Operating Instructions Spare Parts List
Contents
1. 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 5 2 7 5 3 Putting into operation 8 6 Servicing and Maintenance 1 6 1 General cueeoReecd c epe ee ae 1 6 2 Maintenance and servicing table 3 6 3 Warranty 8 6 4 Wearing parts 9 SK SD 007 Overview Operating Instructions Il I SK SD 007 Operating Instructions Introduction SK SD 007 0 1 Introduction 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 Hydros2. CH 8330 Pf ffikon ZH Made in Switzerland Fig 1 2 Name plate SK SD 007 Operating Instructions Product description SK SD 007 1 1 4 1 1 1 4 2 EC Declaration of Conformity Description Wire saw Type designation SK SD Year of construction 1994 We declare under our sole responsibility that this product complies with the following directives and standards Directive applied EC Machinery Directive 98 37 EEC EC EMC Directives 89 336 EC Standards applied EN 12100 1 Safety of machines basic concepts general design princi EN 12100 2 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 982 Safety of machines Safety requirements of safety systems and their compo nents Hydraulics TYROLIT Hydrostress AG Roland K gi Department Manager Product description Operating Instructions 1 2 Technical data 1 2 1 Dimensions 1 2 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 14 SK SD 007 Operating Instructions Product description 1 2 2 Diamond wire Information i Detailed information on the diamond wire and the dia
3. Drill rig Drill rig BC 2 1355 26 85 kg 35 35 kg 11 55 kg 28 00 kg Product description Operating Instructions 1 2 6 Feed motor unit Fig 1 8 Feed motor unit 1 Feed motor with mounting flange and coupling Article no 977584 Article no 974263 2 Feedtransmission 1 8 6 and 1 2 2 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 Drive motor II 11 ccm 30ccm 41 ccm 980680 11 ccm 22 33 ccm 980679 8 ccm 19ccm 27 ccm 976655 8 ccm 11ccm 19 ccm 977235 SK SD 007 Operating Instructions Product description SK SD 007 1 2 8 Cutting speed The cutting speed is determined by the drive unit and the motor unit Wire speed in m s Hydraulic motor unit Drive unit output 19ccm 2 ccm 33ccm 41ccm 30 l min 21 33 l min 24 40 l min 29 20 45 l min 23 19 46 l min 23 19 47 l min 24 19 50 l min 25 21 57 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 terial 20 25 m s for 25
4. e Has read and understood chapter 2 Safety instructions Service engineers Has specialist professional training mechanical electrotechnical Has attended specialist courses at TYROLIT Hydrostress AG Hasread and understood the Safety instructions chapter 2 7 Safety instructions Operating Instructions 2 8 SK SD 007 Operating Instructions Design and function 3 Design and function 3 1 General The wire saw SK SD is assembled from various components to form a complete wire saw system 3 1 1 System components Fig 3 1 System components 1 Drill rig BC 2 2 Diamond wire guard 3 Drive roll unit 4 Diverter roll unit Water lances Feed motor Diamond wire Hydraulic drive unit O1 Information The layout and functions of the saw system are described in the Safety Manual System Description for Wall Saws SK SD 007 3 1 Design and function Operating Instructions 3 1 2 Drill rig BC 2 3 1 2 1 Design Fig 3 2 Drill rig BC 2 Chassis Chain Guide columns Support Support rod Undercarriage option Oo O1 BR Information Information about the components can be found in the Operating Instructions of the BC 2 drill rig 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 co
5. SK SD 007 3 5 Design and function Operating Instructions 3 1 7 Feed motor with gearbox Fig 3 7 Feed motor 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 3 6 SK SD 007 Operating Instructions Assembly disassembly SK SD 007 4 1 Assembly disassembly Assembly disassembly of the saw system Information In order to be able to use the wire saw SK SD correctly see Chapter 1 1 1 2 B 1 2 it must have other system components added in order to form a complete saw system see Chapter 3 3 1 1 B 3 1 General Before proceeding first of all read Chapter 2 Safety instructions B 2 1 in these Operating Instructions Be sure also to take note of all the danger information given here and follow the instructions on how to avoid physical injury and damage to property Safety instructions It is essential to observe the following safety instructions in particular in relation to the assembly disassembly of the wire saw SK SD 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 glo
