User manual cutting guide Jr
Contents
1. Antistatic The Guard between the Water control box X Guard the guide and the Operator suitcase is antistatic Make sure this is not damaged Change if damaged D Cylinder Clean for debris Brass Check brass bearings and change if damaged X bearings or worn out The wagon has 6 brass bearings and each Side plate has 1 each 16 Safety Tools Allmet AS Tlf 4756323650 post safetytools no Web www safetytools no Rev 1 3 7 Water control box WATER CONTROL BOX FUJI ANGLE GRINDER Cutting Disk A 0502 652 B 110x 5 mm A 0105 1000 rpm FCDO 10X 52 2400 1 4 MPT SAFETYTOOLS 4 aumer 4 The Water Control Box is used to regulate the flow of air and water There are internal regulators amp filters that help to keep a consistent flow Settings must be adjusted prior to each use On top there are 4 gauges The water control box is integrated in the right side of the robot Water Inlet Water Adjust Air Inlet 8 Air Adjust Training is required prior to using through Safety Tools or the authorized agent in your region The Fuji Angle Grinder A 0105 has special guards that are attached to for both the Cutting 8 Weld Seem Disks When used with the Cutting Disk there are also two special chucks that are used to hold the disk firmly in place This Angle grinder is the same machine we use with our Grinding Disk for Paint The Cutting Disk is 5mm thick and gives a very clean cut It works2. Back view Front view A 0077b 42 x 10 mm CHUCK KEY The Chuck Key is used to tighten the front piece of the Cutting Chuck Insert the two sprockets into the front piece of the Cutting Disk Chuck and turn clockwise to tighten and counterclockwise to loosen Use the Allen Key in unison with force applied in the opposite direction when putting on and taking off o M J o 200 X 30 mm ALLAN KEY 6mm opposite direction when counterclockwise putting on and clockwise when taking off the Cutting Disk Chuck front piece 6mm Allen Key is used to in unison with the Chuck Key force should be applied in the A 0207 19 Safety Tools Allmet AS Tlf 4756323650 post safetytools no Web www safetytools no TOOLS OLLMEL Rev 1 3 Cutting Disk Mounting When attaching and removing the Cutting Disk A 0502 to the A 0105 Ex Air Tool you will need the following accessories 6mm Allen Key Cutting Disk Chuck Back A 0077a Cutting Disk Chuck Front A 0077b Chuck Key A 0206 step 1 Place Cutting Disk Chuck A0077 back view first on to the A 0105 Air Tool sprocket Make sure it is fit into the notched bolt extending out of the tool step 2 After the above step is completed the picture to the left is how your mounting should look There are 2 sprockets that extend out of the front face of the A0077a Chuck At this stage you are ready to put on the Cutting Disk A 0502 Line up
3. Safety Tools Allmet AS Tlf 4756323650 post safetytools no Web www safetytools no SAFETYTOOLS amer 4 Rev 1 3 Picture 8 Picture 9 Connect water and air to the water control box and air to the Operator suitcase For moving of the guide when assembled use the wheels shown in picture 9 For optimal performance use separate air supply to the operator suitcase and the operator suitcase If separate hoses are not possible try using a 1inch hose for supply then split it to the water control box and the operator suitcase Setting up the Cutting guide with possibility for drop Whenever the cutting guide is used where there is possibility of drops larger then 5cm the guide has to be attached with proper fastening to prevent drops Operating the cutting guide Jr When all precautions and instructions in Setting up the Cutting Guide Jr for cutting have been followed the guide is ready for cutting The Cutting guide Jr is operated by STA Solution Operating Suitcase The different instruments levelers in the suitcase operate indicates different functions on the cutting tool Functions of the Operator Suitcase Emergency Stop gt shuts of air to the entire system Except vacuum Cylinder Arm gt This controls the cylinder that controls up and down of the Fuji Grinder It has a lock middle position for more manual control of the grinder Can be used for the final cut Contact SafetyTools for more information Cylin
