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Circular wire saw system SL Operating instructions Spare parts list SL 0.1 Introduction 0.2 Validity of this Operation Instruction Dear customer, you have decided in favor of a progressive, proven HYDROSTRESS equipment, hence for a standard of technological leadership. Due to our efforts in the field of quality assurance the This Operating Instruction is exclusively valid for the following equipment: Circular Rope Saw Type SL Index 000 Circular Rope Saw Type SL represents a Swiss top performance product: 0.3 System range definition • High sawing performance • Reliable operation • High mobility • Convenient handling • Low maintenance cost Only original HYDROSTRESS spare parts assure quality and compatibility. If proper maintenance work is neglected or done incompetently we can not fulfill the guarantee obligations set forward in our terms of delivery. All repair work is to be made by professionally trained This Operation Instruction describes the use of the Circular Rope Saw Type S including the matching electric drive motor type EM and the hydraulic drive motors. The Circular Rope Saw Type SL must only be operated after the respective Operating Manual has been paid attention to. Spare parts and maintenance instructions for the drive unit engaged in the individual case can be found in the respective Operating Manual. persons only. Our customer service is at your disposal to maintain your equipment in perfect condition. We wish you trouble-free and unproblematic working with your HYDROSTRESS equipment. HYDROSTRESS AG The Management 0.3.1 Operating Manuals of drive units Indications for the use of drive units are meant to increase the safety of operators. However for safe operation of drive units the respective Operating Manual consulting the respective Operating Manual is indispensable! Copyright © HYDROSTRESS AG, 1998 HYDROSTRESS AG Witzbergstrasse 18 CH-8330 Pfäffikon Switzerland Telefon 0041 1 950 10 74 Telefax 0041 1 950 10 18 Hotline 079 / 608 19 07 page 2 sl9806e SL 0.4 Table of contents 0.1 Introduction 2 4.5 Mount protection hoods 23 0.2 Validity of this Operation Instruction 2 4.6 Water cooling 23 0.3 System range definition 2 4.7 0.4 Table of contents 3 Connection of water in case of using a hydraulic unit 23 Connection of water in case of using electric motor "EM" 24 5 Sawing 25 5.1 Before sawing 25 5.2 Sawing, hydraulic 25 5.3 Sawing, electric 26 5.4 Trouble shooting 27 5.5 After sawing 27 6 Maintenance 28 6.1 Maintenance table 28 7 Repair 29 4.8 1 Safety instructions 4 1.1 Basic provisions 4 1.2 Designated usage 6 1.3 Before starting work 6 1.4 During sawing 7 1.5 After finishing work 7 2 Technical Data 8 2.1 Dimensions 8 2.2 Attachable equipment, hydraulic 8 2.3 Attachable electric motor, electric 9 2.4 Design 10 2.5 Function with hydraulic drive 11 2.6 Funktion electric drive 12 7.1 Connection and repair of rope 29 2.7 Protection material 13 7.2 Connecting the rope by joint lock 29 7.3 Connecting the rope by repair sleeve 30 7.4 Connecting the rope by threaded lock 31 8 Transportation, shut-down , storage, disposal 32 3 Preparation for work 14 3.1 Procedure 14 3.2 Select drive unit and sawing motor (hydraulic) 15 3.3 Calculation of rope length 16 8.1 Transportation 32 3.4 Secure construction site 17 8.2 Shut-down, storage 32 3.5 Secure part to be sawn out 17 8.3 Disposal 32 8.4 Accessories 32 9 Spare parts list 33 4 Set-up 18 4.1 Fastening of system 18 4.2 Connecting the drive unit 20 4.3 Connecting the electric module 21 4.4 Mounting of rope 22 sl9806e page 3 Safety instructions 1 Safety instructions 1.1 Basic provisions 1.1.1 Dangers at work on construction sites The equipment is built in accordance with stateof-the-art and generally accepted rules of safety techniques. Nevertheless its operation may effect hazards to life and limb of the user or third persons resp. damage to the equipment or to other objects of value. Pay attention to the special working conditions at a construction site. Protect yourself and others within your area of responsibility extensively against the multiple dangers! 