensure that you have read and understood these instructions before using any of the Pipe Cutter range. We now have resellers in the U.S., Europe & Australasia. Locate your reseller at picotesolutions.com or call for further information.

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

2 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 practical demonstration videos, or to download an electronic copy of these Instructions, please visit Please note that videos are not intended as a replacement or alternative to this operating and safety manual, but only as an additional learning tool. 2

3 SAFETY INFORMATION This section contains important safety information. Failure to comply could result in serious injury or death. Safety Symbols Safety symbols are used throughout this manual to draw attention to potential hazards. Danger risk of serious injury, follow instructions Danger risk of serious injury from rotating parts Personal Protective Equipment (PPE) Always use Personal Protective Equipment when using the Pipe Cutter and Miller systems, including suitable overalls / protective clothing & footwear and the following: Always wear suitable eye protection when using the Pipe Cutter to prevent epoxy or other dust from irritating your eyes. Always wear suitable ear protection when using the Pipe Cutter and Miller systems to prevent any hearing loss. Always remember Always wear suitable cut-resistant gloves when using the Pipe Cutter to prevent any hand injuries. Any open injuries or skin irritations should be covered at all times to avoid contact with epoxy dust. Always wear a suitable ventilation mask when using the Pipe Cutter or Miller systems to prevent any epoxy resin dust being inhaled or consumed, which can cause occupational asthma or epoxy dermatitis as well as eye irritation. Dust produced when working can be dangerous to your health, inflammable or explosive. Make sure the drain pipe has been opened and ventilated 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 rotating parts. 3

AVAILABLE SIZES & POWER SOURCES The Pipe Cutter is used to remove excess cured liner that has overshot during the lining process into the main line.

4 AVAILABLE SIZES & POWER SOURCES The Pipe Cutter is used to remove excess cured liner that has overshot during the lining process into the main line. Selecting the correct Pipe Cutter for the job Choose your Pipe Cutter according to the size of the original host pipe. PIPE CUTTER SIZE OF PIPE Shaft size BEND 90 BEND 45 mm mm Pipe Cutter DN YES YES Pipe Cutter DN YES YES Pipe Cutter DN YES YES Pipe Cutter Ultra Flex 100, 150, YES YES CHOOSING YOUR POWER SOURCE The Pipe Cutter can be attached to a Picote milling machine or to a hand drill, an exception is the DN200 Pipe Cutter which is to be used with the Maxi Miller. The DN100 & 150 Pipe Cutters can be powered by the Midi or Maxi Miller. The DN70 Pipe Cutter can be powered by the Micro or Mini Miller. A regular hand drill can be used to power the Pipe Cutter when the cut is less than 10m away using shaft with standard outer casing, or for slightly longer distances using shaft with thicker outer casing. The hand drill must have an rpm of 1800 (for long distances) to 3000 (for shorter distances). Please note that the rpm will decrease over longer distances due to increasing friction. When the distance from the access point exceeds 10m, a regular hand drill could overheat and the Pipe Cutter should be operated with one of Picote s Millers. 4

5 REQUIRED PARTS Your Pipe Cutter package will include four panels (all packages) and centralizers (DN100 & 150 packages only). You can use the Pipe Cutter panels with Smart Cutter hubs, hubs discs, shaft and shaft sockets. First, make sure you have all the required parts. Pipe Cutter DN70 List of required parts: 1. Two DN70 panels 2. DN50 narrow hub 2W for 12mm shaft (8.5x20x50 2 WEDGE) 3. Wedged hub disc (0x20x6) 4. 12mm shaft with outer casing 5. 12mm Sleeve with bearing for outer casing (recommended, shown in the photo) 6. 12mm shaft socket for drill or Picote Miller Pipe Cutter DN100 List of required parts: Four DN100 panels 2. Centralizers (3 parts) DN70 hub aluminum for 12mm shaft (12.5x35x75) 4. Small hub disc (0x35x6) 5. Tape mm shaft with outer casing 7. 12mm Sleeve with bearing for outer casing (recommended) 8. 12mm shaft socket for drill or Picote Miller PLEASE NOTE: always check that the rotational direction is clockwise before placing the tool inside drain. 5

Pipe Cutter DN150 List of required parts: 2. 1. Four DN150 panels 2. Centralisers (3 parts) 3. DN100 aluminium hub for 12mm shaft (12.5x40x100) 3. 4. Large hub disc (0x40x6) 5. Tape 6.