4. and cause blindness e Use barriers to protect others from wheel fragments and grinding sparks e Daily measure the air tool speed with a tachometer to make sure it is not greater than the RPM marked on the grinding accessory e This Tool and its accessories must not be modified in any way Entanglement Hazards for misuse e Keep away from rotating drive spindle and abrasive Rotation may continue for several seconds after the throttle has been released Do not lay the tool down until rotation has stopped e Do not wear jewelry or loose clothing e Choking can occur if neckwear is not kept away from tool and accessories Scalping can occur if hair is not kept away from tool and accessories When operating remotely controlled cutting equipment always use barring around the tool e The tool has several moving parts Always stay clear the tool when connected to air e The tool might start unannounced Safety Tools Allmet AS Tlf 4756323650 post safetytools no Web www safetytools no Rev 1 3 SAFETYTOOLS amer Mounting Hazards for misuse Always shut off air supply relieve hose of air pressure and disconnect tool from air supply when changing accessories Always shut off water supply relieve hose of water pressure and disconnect tool from water supply when changing accessories Use only recommended sizes and types of abrasives Do not use files or disks that are cracked Correct mounting is necessary to prevent in
5. box Only Trained and Certified people should remove or attach the Weld Seem Disk to the Air Tool Air amp Water Outlets On the opposite side of the Water Control Box there is the Air amp Water outlet This is where the hose s from the T4 Ex Air tool is connected Connect the water before the air Air Outlet Air flows from Water Control Box to Air Tool Water Outlet Water flows form Water Control Box to lubricate Cutting amp Weld Seam Disk Only Trained and Certified people should remove or attach the Weld Seem Disk to the Air Tool There are 4 gauges on top of the Water Control Box Water Inlet 4 Bar minimum Water Adjust 2 2 2 5 Bars Use water adjustments valves on side to set Air Inlet 7 3 Bar Optimal Air Outlet 6 3 Bar Maximum Only Trained and Certified people should operate the Water Control Box 22 Safety Tools Allmet AS Tlf 4756323650 post safetytools no Web www safetytools no SAFETYTOOLS amer Rev 1 3 Water Gauges The Water pressure into the box needs to be e 4Bar minimum e 10 Bar maximum The Water Adjust Gauges need to be adjusted between 2 2 to 2 5 for the Air Tool to operate If the water pressure goes below 2 bars the tool will automatically shut off If the water pressure goes above 3 bars the tool will automatically shut off Air Gauges e Air Inlet 7 3 Bars Optimal e Air Adjust 6 3 Bars Maximum The Oil Refill is also on t
6. fitted with safety START STOP Verify that the air hose has been installed in accordance with current regulations This applies to all connections Inspect the hoses visually to ensure that they do not leak air Test the machine by using the tool for approx 30 seconds to make sure that everything has been correctly installed Before using review Water Control Box information on Page 17 of this manual Do not use the cutting tool if there are any damages to the tool the guide or the operating device Stop the tool and disconnect air and water if in doubt When unattended always disconnect air and water 10 Safety Tools Allmet AS Tlf 4756323650 post safetytools no Web www safetytools no SAFETYTOOLS M amer Rev 1 3 Assembly of Cutting Guide Jr An overview of the cutting guide main parts Guiding rod Side without engine Cutting wagon Cylinder wagon Side with air engine Transport the cutting guide jr to the location for cutting in the transport crate Carefully take all parts and carry them in position for assembly See picture 1 Picture 1 Picture 2 Start by threading the cutting wagon onto the two guiding rods Then thread the chain guard onto the spindle before threading it into the clutch on the cutting wagon picture 2 The spindle has one side with a sprocket This side has to be on the side where the air engine is attached The cutting wagon has to be mounted the correct way See ov
7. Cutting Disk with two sprockets and insert the disk into sprockets 20 Safety Tools Allmet AS Tlf 4756323650 post safetytools no Web www safetytools no TOOLS 4 ZLLMEL Rev 1 3 Step 3 After the Cutting Disk A 0502 is in place screw on Front Piece of the Cutting Chuck A 0077b back view facing the disk see page 11 Screw on clockwise by hand until tight Only Trained and Certified people should remove or attach the Weld Seem Disk to the Air Step 4 After the Front Piece of the Cutting sprocket is hand tightened on you are ready to complete the tightening using the Allen Key and the Chuck Key Step 5 To complete the tightening of the Cutting Disk use the Cutting Chuck Spanner and the 6mm Allen Key Place the Cutting Chuck Spanner into the two holes of the front piece of the Cutting Chuck Insert 6mm Allen Key as shown in the picture to the left and firmly hand turn Allen Key counter clockwise Turn the Cutting Chuck Key clockwise with a firm strong grip 21 Safety Tools Allmet AS Tlf 4756323650 post safetytools no Web www safetytools no TOOLS p LL Rev 1 3 aumer Y Adjustments amp Inlets On one side of the Water Control Box there is Water Inlet Adjustment controls water flow in Water Outlet Adjustment regulates water flow Water Drain Drains excess water o Use before and after set up to drain water Water Inlet Connect water into box Air Inlet Connect water into
