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Operating Instructions

Introduction

SK-SD / 007

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Introduction

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Congratulations!

You have decided to buy an advanced, tried and tested Hydrostress sys-
tem and have thus acquired a highly sophisticated and reliable state-of-the-
art unit.

Thanks to our efforts in the quality assurance area, your Hydrostress sys-
tem is another top-of-the-range Swiss product:

• High performance

• Reliable operation

• High portability

• Easy handling

• Low maintenance costs

Only using original Hydrostress spare parts provides quality and inter-
changeability.

In the case of neglected or inappropriate maintenance, we will be unable
to accept the warranty commitment as specified in our terms of delivery.

All repair work must be carried out by trained personnel only.

Should you need more details concerning your Hydrostress system in or-
der to keep it in perfect condition, please contact our after-sales service for
further information.

We hope that you will not experience any problems while working with your
Hydrostress system.

TYROLIT Hydrostress AG

Management

Copyright © Hydrostress, October 2006

TYROLIT Hydrostress AG
Witzbergstrasse 18
CH-8330 Pfäffikon
Switzerland
Phone +41 (0) 44 / 952 18 18
Fax +41 (0) 44 / 952 18 00

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Содержание SK-SD

Страница 1: ...Operating Instructions Spare Parts List 10994442 en 26 8 13 Wire saw SK SD Index 007 ...

Страница 2: ...ht to make technical changes without prior notice Copyright 2005 TYROLIT Hydrostress AG CH 8330 Pfäffikon ZH All rights reserved in particular the copying and translation rights The reprinting of these Operating Instructions including extracts is prohibited No parts may be reproduced or processed copied or distributed using electronic systems in any form whatsoever without the written permission o...

Страница 3: ...rinciples 2 2 3 General safety rules 3 2 4 Information and symbols 4 2 5 Generally applicable warnings of residual dangers 5 2 6 Responsibility 6 3 Design and function 1 3 1 General 1 4 Assembly disassembly 1 4 1 Assembly disassembly of the saw system 1 4 2 Transport and place of installation 3 4 3 Assembly wire saw SK SD 3 4 4 Removal wire saw SK SD 11 5 Operation 1 5 1 Operation wire saw SK SD 1...

Страница 4: ...Overview Operating Instructions II II SK SD 007 ...

Страница 5: ...rovides quality and inter changeability In the case of neglected or inappropriate maintenance we will be unable to accept the warranty commitment as specified in our terms of delivery All repair work must be carried out by trained personnel only Should you need more details concerning your Hydrostress system in or der to keep it in perfect condition please contact our after sales service for furth...

Страница 6: ...upple mented by the Wire saws Safety Manual System Description see document structure 0 5 0 3 This manual is only valid for the following system Wire saw SK SD 0 3 Standards This Operating Manual has been prepared in accordance with CE Machin ery Directive Appendix I and with the relevant standards in force at the time of printing 0 4 Delimitation of the system These Operating Instructions describ...

Страница 7: ...uctions describe the characteristics of the wire saw SK SD only 0 5 2 2 Spare Parts List The spare parts list is a standard part of the Operating Instructions 0 5 3 Instruction leaflet Instruction leaflets are used for system components that do not have their own Operating Instructions but still require information to be provided for safe assembly or trouble free operation Document General system ...

Страница 8: ...Introduction Operating Instructions 0 4 SK SD 007 ...

Страница 9: ...cription of the main components Fig 1 1 Main components 1 Drill rig BC 2 6 Water supply 2 Drive roll unit 7 Drive motor unit 3 Diverter roll unit 8 Feed motor unit 4 Drive roll 1 9 Diamond wire guard 5 Drive roll 2 Information The wire saw SK SD consists of drill rig BC 2 No 974266 and the wire saw kit SK SD No 977084 1 2 5 4 6 7 3 8 9 ...

Страница 10: ...nd angle cuts in ceilings floors or walls The wire saw SK SD should only be used and operated with the author ised anchoring systems Only original TYROLIT cutting tools diamond wire connectors and ac cessories should be used The applicable mandatory limitations on use and parameters are contained in Chapter 1 Technical Data 1 2 1 4 1 1 2 1 Safety measures Any use other than for the intended purpos...

Страница 11: ... 1 4 2 Standards applied TYROLIT Hydrostress AG Roland Kägi Department Manager Description Wire saw Type designation SK SD Year of construction 1994 EN 12100 1 EN 12100 2 Safety of machines basic concepts general design princi ples EN 294 Safety of machinery Safety distances to prevent upper limbs reaching danger areas EN 349 Safety of machinery Safety distances to avoid crushing of body parts EN ...