6 Required parts continued Your Pipe Cutter package will include four panels (all packages) and centralizers (DN100 & 150 packages only). You can use the Pipe Cutter panels with Smart Cutter hubs, hubs discs, shaft and shaft sockets. First, make sure you have all the required parts. 1. Pipe Cutter DN150 List of required parts: Four DN150 panels 2. Centralisers (3 parts) 3. DN100 aluminium hub for 12mm shaft (12.5x40x100) Large hub disc (0x40x6) 5. Tape 6. 12mm shaft with outer casing 7. 12mm sleeve with bearing for outer casing (recommended) 4. Power source: Picote Miller or 6. A drill, 12mm shaft with outer casing & 12mm shaft socket PLEASE NOTE: always check that the rotational direction is clockwise before placing the tool inside drain. 6

DN100 & 150 PIPE CUTTER ASSEMBLY & USE First, make sure you

Please see photo parts lists on previous pages.

use. Pipe Cutter DN100 DN70 aluminium Small hub disc

Pipe Cutter DN150 100x150 panel DN100 aluminium hub for 12mm

7 DN100 & 150 PIPE CUTTER ASSEMBLY & USE First, make sure you have all the required parts. Please see photo parts lists on previous pages. Please read safety information on page 3 before assembly and use. Pipe Cutter DN100 DN70 aluminium Small hub disc Centralisers 100x100 panel hub for 12mm shaft with screws Pipe Cutter DN x150 panel DN100 aluminium hub for 12mm shaft Large hub disc with screws Centralisers Step 1. The shaft without outer casing should be the length of a hub slot. 7

Assembly & use (DN100 & 150) continued Pipe

Position the biggest centraliser about 0.

to secure the centralizer at the right spot.

8 Assembly & use (DN100 & 150) continued Pipe Cutter DN100 & 150 Step 2. Position the biggest centraliser about 0.5m from the end of the outer casing (Pipe Cutter end). Use tape on the both sides of the centraliser to secure the centralizer at the right spot. PLEASE NOTE: always check that the rotational direction is clockwise before placing the tool inside drain 8

9 Assembly & use (DN100 & 150) continued Pipe Cutter DN100 & 150 Step 3. Position the second centraliser against the outer casing. Step 4. Position the centralising bearing against the second centraliser. Step 5. Insert the hub on the shaft against the centralisers. Tighten the screws with a hex key. Please see the Smart Cutter manual for more detailed information. 9

For DN150 Pipe Cutter only: prepare the panel

liner when pushing the cutter in or pulling it

Insert four Pipe Cutter panels into the Smart

liner when you run the cutter clockwise. Step 8.

10 Assembly & use (DN100 & 150) continued Pipe Cutter DN100 & 150 Step 6. For DN150 Pipe Cutter 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 cutter in or pulling it out. Step 7. Insert four Pipe Cutter panels into the Smart Cutter hub so that the blades point towards the liner when you run the cutter clockwise. Step 8. Attach the small hub disc (DN100 Pipe Cutter) or the large hub disc (DN100 Pipe Cutter) to the hub. Make sure the screws are tightened securely. 10

Assembly & use (DN100 & 150) continued Pipe Cutter DN100 & 150 Step 9.

Wrap the panels evenly around the hub so that the blades point outwards.

11 Assembly & use (DN100 & 150) continued Pipe Cutter DN100 & 150 Step 9. Your Pipe Cutter has been assembled. Step 10. Wrap the panels evenly around the hub so that the blades point outwards. Put the entire Pipe Cutter inside the pipe. Step 11. Now you can turn the power on. Set the rpm low (500rpm). Step 12. While you push the cutter to the right spot, you can facilitate the movement of the cutter by increasing the rpm slightly in the bends for a short period of time. However, be careful not to damage the liner. PLEASE NOTE: always check that the rotational direction is clockwise before placing the tool inside drain. 11

Change the rpm to 1000-2000 (max 3000rpm). Hold on tightly to the shaft so the Pipe Cutter does not move. Turn the power source on with full speed as mentioned before.