8. GUI tio 16 O Malitenahce Pla estada S s eee ae tacita ibid 16 Ta Wiler con ON o E 17 Cute DIEKE oa R O O cid abone 20 Setting the Water control BOX TOT USO dia 24 Sr WINE Sana 25 T Keep this manual in a safe accessible place at all times Keep this instruction manual for future reference Additional safety information may be available from the authorized agent in your country Consult them when necessary Do not remove or allow any labels to become obscure 1 Function document description This document is an instruction for operating of Safety Tools Cutting Guide Jr A 0320 Safety Tools Allmet AS Tlf 4756323650 post safetytools no Web www safetytools no SAFETYTOOLS amer Rev 1 3 u Version control Changes O User 12 04 13 Separate air supply wcb and operator suitcase 18 07 13 Pressure and force down table removed Separate table attached 30 10 13 Some smaller changes for ATEX certification 10 12 13 2 Important safety information A rox these instructions fully before use Failure to do this may result in serious injury The user of this equipment must be competent in its use The user must ensure that the equipment is selected installed and used in accordance with regulations and is checked fully before use The equipment must only be used for its intended purpose and be maintained regularly Safety is a primary consideration when using Safety Tools equipment The tools should be used in the
9. SAFETYTOOLS amer Rev 1 3 EXPLOSIVE ATMOSPHERES ii MEE MES BE RY MAD LA LA Fs 4 d I EA ZE SF LF EP SF S LO MET E M e f 1 i r IEP ROPERS RKO RKP KKK KKK KKK KKK KKK KKK KPO KKK KSPR DOK K KKK KKK RR ROD AK XOOK OOOO O SON EEO OOOO O Ee REBEL B9097 KKK KKK AE ORK RK KKK YS ALIAS TREK RKP PEP POOF ERK RRR KR RK mF ORO KIRK KKK ZAP XX XXX 6666 66 64 SPIRO AX XXX AXA ERRORS A OS RRA EE SK PS a ZONE Safety Tools Allmet AS Tlf 4756323650 post safetytools no Web www safetytools no SAFETYTOOLS M OLUMELE Rev 1 3 User manual Cutting Guide Jr Documentation created by STA Solutions AS for SafetyTools Allmet AS Content 1 Function document GESCLIPTION cceeeeeeceeecccccsccceeeeceseeueeeeeessseeeeececeessusceuueueeeesseeeeeceeeseseeeeeeess o O O O ET 2 WM ON VAIN sale MAO Mao peas tierce O O E A O o O O A EGUIPDMent OVEIVICW sarrianet Be TDperaton manual Pro ce Serapio 10 a E e o E NE UE PO teas teninia decades phetieanniens 10 Assembly OF Cutting Guide risas aii 11 Setting up the Cutting guide Jr for cutting cccoocccnnonoccnnonnnonnnnonanonnnnnanononononononcnnnonanonnnnnncnnnonancnnnos 13 Setting up the Cutting guide with possibility for FrOP ccooccccnnccnnnnncnnnnacinonacononananancnonanononarononanoss 14 Operatine the cutting guide estas ataca oia 14 Aner ushe the Cutie
10. at there is sufficient space for the cutting tool and the task to be carried out Provide for the best access for air hoses Provide for the best access for water hoses Verify that the working pressure is 6 3 bar for the rotating Air engines Verify that the water pressure supply to the control box is above 4 bar Use the correct lifting technique Do not ever use the hose as a lifting handle Adopt a good stance and avoid overreaching Make sure that air hoses are fitted with whip checks Make sure that water hoses are fitted with whip checks The operator must use the correct grinding tool for the task at hand Install the rotating file or disk Do not exert unnecessary force during this work Make sure that the equipment has the required marking in accordance with the ATEX DNV certificate Do not modify the tool without first contacting Safety Tools Allmet Do not use the tool until you are completely familiar with its operation The tool is to be earthed Use an antistatic hose with a steel wire Se DNV certificate for more information Do not use the equipment if it emits unusual sounds or if it vibrates or the speed varies Do not touch a rotating file ore disk during operations as this may lead to injury If you have long hair or wear loose garments be careful so as to avoid your hair or garment being caught in the equipment Make sure hair and garments is not near the rotating parts Make sure that the grinding cutting tool is
11. can create hazards Use accessories or attachments only in accordance with the operating instructions Do not wear loose clothing whilst operating this tool Neckties rings bracelets or other jewellery may get caught in the tool and should be removed or covered Good non slip footwear is recommended Wear protective hair covering to contain long hair Keep a good footing and balance at all times Don t overreach A rotating wheel can catch an article of clothing and cause personal injury Secure work Use clamps if necessary to secure the work piece 25 Safety Tools Allmet AS Tlf 4756323650 post safetytools no Web www safetytools no SAFETYTOOLS M Rey 1 3 OLLME L Warning Only use this tool in well lit and ventilated areas If necessary wear respiratory Protection from dust created from the use of this tool Warning Do not fit any damaged accessories to this tool Only use accessories in good condition free from visible cracks Caution Use the correct tool Don t force tool or attachment to execute a task for which it is not intended 26 Safety Tools Allmet AS Tlf 4756323650 post safetytools no Web www safetytools no