6. effect individual diamond wire beads or entire connectors may also come loose and fly through the air at great speed A Always work with the protective devices fitted Always observe the safety distances and working areas stated in the Diamond wire saws Safety Manual System Description During sawing operations no persons should remain in the danger area Failure to observe this regulation may lead to serious physical injury possibly even death and to property damage SK SD 007 5 1 Operating Instructions Danger Danger from machine suddenly starting up other person is present in the danger areas If the system is left unattended it must be switched off and secured against being powered up again T Before switching on the system the operator must ensure that no Failure to adhere to this regulation may result in crushing or cut wounds to body parts and damage to property Hazard from falling building structures The building structure must be correctly secured see Operating Instructions 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
7. persons who work on and with the wire saw SK SD have a duty to read and understand the chapters of the Operating Instructions relevant to their particular activities and the Diamond wire saws Safety Manual System De scription This applies in particular to the Safety instructions chapter which is man datory for all persons and activities Observance of the safety instructions No work must be performed on or with the wire saw SK SD before the safe ty instructions contained in the Operating Instructions Chapter 2 have been read and understood The Operating Instructions are mandatory for all work abridged instructions should only be used in the form of check lists The wire saw SK SD has been inspected 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 Instructions and the Diamond wire saws Safety Manual Sys tem Description or shown on the warning signs fitted to the machine Damage caused by defective or neglected maintenance work Independently performed conversions and alterations may affect safety and are not permitted Use for intended application The intended app
8. pressure Depressurise the hoses by means of the pressure relief Never use force to connect couplings Releasing pressure in the hose 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 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 Chapter 4 4 4 1 B 4 11 Disconnect hose connections see Chapter 4 4 4 2 3 8 4 12 Disassemble the wire saw kit Disconnect drill rig fastening Assembly disassembly Operating Instructions 4 4 2 1 Disassemble the diamond wire guard Fig 4 6 Disassemble the diamond wire guard 4 4 2 2 Remove the diamond wire Danger from sharp edges on cutting tool diamond wire IN 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 wire saw SK SD open or closed 4 4 2 8 Detach hose connections Proceed as follows when disconnecting hydraulic and water hoses Rotate locking ring Hold hose straight Slide back coupling sleeves Pull off hose 4 12 SK SD 007 Operating In
9. to be provided for safe assembly or trouble free operation SK SD 007 0 3 Introduction Operating Instructions SK SD 007 Operating Instructions Product description 1 Product description 1 1 Important information on the wire saw SK SD 1 1 1 Description of the main components gh 5 JA 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 SK SD 007 1 1 Product description Operating Instructions 1 1 2 1 Application The wire saw SK SD is designed and built for the following application Cutting concrete including reinforced concrete and natural stone for other materials please contact us Cutting of parting cuts flush cuts and 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 B 1 4 Safety measures Any use other than for the intended purpose see Chapter 1 1 2 1 2 constitutes abuse or misuse Name plate
10. when the dimension between the outside edge of the bandage and the bottom of the groove is greater than 22 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 property 6 5 Servicing and Maintenance Operating Instructions 6 6 6 2 2 Tension the chain Fig 6 3 Tensioning chain 1 Guide carrier fastening screws 2 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 SK SD 007 Operating Instructions Servicing and Maintenance 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 SK SD 007 6 7 Servicing and Maintenance Operating Instructions 6 8 6 3 Warranty TYROLIT Hydrostress AG Guarantees that the system supplied is free from material and manufacturi