Страница 12: ...1 1 Main dimensions Fig 1 3 Main dimensions 1 2 1 2 Dowel dimension The dowel dimension for anchoring the drill rig is 42 cm from the cutting line to the middle of the dowel space Fig 1 4 Dowel dimension A Cutting line B Middle line of dowel space Ø20cm 90cm 134cm Ø28cm 78cm 80cm 28cm 5cm 42cm B A ...

Страница 13: ...on on the diamond wire and the diamond wire joining elements can be found in the diamond wire saw Safety Manual System Description Information Depending on the wire guide the length of the stored diamond wire var ies between 1 8 m and 4 0 m Also 1 5 m to 6 5 metres of wire is stored due to the stroke during the cut depending on the wire guide ...

Страница 14: ...em L2 Length of stored wire at start of cut 0 5 m Example Fig 1 6 Wire length calculation L1 1m 0 8m 1 3m 0 6m 2 2m 0 8m 5 1 m L2 2 4 m wire guide variant 1 0 5m 2 9 m L Total 8 m Information In order to be able to reap the benefits of the wire saw SK SD we rec ommend always using 1 5 m of diamond wire This means that cuts of 0 to 9 m can be made on the main body without shortening the diamond wir...

Страница 15: ...n SK SD 007 1 7 1 2 5 Weights 1 2 5 1 Weights of attachment parts Fig 1 7 Weights of attachment parts 1 2 5 2 Drill rig 1 Drive roller unit 26 85 kg 2 Diverter roll unit 35 35 kg 3 Diamond wire guard 11 55 kg Drill rig BC 2 1355 28 00 kg 1 2 3 ...

Страница 16: ... 2 2 Article no 974263 1 2 7 Drive motor unit Fig 1 9 Drive motor unit 1 Drive motor I 2 Drive motor II Information Four motor units are available for the wire saw SK SD with different ca pacities 19ccm 27ccm 33ccm 41ccm Drive motor unit Capacity Article no Drive motor I Drive motor II 11 ccm 30ccm 41 ccm 980680 11 ccm 22ccm 33 ccm 980679 8 ccm 19ccm 27 ccm 976655 8 ccm 11ccm 19 ccm 977235 1 2 1 2...

Страница 17: ...9 46 l min 23 19 47 l min 24 19 50 l min 25 21 57 l min 29 24 19 60 l min 31 25 20 61 l min 25 21 70 l min 29 24 76 l min 31 26 80 l min 33 27 90 l min 31 Information The cutting speed must be selected according to the nature of the ma terial The recommended values are 20 25 m s for granite marble old concrete with or without reinforcement 25 30 m s for abrasive materials fresh concrete asphalt sa...

Страница 18: ...l 75dB Sound pressure 85dB The noise can cause permanent harm to the hearing of operating person nel and of other people nearby within a short time Ear protectors must therefore always be worn while working Information The wire saw SK SD must only be operated with TYROLIT Hydrostress AG drive units Obtain advice from TYROLIT Hydrostress AG when selecting the drive unit Danger Noise danger When usi...

Страница 19: ... Ring fork wrench size across flats 24 973786 1 Ring fork wrench size across flats 19 973784 1 Allen key size across flats 4 973790 1 Allen key size across flats 5 973791 1 Allen key size across flats 6 973792 1 Allen key size across flats 8 973793 1 Screwdriver size 5 973803 10 Drive in dowel 971622 1 Dowel iron 977153 1 1250g steel hammer 973770 1 Tension spindle fixing point 977619 2 Hose nippl...

Страница 20: ...Product description Operating Instructions 1 12 SK SD 007 ...

Страница 21: ...ted before being shipped and is de livered in perfect condition TYROLIT Hydrostress AG does not accept any liability for damage which is caused by failure to observe the instructions and information provided in the Operating Instructions This applies in par ticular to Damage caused by improper use and operator error Damage caused by failure to observe safety related information in the Operating In...

Страница 22: ... parts which carry hazardous voltages are shock protected by suitable covers 2 2 3 Removal of protective devices Protective devices may only be removed if the unit has been switched off disconnected from the mains and is at a standstill Safety components in particular may only be removed and refitted by authorised personnel see Chapter 2 2 6 1 2 6 Before using the wire saw SK SD again the safety e...

Страница 23: ...tified without delay 2 3 3 Spare parts Only original spare parts should be used Otherwise damage may be caused to the wire saw SK SD or to other property and persons 2 3 4 Power connections The wire saw SK SD must be connected and coupled to the drive unit used in accordance with the Operating Instructions 2 3 5 Modifications No technical alterations should be made to the apparatus in the form of ...