12. correct way with a good understanding of how to use the tools safely The tools together with attachments and accessories should only be used for the purpose for which they are designed Safety devices and accessories supplied should be used appropriately Do not use outside the design intent unless first agreeing upon such use with the manufacturer and or authorized agent Read and fully understand all the instructions before attempting to install use service or maintain the equipment Training is available through Safety Tools Allmet and the authorized agent in your region Training from Safety Tools Allmet and or the Authorized agent in your region is required prior to using Safety Tools Cutting amp Weld Seem Removal tools Training is also required for Cutting guide Jr A WARNING To reduce the risk of injury before using or servicing tool read and understand the following information The features and descriptions of our products are subject to change without prior notice This product is designed for cutting amp removing material using abrasives The abrasives are very hard and solid 9 7 Rockwell scale No other use permitted for professional use only Before servicing of the pneumatic tool the supply of compressed air must be disconnected or shut off Training is required before using Safety Tools Cutting Equipment Safety Tools Allmet offers training at our office in Norway and offsite Training is also available through the Autho
13. der pressure gt you can set 2 different pressures on the regulators The switch allows the operator to quickly switch between two pressures High Low Pressure The two regulators can be adjusted separately to different pressures and therefor controlling the force the cylinder pressure the Fuji angle grinder down depends on material thickness and where in the cutting process you are contact SafetyTools if you have any questions Always regulate the pressure so that the cutting machine is running without stops or reduced speed The Grinder will break if forced 14 Safety Tools Allmet AS Tlf 4756323650 post safetytools no Web www safetytools no SAFETYTOOLS ZLLMEL Rev 1 3 Pressure and force down o The force down varies slightly from product to product Please see own table for min max pressure force on your Cutting guide Every cutting guide has a table for pressure Cylinder wagon cutting wagon gt this controls the air engine that drives the cutting wagon You can go forward stop or backwards Cutting Engine gt this turns the Fuji angle grinder on or off Vacuum gt This is an option on the cutting guide If applicable it turns on off the vacuum attachment device Air inlet gt this is for air inlet All air quick connectors are marked with similar marking on the hose bundle In operation Use the length of the Hose bundle to get the Operator Suitcase 3m away from the Cutting Guide Jr for noise red
14. erview drawing and picture 1 and 3 11 Safety Tools Allmet AS Tlf 4756323650 post safetytools no Web www safetytools no SAFETYTOOLS ZLLMEL 4 Rev 1 3 Always set the clutch in release before threading the spindle Attach both of the side plates with magnets to the guiding rods and the spindle as shown in picture 1 Fasten the guard and adjust the chain in such a way that the chain is not too loose and not touching the guard See picture 4 Picture 3 Picture 4 When the cutting guide is ready mount the SafetyTool Fuji Angle grinder A 0105 onto the cutting wagon Make sure it is attached correctly and is properly fastened Place the Operator suitcase and the water control box in range of the cutting guide and connect all hoses according to markings Make sure all connections are properly connected and that there are no bends on any hoses Make sure there is no possibility of entanglement by any moving parts Make sure that all the grounding cables are attached and that the system is grounded into a clean and paint free surface so that the entire system is grounded Picture 5 12 Safety Tools Allmet AS Tlf 4756323650 post safetytools no Web www safetytools no SAFETYTOOLS 4 amer Rev 1 3 Setting up the Cutting guide Jr for cutting e Make sure all maintenance procedures have been followed e Make sure that the gears on the spindle and the air engine is aligned and that the chain is tight and faste