1.1.2 Qualification of operating personnel The operators need to be introduced and trained for work by experienced experts. For maintenance and repair specifically trained personnel has to be engaged. SL 1.1.3 Read the Operating Manual and inform your co-workers! This Operating Manual contains important indications for operating the equipment both safely and economically. The owner of the equipment needs to make sure that the instructions of the Operating Manual are paid attention by each and every person who will in any possible way be dealing with the equipment or the connected auxiliary and operating materials. The Operating Manual has to be made available at the working site at all times Noise impact (sound level) The noise level during work lies above 90 dB(A). This noise strain may permanently damage your hearing. Therefore during operation always wear ear protection devices. HYDROSTRESS can assist you for training. page 4 sl9806e SL 1.1.4 Safety instructions Recognize the Safety Alerts! Danger: Pay attention to the following phrases, their symbols (characteristics, displays, markings) and their meaning: 1.1.5 Personal protective clothing During drilling, sawing, biting, and pressing of concrete and stone wearing protective clothing is necessary to give protection against the following dangers: Danger: Specific information for prevention of bodily injuries Attention: Specific information for prevention of damage to the equipment Advice: Source of danger protective clothing: falling pieces: helmet, steel reinforced footwear moving, sharpedged pieces: gloves flying stone pieces, flying sparks: goggles slipping: footwear with non-slip soles noise: earmuffs contamination of respiratory tract: breathing mask Specific information for economic use of the equipment . sl9806e page 5 Safety instructions 1.2 Designated usage The system is designated for sawing with diamond ropes of Ø11mm into the materials quoted below. Any different usage may create risks which are not described in this Operating Manual and will void any warrantee by HYDROSTRESS. Process with this equipment exclusively: • Concrete, rock, masonry, asphalt SL 1.3 Before starting work 1.3.1 Static of the edifice The sawing of large openings can impair the static of an edifice. Therefore the sawing of large openings must be planned in coordination with construction static experts. 1.3.2 Tension reinforced concrete Other materials are not allowed for proces- Inform yourself if any tension rods are situated within the range of your planned cuts. Sever sing, especially: these only after explicit authorization. – Wood, plastics and glass 1.3.3 1.2.1 Sawed-off pieces These pieces may weigh heavily. Example: A cube of concrete of 1m edge dimension (~33") weighs about 2.5 tons (~5600 lb.). Secure such pieces against dropping or tipping over and close off that area of the construction site! 1.2.2 Drive units and accessories Use the machine or equipment exclusively with the recommended drive units or equipment and accessories (see “Attachable units” or “Attachable equipment” and “Accessories” in this Operation Instruction) 1.2.3 Accident prevention regulations in your country Observe the general and particular accident prevention regulations of trade associations and federations in your country! page 6 Emergency Stop Make sure that you can promptly stop the machine in case of emergency (see “Emergency Stop” in this Operation Instruction)! 1.3.4 First Aid in accidents Find out how to organize help fastest possible in case of accident! 1.3.5 Water-, Gas and Power-lines Make sure that such lines within your cutting or drilling range are out of operation! Obtain information whether such lines may be cut through! 1.3.6 Reinforcement rods Obtain information whether you may sever possibly present reinforcement rods in the course of the cut or bore. sl9806e SL 1.3.7 Safety instructions Organize your working place Organize your working place properly! Thereby you will considerably reduce accident hazard! 1.3.8 Lighting of working place 1.4.3 Rotating and moving parts Keep away from the rope and the pulleys. In order to avoid being caught by rotating or moving parts wear tight clothes, and if having long hear, wear a hair net! Provide for sufficient lighting of working place. 1.5 1.3.9 Protection gear Never start sawing before all protection gear is attached and in place. After work pull out the power plug of the drive unit to prevent unintentional switching on! 1.5.1 1.3.10 Flushing water Ascertain that flushing water can not spill over into electric installations. Avoid material damages by flushing water by exercising good control of the water’s draining flow. 1.4 During sawing 1.4.1 Rope ruptures After finishing work Removal of concrete and rock pieces Utilize suitable lifting equipment for the removal of those pieces, in order to avoid injuries! A rope rupture must be taken into account at any time. Observe the measures for avoiding rope ruptures (see “Malfunction remedy”). 