11. 30 m s for wires is 35 m s The recommended values are The cutting speed must be selected according to the nature of the ma granite marble old concrete with or without reinforcement abrasive materials fresh concrete asphalt sandstone The maximum permissible cutting speed for TYROLIT diamond Product description Operating Instructions 1 2 9 1 2 10 1 2 11 A Water connection Pressure min 1 bar to max 6 bar Quantity min 4 l min Temperature 256 Connectable drive units 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 Noise exposure noise level Depending on the working environment the wire saw SK SD can cause ex cessive noise during operation Noise level 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 Noise danger When using the wire saw SK SD hearing protection must be worn If this instruction is not followed irreparable hearing damage may result SK SD 007 Operating Instructions Product description 1 2 12 Tool chest Tool chest with contents Part number 975746 Tool chest excluding contents Part number 973801 1 2 12 1 Tool chest cont
12. RO HYDROSTRESS Operating Instructions Spare Parts List Wire saw SK SD Index 007 10994442 en 26 8 13 Operating Instructions Manufacturer s address TYROLIT Hydrostress AG Witzbergstrasse 18 CH 8330 Pf ffikon Switzerland Phone 41 0 44 952 18 18 Fax 41 0 44 952 18 00 TYROLIT Hydrostress AG reserves the right to make technical changes without prior notice Copyright 2005 TYROLIT Hydrostress AG CH 8330 Pf ffikon 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 of TYROLIT Hydrostress AG 10994442 en 26 8 13 Operating Instructions Overview Overview Page 0 Introduction 1 0 1 Congratulations 1 0 2 Validity of these Operating Instructions 2 0 3 Standards 2 0 4 Delimitation of the system 2 0 5 Document structure 3 1 Product description 1 1 1 Important information on the wire saw SK SD 1 1 2 Technical data 4 2 Safety instructions 1 2 1 1 2 2 Safety principles
13. SK SD 007 Operating Instructions Operation SK SD 007 5 2 Troubleshooting Proceed systematically when looking for the causes of a fault When searching for and correcting faults use the troubleshooting table in the Diamond wire saws Safety Manual System Description Information The troubleshooting tables can be found in Chapter 6 of the Wire saws Safety Manual System Description If you are unable to remedy a fault please call our service centre see Manufacturer s address 8 11 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 5 7 Operating Instructions 5 3 Putting into operation The wire saw SK SD is supplied 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 5 8 SK SD 007 Operating Instructions Servicing and Maintenance 6 1 SK SD 007 Servicing and M
14. X X X X Drive motor Check for cleanliness damage X X X X Diamond wire Water cleaning X Check for wear X X X X Major service May only be carried out by TYROLIT Hydrostress AG or an authorised X representative SK SD 007 6 3 Servicing and Maintenance Operating Instructions 6 2 1 Bandaging drive and deflection pulleys 6 2 1 1 Drive pulley bandages 2 A Fig 6 1 Drive pulley bandage A New bandage B Worn bandage When does a roll have to be replaced The roll must be replaced when the dimension between the outside edge of the bandage and the bottom of the groove is greater than 20 mm 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 pulley bandage the drive pulley at the taut side can be switched with the drive pulley at the slack side when the bandage is half worn 6 4 SK SD 007 Operating Instructions Servicing and Maintenance 6 2 1 2 SK SD 007 Deflection pulley bandages 5 A 15 mm Fig 6 2 Deflection pulley bandage A New bandage B Worn bandage When must a bandage be replaced The bandage must be replaced
15. YROLIT Hydrostress AG to designate a person who independently performs the following work Sets up TYROLIT Hydrostress AG machines or systems for tasks ac cording to the intended purpose Performs tasks independently and monitors these Locates malfunctions and initiates or performs troubleshooting Carries out servicing and simple maintenance Monitors the correct functioning of the safety devices Service engineers Service engineer is a term used by TYROLIT Hydrostress AG to designate a person who independently performs the following work Installs TYROLIT Hydrostress AG machines and systems and controls their correct application Makes adjustments to machines and systems for which special access rights are required Performs repairs complex service work and maintenance work SK SD 007 Operating Instructions Safety instructions SK SD 007 2 6 5 2 6 5 1 2 6 5 2 2 6 5 3 Qualification and training Operator Trained building expert in a management position Hasrelevant experience in personnel management and danger assess ment Hasread and understood the Safety instructions chapter Operator user Hastrained as a concrete cutting expert or completed a technical course from the regional professional association and federation or has profes sional experience Hasreceived an introduction basic training to the operation of the wire saw SK SD from a service engineer