Страница 24: ...ning notices 2 4 2 Information symbol Fig 2 2 Information notice Danger Warning of danger where failure to comply could lead to death or serious injury Warning Warning of danger where failure to comply could lead to injury or damage to property Information Text displayed in this way is practical information and is aimed at achiev ing optimum use of the installation or apparatus Failure to take not...

Страница 25: ...e shown that are generally applicable to all work with and on the wire saw SK SD and during all phas es of the life of the wire saw SK SD Warning Danger from sharp edges on cutting tool diamond wire When touching tools at a standstill it is recommended that protec tive gloves are worn Failure to adhere to this regulation may result in cut wounds to the hands ...

Страница 26: ...erator The operator named by TYROLIT Hydrostress AG is the primary legal en tity responsible for the designated correct use of the product and for the training and assignment of the authorised personnel The operator sets out the mandatory skills and level of training of the authorised personnel for his company 2 6 3 Operator user User is the term employed by TYROLIT Hydrostress AG to designate a p...

Страница 27: ... as a concrete cutting expert or completed a technical course from the regional professional association and federation or has profes sional experience Has received an introduction basic training to the operation of the wire saw SK SD from a service engineer Has read and understood chapter 2 Safety instructions 2 6 5 3 Service engineers Has specialist professional training mechanical electrotechni...

Страница 28: ...Safety instructions Operating Instructions 2 8 SK SD 007 ...

Страница 29: ... complete wire saw system 3 1 1 System components Fig 3 1 System components 1 Drill rig BC 2 5 Water lances 2 Diamond wire guard 6 Feed motor 3 Drive roll unit 7 Diamond wire 4 Diverter roll unit 8 Hydraulic drive unit Information The layout and functions of the saw system are described in the Safety Manual System Description for Wall Saws 1 2 3 4 5 7 8 6 ...

Страница 30: ...rt rod 6 Undercarriage option 3 1 2 2 Function Holes for diamond wire saw work can be drilled with the BC 2 drill rig supplemented by the drill motor and drill bit By means of the wire saw kit the BC 2 drill rig is converted to the wire saw SK SD Information Information about the components can be found in the Operating Instructions of the BC 2 drill rig 1 6 3 4 5 2 ...

Страница 31: ...ign Fig 3 3 Diamond wire guard 1 Metal guard 2 Guard mesh 3 1 3 2 Function The diamond wire guard is a safety device It prevents contact with the diamond wire when it is motion intercepts flying parts and thus reduces the risk of injury At the same time the wire guard acts as a spray guard 2 1 ...

Страница 32: ...Design Fig 3 4 Drive roller unit 1 Drive motor 2 Drive roll Ø 280mm 3 Diverter roll Ø 200mm 4 Support 3 1 4 2 Function The diamond wire is driven using two hydraulic motors via the two drive rolls The twin drive unit also serves as a tensioning element in the diamond wire storage 1 2 3 4 2 ...

Страница 33: ...ter connections and water line 3 1 5 2 Function The diverter roll unit serves the diamond wire guidance and the diamond wire storage The water connection and the water distribution of the wire saw SK SD are located on the diverter roll unit 3 1 6 Water lances Fig 3 6 Water lances Function Water lances are used to convey water to the point where the diamond wire enters the cut 1 3 4 2 ...

Страница 34: ...tor 1 Feed motor 2 Drive pinion 3 Link chain 4 Diverter pinion Function With the aid of the feed motor the drive unit of the wire saw SK SD can be driven up and down via a link chain The feed motor is connected to the drive unit The feed direction and the feed speed can be set on the drive unit 1 2 3 4 ...

Страница 35: ...n to the assembly disassembly of the wire saw SK SD Information In order to be able to use the wire saw SK SD correctly see Chapter 1 1 1 2 1 2 it must have other system components added in order to form a complete saw system see Chapter 3 3 1 1 3 1 Danger Danger of falling heavy parts When performing the types of work described in this chapter it is absolutely essential to wear the following pers...

Страница 36: ...professional experience Has received an introduction basic training to operation of the wire saw SK SD from a service engineer Has read and understood chapter 2 Safety instructions Warning Danger from uncontrolled movements of the wire saw SK SD Never connect or disconnect hoses when the wire saw SK SD is running Failure to observe this regulation may result in cut wounds or injury to body parts a...

Страница 37: ...t 4 3 Assembly wire saw SK SD Always proceed as follows Secure the BC 2 drill rig to the floor surface Assemble the wire saw kit SK SD Align the wire saw SK SD on the object to be cut Position diamond wire Set up and connect water supply Mounting the diamond wire guard Connect the drive unit Information The wire saw SK SD should be carried carefully by two people if possible to prevent spinal dama...