1.4.2 Motorized forward feed Equipment with motorized forward feed are not automates. During operation they must be supervised at all times. A emergency shut-off must be possible at any time. sl9806e page 7 Technical Data SL 2 Technical Data 2.1 Dimensions 2.1.1 Sawing diameters 2.2 min. 50 cm max. 200 cm 2.1.2 Thickness max. 2.1.3 Attachable equipment, hydraulic 60 cm Weights Weight 122 kg (~276 lbs.) separable into subassemblies of max. 20 kg ea. (~43 lbs.) 2.1.4 Drive wheel effective diameter for rope grip 2.1.5 Ø 180mm(~7-1/8”) Diamond ropes Diameter Ø 11mm (~7/8”) Length 621 cm max. (~20’4-11/16”) 351 cm min. (~11-1/2’) 2.1.6 Cutting speed with electric motor V= 2.1.7 26m/s Cutting speed with hydraulic motor See chapter page 8 Fig.sl_conn.tif Do not use any other equipment! 3.2 sl9806e SL 2.2.1 Technical Data Particular characteristics of the various drive units 2.3.1 Which extension arm for what diameter? The power output differs from drive unit to drive unit. Therefore: – choose correct sawing motor – choose correct level at the drive unit (see "Selecting drive unit and sawing motor", Chapter 3.2.) 2.3 Attachable electric motor, electric Fig.auslzent.tif Fig. sl_conn2.tif Do not use any different electric motor or control unit! sl9806e Extension arm Ø 750 mm (~2-1/2’) 500 - 700 mm (~1’71/2” – 2’3-1/2”) 1500 mm (~5’) 700 - 2500 mm (~21/2’ – 8’2-1/2”) 2.3.2 The center tube Center tube thickness "D" max. 1000 mm (~3’3-3/8”) 0.6 m (~2’) page 9 Technical Data 2.4 SL Design Fig.aufbau.tif 1) Electric motor or hydraulic motor 2) Drive wheel 3) Crank for rope tension 4) Swivel rack 5) Central reversal pulley, top 6) Forward feed motor electric or hydraulic Extension arm, bottom 7) 8) Central reversal pulley, bottom 9) Deflection pulley, bottom 10) Guiding pulley, bottom 11) Diamond rope 12) Center tube 13) Guiding pulley, top 14) Deflection pulley, top 15) Extension arm, top page 10 sl9806e SL 2.5 Technical Data Function with hydraulic drive > which engages with the gearwheel circumference at the support. Hydraulic drive 2.5.3 Rope drive, hydraulic > When the Main circuit of the drive unit is opened, 2.5.1 Guiding and tightening of rope > the sawing motor (1) will turn and will drive The rope is being guided by ... > the drive wheel (2) and thereby – the drive wheel (2) > will drive the rope. – two central deflection pulleys - top and bottom (5 and 8), – two deflection pulleys top and bottom (9 and 14), The speed of the rope is determined by... 1) ... the oil flow from the drive unit 2) ...flow intake of the sawing motor (controllable) – and by the guiding reels top and bot- tom (10 and 13). 2.5.4 The rope is being tightened by ... > turning the tension spindle (3) clockwise, > by which the swivel rack (4) tilts outward Emergency Stop The system can only be stopped at the drive unit. Observe also the Operating Manual of the drive unit. > and the diamond sawing rope is being tightened across the drive wheel (2) 2.5.2 Circular motion /Forward feed, hydraulic The movable portion of the system turns around the center tube (12), when... > the connected forward feed circuit at the drive unit is being opened, > the hydraulic forward feed motor (6) will turn > and through the transmission gear in front of the feed motor > will drive the cogwheel (on the feed transmission gear) sl9806e page 11 Technical Data 2.6 Funktion electric drive SL > which engages with the gearwheel circumference at the support Electric drive 2.6.3 Rope drive, electric > When the main drive unit is switched on at the electric control, 2.6.1 Guiding and tightening of rope > the electric sawing motor (1) will run The rope is being guided by ... > and drive the drive wheel (2) – the drive wheel (2) > and thereby the rope. – two central deflection pulleys - top and bottom (5 and 8), – two deflection pulleys top and bottom (9 and 14), – and by the guiding reels top and bot- The speed of the rope is determined by... 1) 2) tom (10 and 13). 