16. adhere to this regulation may result in cut wounds to the hands SK SD 007 2 5 Safety instructions Operating Instructions 2 6 2 6 1 2 6 2 2 6 2 1 2 6 2 2 2 6 3 2 6 4 2 6 Responsibility Authorised personnel All work on or with TYROLIT Hydrostress AG machines or systems must be performed by authorised personnel Personnel are considered by TY ROLIT Hydrostress AG to be authorised if they meet the necessary training and know how requirements and they have been assigned a precise func tional role The personnel qualifications for the corresponding work are contained in the introduction under General of the respective chapters Delimitation of authority functional roles The manufacturer TYROLIT Hydrostress AG or a company expressly nominated by TY ROLIT Hydrostress AG is deemed to be the manufacturer of the products supplied by TYROLIT Hydrostress AG Within the context of an integrated quality assurance and safety control system the manufacturer is entitled to request information about the products from the operator Operator 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 Operator user User is the term employed by T
17. aintenance General Before proceeding first of all read Chapter 2 Safety instructions B 2 1 in these Operating Instructions Be sure also to take note of all the danger information given here and follow the instructions on how to avoid physical injury and damage to property Safety instructions It is essential to observe the following safety instructions in particular in relation to the servicing and maintenance of the wire saw SK SD 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 may lead to serious physical injury possibly even death and to property damage 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 adhere to this regulation may result in physical injury and damage to property Servicing and Maintenance Operating Instructions 6 1 2 Personnel qualifications The wire saw SK SD should not be maintained by unauthorised persons Personnel are only authorised where they meet the following requirements Has trained as a concrete cutting expert or completed a tec
18. and from flying parts and at the same time acts as a spray guard Working without the diamond wire guard is prohibited Emergency Stop pushbutton Example LH drive unit remote control Fig 5 2 Emergency stop In danger situations the Emergency Stop pushbutton must be pressed immediately Pressing the Emergency Stop pushbutton immediately halts the system and prevents the system being accidentally switched on again SK SD 007 Operating Instructions Operation 5 1 6 Application 5 1 6 1 The correct cutting direction Fig 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 SK SD 007 5 5 Operating Instructions 5 1 6 2 Finishing the cut Fig 5 4 Finishing the cut A Swivel roll on taut side Z Taut side of diamond wire During the 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 5 6
19. ating Instructions A copy of the Operating Instructions must be available at all times to staff at the place of use of the apparatus SK SD 007 Operating Instructions Safety instructions SK SD 007 2 3 2 3 1 2 3 2 2 3 3 2 3 4 2 3 5 2 3 6 General safety rules Statutory provisions The generally applicable national and local safety and accident prevention provisions and the supplementary operator regulations must be followed and complied with Inspection and maintenance obligation The operator is under an obligation to only use the wire saw SK SD when itis in a perfect and undamaged condition The maintenance intervals list ed in the Operating Instructions must be adhered to without fail Malfunc tions and mechanical damage must be rectified without delay 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 Power connections The wire saw SK SD must be connected and coupled to the drive unit used in accordance with the Operating Instructions Modifications No technical alterations should be made to the apparatus in the form of ad ditions or conversions without the written consent of TYROLIT Hydrostress AG Safety instructions in the individual chapters The chapters of these Operating Instructions contain additional safety in structions These make reference to specific potential dangers residual dang