12 Assembly & use (DN100 & 150) continued Pipe Cutter DN100 & 150 Step 13. Verify the right spot where to position the Pipe Cutter blade with a CCTV camera. Turn the power on for a moment and double check that the Pipe Cutter is in the right spot. If the spot is right, hold on to the shaft tightly so that the Pipe Cutter does not shift or move. Step 14. Change the rpm to (max 3000rpm). Hold on tightly to the shaft so the Pipe Cutter does not move. Turn the power source on with full speed as mentioned before. Follow the cutting process with a CCTV camera. The blades should point outwards. As soon as the cut is finished turn the power off immediately. DN100 Pipe Cutter DN150 Pipe Cutter Step 15. Change the rpm back to 500. Turn the power on and let the cutter 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 positioned upwards. If they are not, push the Pipe Cutter back to the main and start step 11 over again. Do not pull back the Pipe Cutter from the main unless the cutter is turning at low speed. If the cutter is not running at a low rpm while pulling it back, the Pipe Cutter panels will spring open into the main. It will then be difficult to pull it back into the lateral. Running the Pipe Cutter at low rpm will help to collapse the panels back around the hub for easy removal. Step 16. Pull the Pipe Cutter out of the pipe the same way you put it in. 12

DN70 PIPE CUTTER ASSEMBLY & USE First, make sure you have all the required parts. Please see photo parts lists on previous pages.

5x20x50 2 WEDGE) Small wedged hub disc (0x20x6) Insert two DN70 panels into the narrow Smart Cutter hub so that the blades point towards the liner when you run the

Step 2. Attach the small wedged hub disc to the hub. Make sure both screws are tightened securely. Step 3.

13 DN70 PIPE CUTTER ASSEMBLY & USE First, make sure you have all the required parts. Please see photo parts lists on previous pages. Please read safety information on page 3 before assembly and use. Pipe Cutter DN70 blade 50X70 panel Step 1. DN50 narrow hub for 12mm shaft (8.5x20x50 2 WEDGE) Small wedged hub disc (0x20x6) Insert two DN70 panels into the narrow Smart Cutter hub so that the blades point towards the liner when you run the cutter clockwise. Insert the DN70 panels into the Smart Cutter hub. The blades on the panel should point towards the cured liner when the cutter is operated. Step 2. Attach the small wedged hub disc to the hub. Make sure both screws are tightened securely. Step 3. Add a 12mm sleeve bearing for the outer casing on the casing. Step 4. Attach the Pipe Cutter to the shaft. Please see the Smart Cutter manual for more detailed information. PLEASE NOTE: always check that the rotational direction is clockwise before placing the tool inside drain. 13

Assembly & use (DN70) continued Pipe Cutter DN70 Step 5. Wrap the panels evenly around the hub so that the blades point outwards. Step 6. Put the entire Pipe Cutter inside the pipe. Step 7.

14 Assembly & use (DN70) continued Pipe Cutter DN70 Step 5. Wrap the panels evenly around the hub so that the blades point outwards. Step 6. Put the entire Pipe Cutter inside the pipe. Step 7. Now turn your power source on. Set the rpm low (500rpm). Step 8. While you push the cutter to the right spot, you can facilitate the movement of the cutter by increasing the rpm slightly in the bends for a short period of time. However, be careful not to damage the liner. Step 9. Verify the right spot where to position the Pipe Cutter blade with a CCTV camera. Turn the power on for a moment and double check that the Pipe Cutter is in right spot. If the spot is right, hold on to the shaft tightly so that the Pipe Cutter does not shift or move. Step 10. Change the rpm to (max 3000rpm). Hold on tightly to the shaft so the Pipe Cutter does not move. Turn the power source on with full speed mentioned before. Follow the cutting 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 cutter 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 positioned upwards. If they are not, push the Pipe Cutter back to the main and start step 11 over again. Step 12. Pull the Pipe Cutter out of the pipe the same you put it in. PLEASE NOTE: always check that the rotational direction is clockwise before placing the tool inside drain. 14