2.6.4 The rope is being tightened by ... > turning the tension spindle (3) clockwise, > by which the swivel rack (4) tilts outward ...the number of revolutions of the electric drive motor (not controllable) ...the diameter of the drive wheel (not controllable) Emergency Stop The system can only be stopped at the electric control unit. Observe also the Operating Manual of the electric control unit. >and the diamond sawing rope is being tightened across the drive wheel (2) 2.6.2 Circular motion/Forward feed, electric The movable portion of the system turns around the center tube (12), when... > the connected forward feed is switched on at the electric control, > the electric feed motor (6) runs > and through the transmission gear (in front of the feed motor) > drives the cogwheel (at the feed transmission gear) page 12 sl9806e SL 2.7 Technical Data Protection material Fig.schutz.tif 1) 2) 3) 4) 2.7.1 Splash channel long/short, top (2 pcs. ea.) Splash channel long/short, bottom (2 pcs. ea.) Splash shielding, deflection pulleys (4pcs.) Splash shielding, tension reel (1 pc.) Protective provisions Never start sawing before having all protective devices in place sl9806e page 13 Preparation for work 3 Preparation for work 3.1 Procedure SL Always proceed as follows: 1) 2) Select drive unit and sawing motors (hydraulic only) Calculate length of rope 3) Secure construction site 4) Secure parts designated for sawing out Fix system solidly fast 5) 6) 7) Connect drive unit or electric motor including control unit Put on rope 8) Put on safeguard hood 9) Connect water 10) Start sawing 11) Conduct maintenance work page 14 sl9806e SL 3.2 Preparation for work Select drive unit and sawing motor (hydraulic) • Set the mark Ø 180 onto the range SK-SD (1:1) and ... Hydraulic drive • ... depending on output rate of drive unit read out the correct sawing motor. Drive units 3.2.2 Through correct selection of drive unit, power level (in case of multi-level drive units) and Multi-level drive units: Use Level II or higher. When hitting upon reinforcement steel rods one can then switch down. Sawing motor the correct cutting speed will be obtained, hence: – optimum sawing performance – best endurance of rope – few rope ruptures BR-3 DK (I) CR-3 (I) CR-3 (II) (I) BR-4 BR-3 (II) AD-S2 DK (III) AD-S3 (I) DK (II) CR-3 (III) AD-S3 (II) BL-S CR-L 26 l/min 30 l/min 33 l/min 40 l/min 42 l/min 45 l/min 47 l/min 50 l/min 11 ccm 22 m/s 26 m/s 28 m/s 34 m/s - - - - 16 ccm - - - 24 m/s 24 m/s 26 m/s 28 m/s 29 m/s 18 ccm - - - 21 m/s 22 m/s 24 m/s 25 m/s 26 m/s Fig.drehztab.tif 3.2.1 Specifics for the use of the "profi disk" The effective diameter of the drive wheel measures 180mm (~7-5/64”). Therefore: sl9806e Work only with the designated drive units and only on the recommended levels (base: v = 20...30 m/s (~22...33 yards/second)) page 15 Preparation for work 3.3 SL Calculation of rope length The minimum length of the rope results from: – Invariant = 331 cm – two times thickness "D" of building – "A" according to saw-Ø from table (see bottom) Ltotal Ø A 0.5 m 0.0 1.0 m 55 cm 1.5 m 115 cm 2.0 m 140 cm 2.5 m 170 cm = 331 + 2 x D + A Fig. dicke.tif Example: Thickness D = 45 cm Ø = 1.5 m, therefore A = 115 cm Ltotal= 331 + (2 x 45) + 115 = 536 cm 3.3.1 Length of extension arm and center tube Depending on diameter 2 different extension arms are available. See "Which extension arm for what application " and "The center tube " (Chapter 2.3.1. and 2.3.2.) and "Spare parts list". page 16 sl9806e SL 3.4 Preparation for work Secure construction site Secure danger zone and make sure that nobody enters that zone during active work. 3.5 Example: Securing with prop-jacks in three steps (Cut into the ceiling, view from below!) Secure part to be sawn out Secure the parts to be sawed out in their initial position, such that... 1) ... the rope will not be jam 2) ... nobody will be endangered by uncontrollable motion of the parts being sawed out. Depending on situation utilize these auxiliary means or a combination thereof: – Wedges – Connecting straps – Supporting it – Suspending it by crane or from building Secure the parts being sawed out according to their weight (approx. 2.5 to per m3) (~200 lbs. per cu.ft) and position. Fig. sichern.tif sl9806e page 17 Set-up SL 4 Set-up 4.0.1 Set-up for first operation The system is supplied ready for use. The procedures described under ”Set-up” apply also to the first operation run of a new machine. 