20. ctive Appendix and with the relevant standards in force at the time of printing Delimitation of the system These Operating Instructions describe the use of the wire saw SK SD SK SD 007 Operating Instructions Introduction 0 5 Document structure The wire saw SK SD documentation is structured as follows Document General system Wire saws Safety Manual System Description Machine Operating Instructions Spare parts list wire saw SK SD Components Instruction leaflet 0 5 1 Wire saws Safety Manual System Description Hydrostress Machines and components have a modular design and can be assembled into various machine systems The Wire saws Safety Manual System Description has been provided to help you operate the wire saw systems safely 0 5 2 Operating Instructions Spare parts list wire saw SK SD 0 5 2 1 Operating Instructions These Operating Instructions describe the characteristics of the wire saw SK SD only Information These Operating Instructions are supplemented by the primary Wire saws Safety Manual System Description documentation and by the documentation accompanying the product 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
21. dual component of it is in any way converted changed or modified 8 Provided that a special written contract was concluded for the system any warranty agreements established therein shall apply Any verbal or implicit warranty agreements are invalid SK SD 007 Operating Instructions Servicing and Maintenance 6 4 Wearing parts 6 4 1 Wearing part regulations Wearing parts are those parts which are subject to operational wear and tear when the machine is used correctly A uniform definition of wear is not possible as this will differ according to the intensity of use Wearing parts must be maintained adjusted and if necessary replaced differently for each system according to the Operating Instructions of the manufacturer Operational wear and tear cannot justify a warranty claim Wear parts SK SD 007 feed and drive elements such as toothed racks toothed wheels pinions spindles spindle nuts spindle bearings wire chains chain wheels and belts seals cables hoses collars connectors couplings and switches 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
22. e drive unit 4 9 Assembly disassembly Operating Instructions The following hose connections must be established Hose connections Fig 4 5 Hoses wire saw SK SD Drive unit hoses Diamond wire drive motor A Main circuit oil return Coupling male connector Main circuit oil flow Coupling female connector Main circuit oil return Coupling female connector Main circuit oil flow Coupling male connector Feed circuit Coupling male connector Feed circuit Coupling female connector Feed motor travelling motion B Feed circuit Coupling female connector Feed circuit Coupling male connector Water C Water inlet Coupling male connector Water outlet Coupling female connector SK SD 007 Operating Instructions Assembly disassembly SK SD 007 4 4 4 4 1 4 4 1 1 4 4 2 Removal wire saw SK SD Disconnect the wire saw SK SD from the system Fundamentals Keep hose couplings clean and never allow them to drop Always switch off the drive unit and relieve the pressure in the hoses before handling the wire saw SK SD Do not uncouple hoses at the drive unit end the pressure can then be reduced via the drive unit Do not leave hoses in the sun Pressure build up through oil expansion Information If hoses cannot be connected or are difficult to connect they are under
23. ent spinal damage and accidents Assembly wire saw SK SD Information Before connecting the wire saw SK SD to the control unit the wire saw SK SD must be set up and aligned with the object to be cut 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 Setup and connect water supply Mounting the diamond wire guard Connect the drive unit Assembly disassembly Operating Instructions 4 3 1 Assemble the wire saw kit SK SD Fig 4 1 Drive and diverter roll unit Proceed as follows Assemble the drive roll unit 1 Assemble the diverter roll unit 2 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 SK SD 007 Operating Instructions Assembly disassembly 4 3 2 Mount the drive motor Fig 4 2 Mount the drive motor Proceed as follows Push the 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
24. ents Quan Description Part Number 1 Fork wrench size across flats 41 973779 1 Fork wrench size across flats 36 973777 1 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 nipple 972788 1 Chain lock 972480 1 Grease gun 975056 1 Spare cartridge 975057 5 Support ring 974984 1 Ear plugs 977224 SK SD 007 1 11 Product description Operating Instructions 1 12 SK SD 007 Operating Instructions Safety instructions SK SD 007 2 1 2 1 1 Safety instructions Information The safety instructions for the wire saw SK SD are supplemented by the safety instructions of the Diamond wire saws Safety Manual System Description No work should be performed on or with the wire saw system until the safety instructions in the wire saw Operating Instructions and the Safety Manual System Description have been read and understood General Target audience This chapter describes the safety instructions that are essential to follow when using the wire saw SK SD All