Страница 38: ...lows Assemble the drive roll unit 1 Assemble the diverter roll unit 2 Warning Risk of accident through tipping of the BC 2 drill rig Secure the drill rig before mounting the drive roll unit and the diverter roll unit so that the drill rig cannot tip over Failure to adhere to this regulation may result in physical injury and damage to property 1 2 ...

Страница 39: ...he drive shafts of the drive motors onto the toothed profile couplings of the drive rolls Tighten the drive motors with the Allen screws width across flats 6 Information For the Wire saw SK SD the TYROLIT Hydrostress AG has complete motor units with different power levels Information about the motor units can be found in Chapter 1 1 2 7 1 8 ...

Страница 40: ...al system description for diamond wire saws Diamond saw guidance and securing see safety manual system description for diamond wire saws Taut and slack side of diamond wire see safety manual system description for diamond wire saws Cutting force see safety manual system description for diamond wire saws Water supply and water set up see safety manual system description for diamond wire saws Diamon...

Страница 41: ...ctive gloves are worn Failure to adhere to this regulation may result in cut wounds to the hands Information Information on the design and for the correct handling of the diamond wire can be found in the Diamond wire saws Safety Manual System Description Information The diamond wire can be inserted into the wire saw SK SD open or closed Information Information about wire guidance and storage can b...

Страница 42: ...s accidental contact with the tool intercepts flying parts and at the same time acts as a spray guard When working with the wire saw SK SD the diamond wire guard must always be fitted Fig 4 4 Mounting the diamond wire guard Information When working with diamond wire saw systems ensure that the water feed is not interrupted or shut off Correct flushing with water will allow you to extend the lifeti...

Страница 43: ...es that are not coupled Position pressure relief device on hose on the coupling and screw in 4 3 7 3 Hose connections Proceed as follows Visual inspection Check Oil leaks from hoses and couplings Couplings for damage and contamination Hoses for damage Push the hose coupling on to its counterpart until you hear it click Twist the locking ring of the coupling Information If hoses cannot be connected...

Страница 44: ...g male connector Main circuit oil flow Coupling female connector Main circuit oil return Coupling female connector Main circuit oil flow Coupling male connector Feed motor travelling motion B Feed circuit Coupling male connector Feed circuit Coupling female connector Feed circuit Coupling female connector Feed circuit Coupling male connector Water C Water inlet Coupling male connector Water outlet...

Страница 45: ...ose 1 Hoses that are coupled to the drive unit see drive unit Operating Instructions 2 Hoses that are not coupled Position pressure relief device on hose on the coupling and screw in 4 4 2 Dismantling the wire saw SK SD Always proceed as follows Disassemble the diamond wire guard Move drive roll unit to start position Remove the diamond wire Disconnect the wire saw SK SD from the system see Chapte...

Страница 46: ...hen disconnecting hydraulic and water hoses Rotate locking ring Hold hose straight Slide back coupling sleeves Pull off hose Warning Danger from sharp edges on cutting tool diamond wire When touching tools at a standstill it is recommended that protective gloves are worn Failure to adhere to this regulation may result in cut wounds to the hands Information The diamond wire can be pulled out of the...

Страница 47: ... 4 4 2 4 Disassemble the wire saw kit Warning Risk of accident through tipping of the BC 2 drill rig Loosen the drill rig fixing only after disassembling the wire saw kit Failure to adhere to this regulation may result in physical injury and damage to property ...

Страница 48: ...Assembly disassembly Operating Instructions 4 14 SK SD 007 ...

Страница 49: ...in order to form a complete saw system see Chapter 3 3 3 1 In order for you to be able to safely operate the wire saw SK SD in the saw system you must first read the Safety Manual System Description for diamond wire saws Danger Danger from diamond wire breaks If the diamond wire breaks the whiplash effect can lead to throwing of the free wire length When there is a whiplash effect individual diamo...

Страница 50: ...tructions in the Diamond wire saws Safety Manual System Description Failure to observe this regulation may lead to serious physical injury possibly even death and to property damage Danger Noise danger When using diamond wire saw systems hearing protection must be worn If this instruction is not followed irreparable hearing damage may result Warning When handling diamond wire and wire rolls there ...

Страница 51: ...ncrete cutting expert or completed a technical course from the regional professional association and federation or has professional experience Has received an introduction basic training to operation of the wire saw SK SD from a service engineer Has read and understood chapter 2 Safety instructions ...