15. he top of the box Only Trained and Certified people should operate Safety Tools Allmet Water Control Box 23 Safety Tools Allmet AS Tlf 4756323650 post safetytools no Web www safetytools no TOOLS 4 umer Rev 1 3 n Setting the Water control Box for use Only trained and certified people should operate Safety Tools Allmet Water Control Box Make sure Water Drain valve 1s closed o e Turn Water Inlet Adjustment valve ase clockwise until closed V e el Turn Water Outlet Adjustment valve bi clockwise until closed Attach Air amp Water hoses to Inlets Attach air and water hose from Air tool to water outlet and air outlet o the control box Turn Water Outlet amp Water Inlet valves Adjustments approximately 1 16 of a turn counter clockwise open Hold Air Tool Trigger on and check flow of water flowing from the Water Nozzle to the Disk It should be a light spray Adjust water outlet adjustment valve to desired water flow Continue to hold the trigger on the Air Tool and gently adjust the Water Inlet Adjustment valve so that the Water Adjustment Gauge is set between 2 2 2 5 Bars Release Air Tool Trigger and wait for Water Adjust Gauge to drop to Zero WATER ADJUST 24 Safety Tools Allmet AS Tlf 4756323650 post safetytools no Web www safetytools no Rev 1 3 SAFETYTOOLS A3LLMEE 8 Warnings Warning statements describe conditions which may lead to personal injurie
16. icate Safety Tools Ex Grinding Equipment is suitable for use in ambient temperatures Greater than 20 C to 40 C see Special conditions for safe use on Page 7 e Air supply must be dry 8 clean e Water Supply should be clean filter recommended and above 4 bar Safety Tools Allmet AS Tlf 4756323650 post safetytools no Web www safetytools no SAFETYTOOLS ZLLMEL Y Rev 1 3 Types of Steel Tested Safety Tools Allmet performed test on the 6 different materials three different steel qualities and two different titanium qualities below Stainless Steel Grade 316 Steel ST52 Titanium ASTM B265 Titanium Austenitic Stainless Steel 6MO Maintenance To obtain maximum efficiency from the pneumatic tool preserve its features and avoid repeated repairs a routine inspection and repair program are recommended at least every 1000 hours the intervals between the various inspections depending on the amount of exertion on the power tool Safety Tools ATEX certified Air Tools must be properly maintained and tested by competent and trained personnel At any sign of malfunction or unusual behaviour the tool should be taken out of service for examination and repair If repairs are necessary contact the authorized agent in your country It is recommended to dismantle air tools for overhauling and cleaning after 500 hours of operation or once every six months e Before cleaning the tool for use make sure that it has been correctly asse
17. jury Safety Tools Air Tools are specially designed to work only with Safety Tools Cutting Disks Only Use Safety Tools Air Tools and Accessories as they are designed Do not use with other Accessories and or Air Tools Operating Hazards for misuse Operators and maintenance personnel must be physically able to handle the bulk weight and power of the tool Ensure that the work piece is properly supported Maintain a balanced body position and secure footing Avoid contact with rotating spindle and accessory to prevent cutting of hands and other body parts Wear protective equipment listed Do not use if vibration becomes excessive check the accessory for damage or incorrect mounting There is a risk of electrostatic discharge if used on plastic and other non conductive materials Workplace Hazards for misuse Slip Trip Fall is a major cause of serious injury or death Be aware of excess hose left on the walking or work surface High sound levels can cause permanent hearing loss Use hearing protection as recommended by your employer or occupational health and safety regulations Repetitive work motions awkward positions and exposure to vibration can be harmful to hands and arms If numbness tingling pain or whitening of the skin occurs stop using tool and consult a physician Air Supply and Connection Hazards for misuse Air under pressure can cause severe injury Always shut off air supply drain hose of air pressure and discon
18. low when you hear see the machine start going slower The lock position on the cylinder can also be used for the final break trough Always adjust the pressure so that the cutting machine runs smoothly It will break if misused Do not leave the machine unattended while in operation 15 Safety Tools Allmet AS Tlf 4756323650 post safetytools no Web www safetytools no SAFETYTOOLS OLUMELE Rev 1 3 After using the Cutting Guide After using the cutting guide be sure to unplug the air and water inlet Use water air to clean the machine and make sure you don t have cut debris on the machine Don t use any chemicals on the guide Follow maintenance plan 6 Maintenance plan an adon atv Weekly Monty mes eer LT motors sas ew i motor Dn on the motor en _ardteneresmtnststobecmied switches condition of the switches has to be checked Chain Gears Check for damages and debris Check that al the gears or chain are not bent Clean and oil if necessary Guidance Check for damages and debris before use Clean and lubricate when necessary or after 12hours use Axel Check for damages and debris before use Check daily and lubricate if necessary Clean and lubricate after 8 hours use ee m Suitcase Water See own maintenance manual for grinder s control box and Water Control Box and grinder mad damaged Clean for debris oie wacuumsuface tecptear to the vacuum surface Keep it clean