25. ers The instructions must be followed closely and require that the ac tions described are taken 2 3 Safety instructions Operating Instructions 2 4 Information and symbols In these Operating Instructions information panels are used to draw atten tion to residual dangers and to point out important technical requirements 2 4 1 Hazard symbols in the Operating Instructions Danger Warning of danger where failure to comply could lead to death or serious injury Warning of danger where failure to comply could lead to injury or damage to property Fig 2 1 Danger and warning notices 2 4 2 Information symbol 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 note of this information may mean that the performances shown in the technical data can no longer be guaranteed Fig 2 2 Information notice 2 4 SK SD 007 Operating Instructions Safety instructions 2 5 Generally applicable warnings of residual dangers In the following warnings of residual dangers are 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 Danger from sharp edges on cutting tool diamond wire IN When touching tools at a standstill it is recommended that protec tive gloves are worn Failure to
26. gs adjusting potentiometers and manual control elements fuses and lamps auxiliary and operating resources anchoring elements such as dowels tie bolts and screws floor coverings lamellas membranes spark plugs glow plugs parts of the reversing starter such as starting cord starting handle starting roller starting spring sealing brushes rubber seals splash guards filters of all kinds drive and diverter rolls bandages wire movement guards running and drive wheels water pumps cutting spoil transport rollers drilling parting off and cutting tools 6 9 Servicing and Maintenance Operating Instructions 6 10 SK SD 007
27. hnical 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 6 2 SK SD 007 Operating Instructions Servicing and Maintenance 6 2 Maintenance and servicing table The following maintenance work must be performed according to the prescribed cycles Wear parts that are not subject to particular maintenance intervals should also be checked regularly for wear and adjusted or exchanged as necessary Maintain the system within the indicated intervals in order to ensure Safety for the user Optimum performance Optimum reliability at all times o c 9 o o alee 518 amp 8 SS E wo a D o o Lm 5 Sur s ES ese dis EN Wire saw SK SD Lubricate and retighten accessible X X X screws and nuts Drive rolls and guide rolls Check bandages for wear X see Chapter 6 6 2 1 8 6 4 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 x x x X guide elements Chain Monitor and lubricate X X X Adjustable feet Monitor and lubricate X X X Hoses Check for cleanliness damage X X X X Feed motor Check for cleanliness damage
28. lication is described in Chapter 1 under 1 1 2 8 1 2 2 1 Safety instructions Operating Instructions 2 2 2 2 2 2 1 2 2 2 2 2 2 1 2 2 3 2 2 4 2 2 4 1 2 2 4 2 Observance of the information on workplace safety and danger area Descriptions of the workplace and danger areas are provided in the Dia mond wire saws Safety Manual System Description Safety principles Delimitation of the safety concept The wire saw SK SD has no effect on the safety concept of the connected systems apparatus and installations Safety elements Protection from personal injury is based primarily on a safety concept and design safety Passive safety elements Protection from live electrical parts functional units containing parts which carry hazardous voltages are shock protected by suitable covers 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 B 2 6 Before using the wire saw SK SD again the safety elements must be checked for correct operation Safety measures organisational Product monitoring obligation Operating personnel must notify changes in operational behaviour or safe ty related components to a responsible person or the manufacturer imme diately Location of the Oper