4.1 Fastening of system 4.1.1 procedure Fig.mont5.tif Fasten center tube assembly (6) with two hammer plugs M12 (5) Fig.mont4.tif • Drill Ø 100 mm for center tube (6) • Drill Ø 15 mm for rope at a distance of the sawing radius (1/2D!) Fig. mont3.tif page 18 • Insert central deflection reel (3) into top of central tube unit (6) • and tie fast with bracket (7) (Central deflection reel at bottom analogous) • Insert upper extension arm (2) into the receptacle and tighten up (lower extension arm analogous) sl9806e SL • Mount top reel pair (1) in accordance with sawing direction (bottom reels analogous) • Mount drive tightening pulley assembly (5) onto the upper extension arm (2) • Put on upper shielding (4) (lower shielding analogous) • Mount rope (see chapter 4.3) Set-up Fig. mont1.tif The pairs of reels (6 and 8) must be mounted anti-symmetrically into the extension arm (2), in order to be able to cut in the cutting direction designated by the arrows (S). (See also chapter 4.1.2. "Change of sawing direction ") sl9806e page 19 Set-up SL Change of sawing direction 4.2 Connecting the drive unit Hydraulic drive Fig. mont6.tif Fig. anschl.tif H: Sawing motor to the main circuit V1: Hydraulic motor for forwardb feed motion to the feed circuit 1 V2: Forward feed 2 remains disconncted W: Connect water ALWAYS first to the drive unit (see also chapter 4.7. "Connecting water for use with hydraulic drive unit ") Fig. mont7.tif Never connect or decouple hoses while the drive unit is running. Set control valves to position "0". The reels (16) can be mounted in two different positions depending on direction of sawing. To observe: – First clean couplings thoroughly. – Connect angular shape hose cou- plings with the sawing motor. page 20 sl9806e SL Set-up – Connect straight hose couplings with 4.3 Connecting the electric module the drive unit. Electric drive – Slide hose coupling onto the counter- part until snapping in with an audible click. – Turn securing ring of the coupling. – Hoses not engaged in operation should be coupled among themselves for couplings’ protection. – Never engage couplings by force. – If hoses appear to require force to con- nect they are likely to be under pressure (see below). 1) 2) Relieve pressure of hose. Repeatedly actuate main or feed valve at drive unit. Connect the supplied pressure relief unit to the hose and screw in. Fig. anschdma.tif 1: Control handle 2: Electric connection 3: Electric connection for the main motor 4: Electric connection for the forward feed motor 5: sl9806e Water page 21 Set-up 4.4 SL Mounting of rope Running direction of rope Correct running direction of the rope is important for satisfactory endurance. A used rope must be run always in the same direction as initially used. In order to avoid eccentric wear of the diamond beads the rope needs to be twisted at the point of connection. A new rope of Ø 11mm needs to be twist by one turn per 1 meter of length. In the course of increasing wear more twisting will become necessary. The following table is valid for a rope of a length of 10 m. The running direction of the rope can be recognized by the following attributes: – Arrow on new rope – Wear of the used rope: thin portion of conical bead points forward Rotational direction of the rope sawing system Twisting of rope Ø of rope total Turns 11 10 10.5 13 10 17 9.5 22 9 28 With threaded connectors additionally 5 turns in order to compensate for the threading. Inserting the rope into the equipment, connecting and tightening Insert the rope into the equipment in the correct running direction, connect it (see “Connecting and repairing of the rope”, chapter 7) and tighten it reasonably with the crank (14). Fig.drehr.tif page 22 sl9806e SL 4.5 • Set-up Mount protection hoods Put on protection hood on top and bottom, and never remove during sawing • Open water cock Pressure: min. 1, max. 10 bar / min. 1x105Pa, max. 10x105Pa Never keep sawing without all the correctly mounted protection hoods! Make sure that the water supply is not interrupted during operation. (see spare parts list) 4.6 Water cooling Why is water needed? – Flushing out sawdust from the cut – Flushing the rope of sawdust – Cooling the rope – Cooling of electric motor, in case of using EM (Water feeder connected directly to the motor) – Cooling of the electric motor and the oil cooler, in case of using a hydraulic drive unit (Water feeder connected to the equipment) 4.7 Connection of water in case of using a hydraulic unit Hydraulic drive 1) 2) 3) Connect water feeder with coupling to the water nipple of the hydraulic unit Connect water hose of the hose package between the drive unit and the nipple of the upper reel pair Direct water spout onto the rope before switching on sl9806e Fig.wasser.tif 4) Water input to the unit (1) 5) Extend water hose of the hose package by the supplied water hose and connect to SL unit (2). Direct water spout onto the rope before