19. mbled With all fasteners tightened e Check the rotation frequency of the tool without an attached disk After each maintenance or service e f you are uncertain about the correct way to service a tool contact the authorized agent in your region e Only trained people should service and maintain Safety Tools equipment See water control box information on page 17 of this manual for maintenance of the water control box See Cutting Guide Jr maintenance plan on page 16 in this manual for maintenance plan on the guide Check the free speed of the tool at regular intervals and after each operation or maintenance task Remove the disk to check the speed The maximum allowed speed shown on the tool must not be exceeded and the vibration level must not be excessive Safety Tools Allmet AS Tlf 4756323650 post safetytools no Web www safetytools no SAFETYTOOLS M umer Y Rev 1 3 E Motor speeds These cold grinding tools are designed for use with the following motors A 0105 Fuji FCD 10X 52 special ee 7 9 5mm 3 8 inch we Noise The operator must wear ear protection when the noise level at his position exceeds 83dB or 85 dB lt is recommended that the operator wears the ear protector even if the noise level is less than 83dB or 85 dB Noise regulations might vary in different regions or companies Check with local authorities Noise levels while grinding with Safety Tools Cutting Guide Jr e See attached noise repor
20. more like a milling tool than a cutting tool The special design of the cutting teeth and the hardness along with the slow rotation speed our air tool allow it to cut through very dense steel Cutting Disks can be re surfaced 3 to 4 times for 1 3 of the disk price 17 Safety Tools Allmet AS Tlf 4756323650 post safetytools no Web www safetytools no SAFETYTOOLS 4 amer 4 Rev 1 3 GUARD FOR CUTTING SYSTEM The Guard for Cutting System attaches to the Fuji Angle Grinder A 0105 with a Phillips head screwdriver In the corner there is a hole where the Water Nozzle Connector A 0079 is attached NOZZLE WITH CONNECTOR Water Nozzle with Connector is the water supply line incorporated into the hose system lt should be screwed into the Guard before it is attached to the water supply hose TE 9 20 M6 0 6 MM 18 Safety Tools Allmet AS Tlf 4756323650 post safetytools no Web www safetytools no SAFETYTOOLS M umer Rev 1 3 SL CUTTING DISK CHUCK Back piece There are two Cutting Disk Chucks The Back Piece should be placed back view towards the Air Tool The two sprockets should face outward towards the Cutting Disk v 8 SA x gt gt 4 y xe f Front view B j Back view N 4 ee ae A 0077a 42 x 10 mm SA pi The Front Piece of the Cutting Disk Chuck is attached after the Cutting Disk The back view should be faced towards the Cutting Disk Use the Chuck Key to tighten
21. n 0 Celsius Water may freeze on temperature close to 0 Celsius Make sure water dos not freeze before use Special Conditions for safe use The air tool must be earthed by a supply air hose The air hose used must also be of anti static type or satisfy the requirements of clause 7 4 4 of EN 13463 1 Maximum air supply pressure is 6 3 Bar The cutting disk WC 502 shall only be used with an air tool with max 1000RPM and can only be used against the following listed materials stainless steel Grade 316 Steel ST52 Titanium ASTM B265 Titanium and Austenitic stainless steel 6MO The air tool must only be supplied from the water and pressurized air controller of type STA water control box Water cannot be used as cooling medium at temperatures below 0 C For temperatures below 0 C an isopropanol ethanol water mixture with 50 water can be used as cooling medium 4 Equipment Overview Cutting Guide Jr 1 off side w magnet and air engine 1 off Side w magnet 2 off Guiding rods 1 off spindle Cutting wagon cylinder wagon Hose bundle Operating suitcase Operator panel inside Cutting Solution Fuji Grinder Water Control Box Cutting disk Safety Tools Allmet AS Tlf 4756323650 post safetytools no Web www safetytools no Rev 1 3 SAFETYTOOLS 4 aLLmer 5 Operation manual Procedure Preparation Make sure that the work station and the surroundings are safe and clear of any oil grease etc Make sure th