29. may result When handling diamond wire and wire rolls there is a danger of fingers being crushed When grinding in the diamond wire sufficient clearance between the hands and the rolls or the structure must always be ensured The feed motors must not be started if the diamond wire is still being touched Failure to adhere to this regulation may lead to crushing or cut wounds to body parts 5 2 SK SD 007 Operating Instructions Operation 5 1 3 Personnel qualifications Hastrained 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 to operation of the wire saw SK SD from a service engineer Hasread and understood chapter 2 Safety instructions SK SD 007 5 3 Operation Operating Instructions 5 4 5 1 4 5 1 4 1 5 1 5 5 1 5 1 5 1 5 2 Controls Drive unit The wire saw SK SD is operated using a drive unit Information on connection and on the individual operations can be found in the Operating Instructions of the drive unit Example LH drive unit Fig 5 1 Drive unit with remote control 1 Drive unit LH 2 Remote control Safety related operator s controls Diamond wire guard The diamond wire guard is a safety device It provides protection from accidental contact with the cutting tool
30. mond wire joining elements can be found in the diamond wire saw Safety Manual System Description 1 2 3 Wire guide Information i 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 Fig 1 5 Wire guide SK SD 007 Product description Operating Instructions 1 2 4 1 2 4 1 Diamond wire lengths Wire length calculation The minimum length of the wire results from L Total L1 L2 0 5 L1 Circumference of main body 0 8 m width of saw system L2 Length of stored wire at start of cut 0 5 m Example L2 O 22m E 43M L1 0 8m Fig 1 6 Wire length calculation L1 1m 0 8m 1 3m 0 6m 2 2m 0 8m 5 1m L2 2 4 m wire guide variant 1 0 5m 2 9m L Total 8m 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 9mcan be made on the main body without shortening the diamond wire SK SD 007 Operating Instructions Product description SK SD 007 1 2 5 1 2 5 1 1 2 5 2 Weights Weights of attachment parts Fig 1 7 Weights of attachment parts 1 Drive roller unit 2 Diverter roll unit 3 Diamond wire guard
31. n Information The diamond wire can be inserted into the wire saw SK SD open or closed 4 3 4 Diamond wire storage possibilities Information Information about wire guidance and storage can be found in Chapter 1 1 2 3 B 1 5 Tig Information about diamond saw lengths can be found in Chapter 1 1 2 4 B 1 6 SK SD 007 4 7 Assembly disassembly Operating Instructions 4 3 5 4 3 6 Set up and connect water supply Water is used for cooling the cutting tool In order to ensure guaranteed cooling and flushing of the diamond wire the swivel rollers and the entry points of the diamond wire in the cut must be sprayed with water Connecting the water supply Water pressure min 1 bar max 6bar Water temperature max 250 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 lifetime of your diamond saw significantly Information Detailed information about setting up collecting and disposing of water can be found in the Diamond Wire Saw Safety Manual System Description Dry cutting is possible with a suitable diamond wire saw and after consulting TYROLIT Hydrostress AG Mounting the diamond wire guard The diamond wire guard is a safety device that prevents accidental contact with the tool intercepts flying par
32. ng defects For the undertaking of warranty services by TYROLIT Hydrostress AG in international sales under the express exclusion of the warranty regulations of the UN law on sales of 11 April 1980 the following conditions apply 1 Any warranty claims must take place within 12 months from hand over Any undertaking of warranty service does not extend this time limit 2 The system and or any affected part s must be sent for repair or replacement immediately a defect is discovered to TYROLIT Hydrostress AG or a local authorised TYROLIT Hydrostress AG branch office 3 This warranty covers the free of charge repair or free of charge replacement of defective 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 B 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 preserved i e that only original TYROLIT Hydrostress AG consumable material accessories and spare parts have been used with the system 6 Further claims are excluded In particular TYROLIT Hydrostress AG shall not be liable for direct or indirect damages losses or costs associated with the use of the system 7 The warranty expires immediately if the system or only one indivi
33. nverted to the wire saw SK SD 3 2 SK SD 007 Operating Instructions Design and function 3 1 3 Diamond wire guard 3 1 3 1 Design 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 SK SD 007 3 3 Design and function Operating Instructions 3 1 4 Drive roller unit 3 1 4 1 Design Fig 3 4 Drive roller unit 1 Drive motor 2 Drive roll 280mm 3 Diverter roll 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 3 4 SK SD 007 Operating Instructions Design and function 3 1 5 Diverter roll unit 3 1 5 1 Design Fig 3 5 Diverter roll unit Diverter roll 200mm Swivel roll 200mm 1 2 3 Support 4 Water 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 ET ET Fig 3 6 Water lances Function Water lances are used to convey water to the point where the diamond wire enters the cut