switching on 6) page 23 Set-up 4.8 SL Connection of water in case of using electric motor "EM" Electric drive 1) 2) 3) • Connect water feeder with coupling to the water nipple of the electric motor Connect supplied water hose between the electric motor and the nipple of the upper reel pair Position water spout before switching on Open water cock Pressure: min. 1, max. 10 bar / min. 1x105Pa, max. 10x105Pa Fig.waansdma.tif Make sure that the water supply is not interrupted during operation. page 24 sl9806e SL Sawing 5 Sawing 5.1 Before sawing • check if all screws are fastened tightly • control rope tension and if necessary readjust (A) with the crank (3) 5.2 Sawing, hydraulic Hydraulic drive • Switching water on Open water cock at drive unit Switch on drive unit • Set all valves to position "0" • Start drive unit (see Operating Manual of drive unit) • With multi-level drive units, select the proper level (see "Selecting drive unit and sawing motor ”, chapter 3.2.) • Select level Switch on rope drive Set main valve at the drive unit to position "I" The rope will now be moving (C) Fig. vors1.tif Switch on forward feed (B) Increase forward feed pressure up to... ... main pressure: 100...150 bar sl9806e page 25 Sawing SL When hitting upon reinforcement steel structuWhen hitting upon reinforcement steel structures reduce main pressure to 100 bar by reducing forward feed pressure. Stopping the rope • Switch off forward feed • Let the rope run freely for a few seconds • Switch off rope drive 5.3 res the load of the rope will in all cases be adjusted for optimum relation by the automatic feed unit through reducing the forward feed pressure. Optimum forward feed pressure Sawing, electric Electric drive • Switch on water Open water cock at the electric motor Fig. vordruck.tif Switch on electric motor/rope drive • Push button at electric control unit DM-A • Wait for the electric motor to start (centrifugal force coupling) The rope will now be moving. (C) • The forward feed pressure is to be set in such a way as to have the rope enter into the building object under an angle of approx. 45°. 1) With less slanted rope entry the cut will become less accurate 2) With steeper rope entry the cutting performance will be low Switch on forward feed (B) The forward feed speed is load dependent always regulated for the optimum range by the automatic feed control unit. page 26 Stopping the rope • Switch off forward feed • Let the rope run freely for a few seconds • Switch off rope drive sl9806e SL 5.4 • Sawing Trouble shooting Observe also the Operating Manual of the drive unit In case of rope rupture • excessive forward feed pressure • to narrow radii > forward feed too fast and rope tension too low • Reinforcement elements being sawed with a too narrow wrap-around radius > forward feed too fast and rope tension too low • rope connecting joint too long (=to stiff) > use shorter pressed sleeve joint In case of asymmetric rope wear • too high forward feed pressure • rope not properly twisted (see "Rope twisting " chapter 4.4.3.) • In case of insufficient cutting performance Cutting speed too low (see "Selecting drive unit and sawing motor ") If rope slips on drive wheel • Rope tension too low • Drive wheel cover band worn too much • Plastic gets soft because rope is being cooled insufficiently • Rope getting pulled out of joint sleeve Squeezed portion of rope in joint sleeve too short • Diamond beads getting pushed together If the rope does not run despite the electric motor is running Replace centrifugal weights of the electric motor 5.5 After sawing • Switch off drive unit or electric motor • Close water cock • Pull out power plug • Remove protection hoods • Wash off Circular Rope Saw Type SL with water • Dismantle and remove rope • Conduct daily maintenance work (see "Maintenance", chapter 6) Excessive rope wear • too little water • Cutting speed too low • Running direction of rope inverted sl9806e page 27 Maintenance 6 Maintenance 6.1 Maintenance table SL Disconnect power plug before any maintenance work Conduct the following maintenance work within the designated periods in order to warrant: – Safety for the user – Optimum performance – Ready to use at any time interval GDLO\ \HDUO\ activity remarks FKHFNUROOHUOLQLQJIRUZHDU UHSODFHOLQLQJEHIRUHLWLVFRPSOHWHO\ ZRUQRII FOHDQV\VWHP FKHFNGHIOHFWLRQUROOHUVIRUZHDU PDMRUVHUYLFLQJ PD\EHFDUULHGRXWE\ +<'52675(66RUDQDXWKRUL]HG +<'52675(66UHSUHVHQWDWLRQRQO\ Fig. wart_d.vpo page 28 sl9806e SL Repair 7 Repair 7.1 