Operating instructions Spare parts list Circular wire saw system SL

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Operating instructions Spare parts list Circular wire saw system SL | Manualzz
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
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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
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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
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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
.
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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.
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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.
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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
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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
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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)
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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
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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
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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
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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
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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)
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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 ")
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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
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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:
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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
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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
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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
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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
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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
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UHSODFHOLQLQJEHIRUHLWLVFRPSOHWHO\
ZRUQRII
FOHDQV\VWHP
FKHFNGHIOHFWLRQUROOHUVIRUZHDU
PDMRUVHUYLFLQJ
PD\EHFDUULHGRXWE\
+<'52675(66RUDQDXWKRUL]HG
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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
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=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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