22. nect tool from air supply when not in use before changing accessories or when making repairs Never direct air at yourself or anyone else Whipping hoses can cause serious injury Always check for damaged or loose hoses and fittings Whenever universal twist couplings are used lock pins must be installed Do not exceed maximum air pressure of 6 3 bar 90 psig or as stated on tool nameplate Check and maintain air hoses regularly Use only Earthed Anti Static Hoses 2mm Maximum thickness on coatings See DNV information Make sure the air supply is clean and dry The ambient temperature for safe use must be greater than 0 C Safety Tools Allmet AS Tlf 4756323650 post safetytools no Web www safetytools no Rev 1 3 SAFETYTOOLS gitmec Water Supply and Connection Hazards for misuse Water under pressure can cause severe injury Always shut off water supply drain hose of air pressure and disconnect tool from water supply when not in use before changing accessories or when making repairs Never direct water at yourself or anyone else Whipping hoses can cause serious injury Always check for damaged or loose hoses and fittings Whenever universal twist couplings are used lock pins must be installed Do not exceed maximum water pressure of 10 bar from water supply Check and maintain water hoses regularly Make sure the water supply is clean and whiteout chemicals The ambient temperature for safe use must be greater tha
23. ned properly e Check for damages debris and other defects on the guide e Check that the guide is stable on the surface and that there is no danger of collision with any tools hoses or any obstacles e Set up barrens and warning around the cutting area e Follow country area company rules regarding work permits and notification regulations Make sure the cutting guide is aligned with the cutting area and adjust the height by turning the height adjustment screws on both sides of the cutting guide Make sure that the guide is parallel with the surface it is going to cut Also the height adjustment screws can be used to set the max cutting depth by adjusting it as high as the cylinder can push the grinder down The guide can be fastened with magnets vacuum option or by clamping it It can also be used sideways Do not lift without proper fastening with safety The magnets can be adjusted to compensate uneven surface Use the fastening screw on top of the magnet to loosen the magnet and adjust See picture 7 Se ie Picture 6 always make use drop safety Picture 7 Before connecting air and water to the system make sure that the Operator Suitcase has been set in Start position See picture 8 Start position of Operator Suitcase Emergency Stop gt Not engaged Cylinder Arm gt Lock Cylinder pressure gt High or Low Cutting Cylinder wagon gt Stop Cutting Engine gt Off Vacuum gt Off If applicable 13
24. rized Agent in your region See water control box information on page 17 of this Manual A Disposal When disposing of components lubricants etc ensure that the relevant safety procedures are carried out Safety Tools Allmet AS Tlf 4756323650 post safetytools no Web www safetytools no SAFETYTOOLS OLUMELE Rev 1 3 Check hose size and air pressure The air pressure at the tool inlet with the grinder running shall not exceed the maximum operating pressure of 7 bars or lower if other specified The tool is designed for a working pressure of 6 3 bar 90 psig The compressed air must be clean and dry The installation of a filter is recommended For maximum efficiency and performance comply with the specification of the air hose antistatic earthed hose Avoid the risk of whipping hose regularly check hose hose fitting and clamp conditions Air Pressure Always use the correct and clean air hose and fittings and check that they are all in good condition and are properly installed Do not use damaged frayed or deteriorated hose end fittings Replace them when necessary Always store hoses properly A hose failure can cause injury The air hose may come off and whip Use only earthed hosing in ATEX zones See DNV report Air should be supplied at a constant pressure of 6 3 Bar at the tool with the trigger fully depressed In Line lubricators and air filters are not required unless it is known that plant air supply is likely
25. s including fatal injuries if the tool is not used properly and the warnings are not fully followed Caution statements describe conditions which may lead to equipment damage Warning Warning Warning Warning Warning Warning Warning Warning Warning Warning Warning Warning Do not use this tool until you are completely familiar with the safe operation of the tool all accessories and safety devices Improper use can lead to severe injury This Manual defines proper use of this equipment Before using this tool for any other use please consult the manufacturer Please consult your dealer if you do not understand any part of this manual or operating procedure for this tool Always shut off and disconnect the tool from the energy source when not in use or left unattended for any time The air in the tool and supply hose should be discharged prior to disconnecting from the energy source Do not lay the tool down until all rotating parts have come to a complete stop The tool should be earthed via proper connection to a certified air hose All air hose connections should be secured using whip check restraining devices Do not exceed the maximum air pressure Always use safety goggles with this tool Ordinary safety spectacles are not suitable Full face shields may also be used Use gloves at all times when using this tool Gloves should be suitable for the task Adding unsuitable accessories