Connection and repair of rope 7.2 Connecting the rope by joint lock Do not join ropes with different degrees of wear: Difference of the two Ø: max. 0.2mm (~8 mil) The rope can be joined or repaired by the following locking devices: – Joint lock – Repair sleeve – Threadlock Needed are: – Pressing tongs, sleeve, knife – Angular grinder/shearing cutter Fig.sk2_glvs.tif additionally for joint lock – Mounting kit for joint lock 1) 2) 3) 4) 5) 6) sl9806e Pressing the lock on Cut rope at both ends at 11 mm distance from the first bead (Attention: take care to make a straight cut). Remove rubber sleeving cleanly by pulling reinforcement spring off with pliers, and shorten free rope ends to max. 8 mm. Slide loose fork head part of the joint lock onto the rope end (blank portion of rope must extend to the bore dead end) Press with TYROLIT-Original pressing tongs. Slide the preassembled lock part onto the other rope end (similar to pt. 3) Press as described under pt. 4 page 29 Repair 1) 2) SL Closing the lock Twist rope according to instruction (see application guide supplied with the rope) Connect the two pressed on lock parts with the bolt supplied with the lock kit, by a few hammer strokes. 1) 2) 1) 2) 7.3 Opening the lock Drive out bolt by a few hammer strokes. The rope can be reconnected using a new replacement bolt which is supplied with the lock kit resp. can be ordered separately. Connecting the rope by repair sleeve 3) 4) 5) Pressing on of lock Cut rope at both ends according to drawing at 12 mm resp. 9 mm distance from bead (Attention: take care to make a straight cut). Never mount the locks directly behind the rope beads as rigid portions will lead to untimely rope rupturing. Remove rubber sleeving with reinforcement spring by pulling off with pliers. Slide the rubber rings supplied with the lock kit onto the blank rope ends (important for maintaining flexibility of the rope within the lock range) Slide joint lock part onto the rope end (blank portion of rope must extend to the bore dead end) and take care that the threaded stud points always to the forward running direction. (pay attention to the direction arrow on the rope) Press lock part with TYROLIT-Original pressing tongs and pressing inlay. The pressed The range available for pressing is separated by a ring groove from the threaded portion on the lock 6) Side the 2. lock part onto the other rope end ( similar to pts.3 + 4) and press as under (Pt. 5). Fig.seilrep.tif page 30 sl9806e SL Repair 7.4 Connecting the rope by threaded lock Pressing on of lock • Procedure similar to pt. 7.3. Closure of lock • Twist rope according to instruction (see application guide supplied with the rope) • The rope needs to twisted by additional 5 turns in order to compensate for the thread turns of the lock. • Screw the two lock parts together –counter clock thread. 1) 2) Opening of lock Open the lock by turning clockwise with the help of a waterpipe pliers. Before repeated closing the lock should be inspected for wear and if need be replaced by a new lock. sl9806e page 31 Transportation, shut-down , storage, disposal SL 8 Transportation, shut-down , storage, disposal 8.1 Transportation 8.3 Disposal The system is a high value technical system. Protect it against damage in transportation: The system consists of the following materials: – Dismantle rope – Steel – Do not deposit any parts onto or side- – Rubber wise to the sawing system The rope sawing system weighs approx. 122 kg (~270 lbs.). Disassemble it for transportation and carry the individual parts (max. 20 kg, ~45 lbs.) with caution, and if possible twosome, to avoid back damage and accidents. 8.2 Shut-down, storage The system consists to some extent of material which may corrode. If out of use for ext periods proceed as follows: – Oil and store in a dry place page 32 – Aluminum – Rubber/nylon fabric – Synthetic grease – Plastics Obtain information on the regulations on disposal in your country. 