15 PIPE CUTTER ULTRA FLEX DN100, 150 & 200 The Ultra Flex models come fully assembled. The Ultra-Flex Pipe Cutter centers itself even if the lateral pipe connecting to the main has a bend or bends in it just before the location where the cured liner will be cut off. The centralising white brushes hold the Pipe Cutter head centered during the cutting process allowing a fast and accurate cut. Please read safety information on page 3 before assembly and use. Pipe Cutter Ultra Flex DN200 with 6 panels (Use DN150 panels with a six panel Smart Cutter hub). DN100 & 150 models have four panels each. Attach to the shaft The shaft without outer casing should be the length of a shaft connector slot. Insert the shaft into the slot. Your Pipe Cutter is now ready. The Pipe Cutter Ultra Flex DN100 AND 150 can be attached to a Picote milling machine (Midi or Maxi Miller) or to a hand drill. The DN200 Pipe Cutter is to be used with the Maxi Miller. 15

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.

16 MAINTENANCE CARING FOR THE FLEXIBLE SHAFT The flexible shaft is pre-treated with paraffin oil and the casing replaced prior to shipping. Always inspect the condition and apply oil between the flexible shaft and its outer casing when required. If necessary remove the shaft 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 time. FASTENER SCREWS If you are unable to tighten 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 cutting process and fall into the pipe. SPARE PARTS Pipe Cutter panels The Pipe Cutter panel packages include four panels. The DN100 AND 150 packages also include the required centraliser parts. The DN200 Pipe Cutter requires six DN150 panels with a 6-panel Smart Cutter hub Pipe Cutter DN70 panel package Pipe Cutter DN100 panel package, inc. Centralisers Pipe Cutter DN150 panel package, inc. Centralisers SPARE PART: Pipe Cutter Centraliser package DN SPARE PART: Pipe Cutter Centraliser package DN SPARE PART: Pipe Cutter DN200 spare panels (6) 16

PRACTICAL TIPS & SAFETY ADVICE Here are some useful tips on

Always use the recommended tools for maintenance to avoid

SHAFT ROUNDER The shaft rounder smooth's the end of the

cut off the damaged length using an angle-grinder.

17 PRACTICAL TIPS & SAFETY ADVICE Here are some useful tips 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 shaft rounder smooth's the end of the flexible shaft, preventing the user from being cut by the otherwise sharp metal edge. ATTACHING A SHAFT SOCKET Feed the shaft through the socket to the end and securely fasten. The outer casing should reach all the way to the base of the shaft socket to protect the shaft. CUTTING THE FLEXIBLE SHAFT Always inspect the flexible shaft before each use. If there are potential weak points or the shaft 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 Attach a visual marker (tape) to the outer casing of the flexible shaft. Place it around half a meter from the end point of the shaft. The mark will indicate the chain s location and prevent possible injuries when the Pipe Cutter is removed from the drain, including injury by rotating parts. 17

INNOVATIVE THINKING In Finland, Picote is a very well established contracting company, successfully rehabilitating thousands of drains and sewer pipes with trenchless methods since 2008.

These resourceful tools and machinery have been devised and perfected as a direct result of feedback and evaluation from worksites.

18 INNOVATIVE THINKING In Finland, Picote is a very well established contracting company, successfully rehabilitating thousands of drains and sewer pipes with trenchless methods since By focusing on in-house research and development, our company also offers a growing range of unique, patented and patentpending products, which are now available to the international market. These resourceful tools and machinery have been devised and perfected as a direct result of feedback and evaluation from worksites. As a contractor ourselves, we know that durability, reliability and safety do matter at the work site, and that value for money is also a priority. That s why at Picote we are proud of our innovative, quality products. Designed for professionals, by professionals. International Sales Offices Picote UK Ltd Unit 12, Space Business Centre, Molly Millars Lane, Wokingham, RG41 2PQ, United Kingdom Dawn Greig Sales Director dawn@picotesolutions.com Picote Solutions Inc. Anthony DeCavitch WW Director of Product Management tony@picotesolutions.com Authorised Resellers: Hammerhead LMK Technologies Perma-Liner Industries Technical Support Jake Saltzman WW Technical Director jake@picotesolutions.com Production & R&D Picote Oy Ltd Urakoitsijantie Porvoo, Finland sales@picotesolutions.com 18

SAFETY MANUAL CHAIN KNOCKERS SAFETY INFO WARNING! READ BEFORE USE OF TOOL

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