Страница 52: ...r s controls 5 1 5 1 Diamond wire guard The diamond wire guard is a safety device It provides protection from accidental contact with the cutting tool and from flying parts and at the same time acts as a spray guard Working without the diamond wire guard is prohibited 5 1 5 2 Emergency Stop pushbutton Example LH drive unit remote control Fig 5 2 Emergency stop In danger situations the Emergency St...

Страница 53: ... 5 3 Cutting direction Z Taut side S Slack side Information The saw cut should be carried out with the taut side Z of the diamond wire since this provides the best cutting conditions Therefore only cut with the slack side S of the diamond wire if the Wire saw SK SD cannot be positioned in any other way Z S ...

Страница 54: ...he finishing cut the swivel roll A must be swivelled inwards at the tensioned side Z so that the diamond wire can be caught by the swivel rolls at the end of the cut Information Towards the end of a cut a reduced feed force should be used This measure makes it possible for the swivel rolls to catch the diamond wire perfectly upon the exit of the diamond wire Z A ...

Страница 55: ...ll our service centre see Manufacturer s address II on the back of the title page To guarantee a rapid and professional solution to the problem it is important that you have prepared as follows before calling Try to describe the fault as accurately as possible Note the type and index of your system components see name plate Have the Operating Instructions close to hand Fig 5 5 Name plate Informati...

Страница 56: ...ready for use That which is described under Operation in the Diamond wire saws Safety Manual System Description also applies to the putting into operation of the wire saw SK SD Information Information on operation of wire saws can be found in the Diamond wire saws Safety Manual System Description Chapter 6 ...

Страница 57: ...e of the wire saw SK SD Danger Danger of falling heavy parts When performing the types of work described in this chapter it is absolutely essential to wear the following personal protective equipment helmet goggles protective gloves and safety shoes It is essential that the work instructions and procedures described in these Operating Instructions are followed Failure to observe this regulation ma...

Страница 58: ...only authorised where they meet the following requirements Has trained as a concrete cutting expert or completed a technical course from the regional professional association and federation or has professional experience Has received an introduction basic training about operating the wire saw SK SD from a service engineer Has read and understood chapter 2 Safety instructions ...

Страница 59: ...y annually in the event of malfunctions in the event of damage Wire saw SK SD Lubricate and retighten accessible screws and nuts X X X Drive rolls and guide rolls Check bandages for wear see Chapter 6 6 2 1 6 4 X X X Check bearings X X X When there is risk of frost Blow out water lines X X X Guide support Check wear and setting of the guide elements X X X X Chain Monitor and lubricate X X X Adjust...

Страница 60: ... greater than 20 mm Warning Risk of accident from worn bandages In the case of excessive wear the correct locking of the bandage in the rim can no longer be guaranteed The bandage can detach and be thrown off Replace the drive pulley in good time Failure to adhere to this regulation may result in physical injury and damage to property Information In order to increase the service life of the drive ...

Страница 61: ...hen the dimension between the outside edge of the bandage and the bottom of the groove is greater than 22 Warning Danger from worn bandages In the case of excessive wear the correct clamping of the bandage in the rim can no longer be guaranteed The bandage can detach and be thrown off Replace the bandages in good time Failure to adhere to this regulation may result in physical injury and damage to...

Страница 62: ...Guide carrier 3 Support rod fastening screws Proceed as follows Undo the 4 screws 1 of the upper guide carrier Undo the 4 screws 2 of the two support rods Push the guide carrier 3 upwards until the chain is taut Information The chain is correctly tensioned if the chain links just about touch in the middle if they are pushed together by hand 1 3 2 ...

Страница 63: ...ions Servicing and Maintenance SK SD 007 6 7 6 2 3 Adjusting the support clamp Fig 6 4 Adjusting the support clamp Information The clamp and the guide characteristics of the support can be adjusted using the 8 screws A A ...

Страница 64: ...fective parts No undertaking of warranty over and above this exists 4 Parts that are normally subject to wear and tear are not covered by this warranty For wearing parts regulations see Chapter 6 6 4 6 9 5 The warranty service is only undertaken provided that the system has been correctly used handled serviced and cleaned in accordance with the Operating Instructions and the technical integrity is...

Страница 65: ...witches for pneumatics hydraulics water electricity and fuel guide elements such as guide beads guide bushes guide rails rollers bearings and anti slip supports clamps of quick release system flushing head seals friction and anti friction bearings that do not operate in an oil bath shaft sealing rings and seals friction and overload couplings brake device carbon brushes collectors easy release rin...

Страница 66: ...Servicing and Maintenance Operating Instructions 6 10 SK SD 007 ...

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