26. t J Vibration Analysis HAV There is no vibration from the cutting guide to the operator when using SafetyTools Cutting Guide Jr Posture Safety Tools are generally used as a hand held unit It is recommended that it is used whilst standing on a firm surface It may be used in other positions but it is important that the operator is in a secure position and has a firm grip and footing Refer to risk analysis for further guidance Safety Tools Allmet also has Robotic Systems and Automated Tool Guides Contact Safety Tools Allmet or the Authorized Agent in your Region for more information Safety Tools Allmet AS Tlf 4756323650 post safetytools no Web www safetytools no SAFETYTOOLS 4 amer Rev 1 3 Protective Eguipment Always wear necessary protective equipment when using this equipment Safety goggles or face shield gloves and hearing protection are required Ensure all clothing is close fitting to prevent becoming snagged in moving parts Safety Goggles face shield Mandatory Hearing Protection Mandatory Safety Hat Mandatory Respiratory Protection Optional 3 Special Connditions Projectile Hazards for misuse e Always wear impact resistant eye and face protection when involved with or near the operation repair or maintenance of the tool or changing accessories on the tool e Be sure all others in the area are wearing impact resistant eye and face protection e Even small projectiles can injure eyes
27. to be contaminated It is recommended that oil is added to the tool after prolonged use See maintenance information Water Pressure Check hose size and water pressure The water pressure shall not exceed the maximum operating pressure of 2 5 bar The tool is designed for a optimum working pressure of 2 3 bar The water must be clean The installation of a filter is recommended For maximum efficiency and performance comply with the specification of the hose antistatic earthed hose Avoid the risk of whipping hose regularly check hose hose fitting and clamp conditions Always use a clean water hose and fittings and check that they are all in good condition and are properly installed Do not use damaged frayed or deteriorated hose end fittings Replace them when necessary Always store hoses properly A hose failure can cause injury The hose may come off and whip Use only earthed hosing in ATEX zones See DNV report Water should be supplied at a pressure greater than 4 Bar for maximum efficiency 2 Cutting Tempratures Safety Tools Allmet Explosive test were performed using a robotic system lt is not possible using non machanical systems to reach high heat levels when the tools are used under human conditions The average temprature range when using Safety Tools Cutting equiptment is 25 C 45 C It is not possible to exceed 100 C T4 when using Safety Tools Cutting equipment under normal human conditions See DNV ATEX Certif
28. uction Set the cutting wagon in start position and engage the clutch The starting position is where you want your cut to start Set wanted pressure on the regulators Standard startup settings is High 0 24MPa and Low 0 16MPa Start the grinder by turning grinder to on Read water control box setup page 17 for water control box setup When the grinder is working properly set the cylinder to down When the cylinder is going down and the grinding disc is engaging start the Cylinder cutting wagon The system should now work If the system does not work press the Emergency stop and start fault finding When the desired length of cutting is reached switch the cylinder to up and use the clutch on the cutting wagon to pull the wagon back to start position Then switch the cylinder to down and engage the clutch again Repeat this until the desired depth is reached or until the plate is cut trough For setting the machine to cut a predetermined depth use the height adjustment on both side plates to adjust it up and down Adjust the guide so that the cutting disk is just above the surface when the cylinder is all the way down Then screw down both adjustment screws the wanted cutting depth On some materials the final mm can make the cutting disk jam itself and you will hear that the Fuji grinder stats struggling or even stop This is not good for the machine and it will break Use the high low switch and switch it to
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