8.4 #TVKENG Accessories 1TFGT0Q 4XLFNH[FKDQJHNLW$=)=IRUIDVWHUPRXQWLQJDQG H[FKDQJLQJ RIK\GUDXOLFPRWRUV +6$= 5RSHFXWWLQJVKHDUVFRPSOHWHZLWKWKUHDGHGVOHHYHDQG UHSDLUVOHHYH =8+7 sl9806e SL Spare parts list 9 Spare parts list Ordering information For orders of spare parts we need the following information: – Equipment type according to type pla- te (e.g. L Index 000) – Serial number according to type plate (e.g. 12136) – Spare part number according to spare parts list (e.g. 08W7-75648-02) For orders, questions and information please contact the allotted branch office (see below). Unsere Vertretung sl9806e our branch office Fig.typ.tif notre filiale la nostra rappresentanza page 33 Page 34 SL9910 Fig.sl_expl2.tif 99MS-60114-50 3401019 Drive Wheel Comp. SL9910 Page 35 1 2 3 4 5 99MS-60139-06 0000-60114-01 0000-60114-02 0000-60114-03 0000-60114-05 3401943 3400182 3401266 n/a 341267 IdlerPulley Ø 200 mm standard Central tube Cross Pipe pc. Cutting pulley support short Cross clamp 6 1 2 2 8 6 7 8 9 10 0000-60114-06 0000-60114-35 0000-60114-07 0000-60114-08 0000-60114-09 3400936 3400937 3401200 n/a n/a Extension tube Extension tube short Pulley support short Pulley support long Plate 2 2 1 1 2 11 12 13 14 15 0000-60114-38 0000-60114-12 0000-60114-13 0000-60114-14 0000-60114-15 n/a n/a n/a n/a n/a Plate for gear Support Bushing sleeve Threaded pivot block with bushing Spacer 1 1 4 1 1 16 17 18 19 20 0000-60114-16 0000-60114-17 0000-60114-18 0000-60114-22 0000-60114-25 n/a n/a n/a n/a 3401256 21 22 23 24 25 0000-60114-26 0000-60114-28 0000-60059-32 0000-60059-33 0000-60072-26 n/a n/a n/a n/a n/a 26 27 28 29 30 0000-60086-51 0000-60086-52 0000-60086-53 0000-60086-54 0000-60086-68 n/a n/a 3401050 n/a 3401951 Pivot block handle Shaft carriage Worm gear Central tube Spur-toothed wheel 1 1 1 1 1 Support Pan head screw Flange Ring Flange plate 1 3 1 1 1 Snap ring Spacer Driven shaft Flange Lining 2 1 1 1 1 Page 36 SL9910 Fig.sl_expl2.tif 99MS-60114-50 3401019 SL9910 31 32 33 34 35 0000-60114-39 0001-52747-01 0000-60114-31 0000-60114-32 0000-60114-33 n/a n/a n/a n/a n/a 36 37 38 39 40 0000-60114-34 0002-52047-04 0000-60087-31 0000-60087-29 13K1-01924-00 n/a 3400339 41 42 43 44 45 Drive Wheel Comp. Page 37 Pinion Lever Splash Flap Splash Flap Splash drain 1 1 6 1 2 n/a 3400338 Splash drain short Coupling Danfoss Coupling shaft Danfoss flange Star coupling plate 2 1 1 1 1 13V7-03220-20 13V7-03250-50 13P1-09059-05 02S1-03015-50 01S1-08016-00 n/a n/a n/a 3400594 n/a Lamellar plug 20 Lamellar plug 50 Bellow Circlip arbor Hexagonal screw 1 1 1 2 4 46 47 48 49 50 01S1-08045-00 01S1-12040-00 01S1-12025-00 01S1-12030-00 01S1-12055-00 n/a 3402151 n/a n/a n/a Hexagonal screw Hex screw Hex head cap screw Hexagonal screw Hex head cap screw 1 2 3 4 4 51 52 53 54 55 01S1-12070-00 01S1-12100-00 01S1-06025-00 01U2-12028-50 01U2-12037-50 3401165 n/a n/a n/a 3403024 Hex head cap screw Hex head cap screw Hex head cap screw Washer Washer 1 3 4 6 4 56 57 58 59 60 01U6-08035-50 01M1-12000-00 01M3-12000-60 04W2-00007-00 05L1-00040-50 n/a 3402015 3401921 n/a 3401116 Washer Hex nut Stop nut Nut V-Seal 1 3 1 2 Page 38 SL9910 Fig.sl_expl2.tif 99MS-60114-50 3401019 SL9910 61 62 63 64 65 01I1-06020-00 04Z3-03207-00 01I1-06050-00 01M1-06000-00 01I1-06030-00 n/a 3401945 n/a 3402059 3400085 66 67 68 69 70 01I1-10040-00 01I1-08016-00 01I1-06010-00 01I1-06016-00 07S2-07013-13 71 72 73 74 75 Drive Wheel Comp. Allen head screw Angular ball bearing Allen head screw Hex Nut Allen head screw 6 1 6 6 6 n/a 3402017 n/a 3400693 3400683 Allen head screw Allen head screw Allen head screw Allen screw Hose nipple 2 4 1 2 1 12Z2-38639-24 12W1-00525 07S2-07013-00 07S2-17217-38 12Q2-51804-00 n/a n/a 3400359 3400427 3403016 ABA Hose Clip 15-24 Hose no. 525 Water coupling female Plug in nipple 3/8" Loc-Line threaded nipple 2 1 1 1 1 76 77 78 79 80 12Q2-51800-00 12Q2-51806-00 02L1-06012-00 02W1-00807-32 XXKL-00000-02 3401175 3400769 n/a n/a n/a Loc-Line joint sleeve lrg Loc-Line nozzle 6mm 1/2" Grooved pin 6x12 Shaft key 10x8x70 HS-Logo sticker 20 1 2 1 4 81 82 0002-54457-02 02L2-00040-08 3402010 n/a Type plate small Grooved drive stud Page 39 Page 40 SL9910 Fig.200_9907.tif SL9910 Pos Stk 964254 99MS-60139-06 Umlenkrolle Dm 200 Umlenkrolle Dm 200 1 2 3 4 1 2 8 8 977529 964209 971711 971677 0000-60086-68 0000-60139-01 01I1-06025-00 01I1-04008-00 3401951 3401059 3400865 2900761 Lining 200mm 8"Wheel Hub Allen head screw Inbus-Schraube M 4x 5 6 7 8 9 1 1 1 2 2 964218 964210 972000 972149 964355 0000-60139-03 0000-60139-02 02S1-03515-50 04R3-06007-00 05O1-00620-15 3402156 3400856 3400857 3402057 2702791 Front Cover Bushing CIRCLIP Ball Bearing 6007 O-Ring Dm 62x1.5 10 11 12 13 14 8 1 1 1 1 979307 964213 964212 969143 971916 01M1-06000-00 0000-60139-05 0000-60139-04 05D1-45524-00 01S1-12030-00 3402059 3401186 3402157 3401866 n/a Hex Nut Pulley Hub Rear Cover Seal Hex screw M12x30 14 14 1 1 979338 971922 01S1-12055-00 01S1-12070-00 n/a 3401165 6kt-Schraube M12x55 Hex Screw Page 41
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