34. structions Assembly disassembly 4 4 2 4 Disassemble the wire saw kit Risk of accident through tipping of the BC 2 drill rig IN 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 SK SD 007 4 13 Assembly disassembly Operating Instructions 4 14 SK SD 007 Operating Instructions Operation 5 Operation 5 1 Operation wire saw SK SD Information In order to be able to use the wire saw SK SD correctly see Chapter 1 1 1 2 B 1 2 it must have other system components added in order to form a complete saw system see Chapter 3 3 B 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 5 1 1 General Before proceeding first of all read Chapter 2 Safety instructions B 2 1 in these Operating Instructions Be sure also to take note of all the danger information given here and follow the instructions on how to avoid physical injury and damage to property 5 1 2 Safety instructions It is essential to observe the following safety instructions in particular in relation to the operation of the wire saw SK SD 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
35. tress 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 Pf ffikon Switzerland Phone 41 0 44 952 18 18 Fax 41 0 44 952 18 00 0 1 Introduction Operating Instructions 0 2 0 3 0 4 Validity of these Operating Instructions These Operating instructions are just one part of the documentation ac companying the wire saw SK SD These Operating Instructions are supple mented by the Wire saws Safety Manual System Description see document structure 0 5 B 0 3 This manual is only valid for the following system Wire saw SK SD Standards This Operating Manual has been prepared in accordance with CE Machin ery Dire
36. ts 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 SK SD 007 Operating Instructions Assembly disassembly SK SD 007 4 3 7 4 3 7 1 4 3 7 2 4 3 7 3 Wire saw SK SD Connect to the drive unit Fundamentals Clean the couplings regularly Connect together both ends of any hoses which are not used so that the couplings are protected Always switch off the drive unit and relieve the pressure in the hoses before handling the wire saw SK SD Information If hoses cannot be connected or are difficult to connect they are under pressure Depressurise the hoses by means of the pressure relief device Never use force to connect couplings Releasing pressure in the hose 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 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 Connect the hose couplings with angle pieces to the wire saw SK SD Connect the straight hose couplings to th
37. units with different power levels Information about the motor units can be found in Chapter 1 1 2 7 B 1 8 SK SD 007 4 5 Assembly disassembly Operating Instructions 4 3 3 Wire saw SK SD Set up The following points must be taken into consideration during the alignment and set up of the wire saw SK SD Danger and working areas for wire saw work see safety manual 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 Diamond wire direction of travel Fig 4 3 Direction of travel 4 6 SK SD 007 Operating Instructions Assembly disassembly 4 3 4 Inserting storage of diamond wire Danger from sharp edges on cutting tool diamond wire IN 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 4 3 4 1 Preparation of diamond wire 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 Descriptio
38. ves and safety shoes It is essential that the work instructions and procedures described in these Operating Instructions are followed Failure to observe this regulation may lead to serious physical injury possibly even death and to property damage Assembly disassembly Operating Instructions 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 as well as damage to property 4 1 3 Personnel qualifications Hastrained 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 to operation of the wire saw SK SD from a service engineer Hasread and understood chapter 2 Safety instructions 4 2 SK SD 007 Operating Instructions Assembly disassembly SK SD 007 4 2 4 3 Transport and place of installation The wire saw SK SD is a high tech apparatus The wire saw SK SD must be transported in such a way that it is not damaged in transit Where suitable means of transport are available these must be used Do not place any items on the Wire saw SK SD during transport Information The wire saw SK SD should be carried carefully by two people if possible to prev
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