Wall saw system FZ Index 003 Operating instructions Spare parts list
FZ 0.1 Introduction Dear customer 0.2 Validity of this manual This manual is only valid for the following system: You have decided to buy a HYDROSTRESS system. You acquired a highly sophisticated an reliable sta- Wall saw system FZ Index 003 te-of-the-art unit.. Due to our special efforts in the field of quality assurance, the wall saw system FZ is a further Swiss, 0.
FZ 0.5 Table of contents 0.1 Introduction 2 0.2 Validity of this manual 2 0.3 Technical standards 2 0.4 Delimitation of system 2 0.5 Table of contents 3 5.8 Mounting blade and blade guard or flush cutting flange 24 5.9 Connecting the power unit 26 6 Sawing 27 6.1 Before sawing 27 1 Safety instructions 4 6.2 The first cut 27 1.1 Fundamentals 4 6.3 After the first cut 28 1.2 Before machining 6 6.4 End of machining 29 1.3 During sawing 7 1.
Safety instructions 1 Safety instructions 1.1 Fundamentals FZ Recognize warnings! Pay attention to the following words, their characteristics and their meaning: Qualification of operating personnel Machining concrete and stone is neither simple nor without danger. High material assets on the job site, the machine itself and the safety of people are at stake. Danger: Orders or prohibitions designed to prevent injury The personnel has to be trained by experienced experts.
FZ Safety instructions Hazard Safety clothing falling parts: helmet, hard-toed boot moving, sharp-edged parts: Power units and accessories Use the machine exclusively together with the recommended power units and accessories (see "connectable units" and "accessories" in this manual).
Safety instructions FZ Safe areas for the operating personnel and other people The machine is designed to be operated by one single person. During machining other people are to stay whithin safe distance. The controls of the power unit or the remote control must be easily reachable during machining. An emergency stop must be possible at any time (see "Emergency stop"). 1.
FZ Technical data 2 Technical data 2.1 Dimensions (Text) Tracks /HQJWK FP FP Total weight FP NJ ZDOO VDZ ZLWKRXW VDZ PRWRU FP NJ K\GUDXOLF PRWRU VDZ PRWRU FP NJ EODGH JXDUG LQ SLHFHV NJ WUDFNV SHU PHWHU +ROH VSDFLQJ 2.
Range of application 3 Range of application 3.1 Connectable units FZ Particularities of the different power units The output of the various units differs according to type. In order to obtain optimum cut performance, the appropriate saw motor is to be selected according to the unit employed and the type of application (see "choosing the saw motor") %5 %5 %5 OHYHOV &5 &5 OHYHOV &5 $' 6 '.
FZ Design and function 4 Design and function 4.1 Design of wall saw system The wall saw system FZ consists of: 4.3 Track system – fixed to the underground surface by means of the tensioning block and the dowel bolt. – Wall saw head – Blade guard – Tracks 4.4 Design wall saw head Wall saw head The wall saw head incorporates all hydraulic und mechanic components necessary for: – Blade drive – Power feed o – Swivelling 360 4.2 Safety devices Fig. fz2-1b.
Design and function FZ 4.5 Function Hydraulic scheme Function (Figure) Fig. fz2-2b.tif Fig. fz2-2ae.
FZ Design and function Function (table) From where ... WKURXJK ZKDW ...
Design and function 4.6 FZ Operating elements and connections Fig. fz3-1.
FZ Design and function Position in figure Designation Function 1 Bolt for blade guard 0RXQWLQJ WKH EODGH JXDUG 2 Water connection &RQQHFWLQJ WKH ZDWHU KRVH 3 Tensioning block )L[LQJ WKH WUDFN RQ FRQFUHWH 4 Adjusting screws $GMXVWLQJ WUDFN LQ KLJKW DQG DOLJQHPHQW 5 Adjusting grip $GMXVW SOD\ EHWZHHQ ZDOO VDZ KHDG DQG WUDFN 6 Coupling of feed motor ,QSXW RI IHHG FLUFXLW WR WKH IHHG PRWRU 7 Nipple of feed motor 2XWSXW RI IHHG PRWRU WR WKH IHHG FLUFXLW 8 Coupling of saw motor ,QSXW
Set-up 5 Set-up 5.1 Initial set-up The wall saw system is delivered ready for set-up. All instructions in this chapter are equally valid at the initial set-up. 5.2 FZ Secure cutouts Secure the cutouts of walls and especially of ceilings by appropriate means, e.g. by a crane, supports etc.
FZ Set-up Position of cuts Inform yourself about the concrete to be cut. – Where is the reinforcement? – Is the concrete heavily or lightly rein- forced? – Is it suitable for dowel fixing? Determine both the position and the sequence of the cuts prior to starting operation. In case of a door cutout, e.g. first carry out the cut at the bottom, then the lateral cuts, and finally the cut on top. If possible, cut in perpendicular direction to the reinforcement.
Set-up 5.3 FZ Choosing the saw blade Select the saw blade with the required diameter with regard to the requirements both of cut and of technical conditions. 450 - 2200 mm inner Ø: 60 mm Fastening: 6 x M8, screw hole circle Ø 80mm Which depth of cut is to be reached? Table "Depths of cut" shows, which saw blade diameter is to be selected for a given depth of cut. Saw blades of a diameter of more than 1000 mm can only be mounted after a correspondingly deep cut made by a smaller saw blade.
FZ Overcut 900 1000 1200 1500 500 600 750 800 900 1000 1200 1500 Diameter of saw blade 800 Diameter of saw blade 750 Minimal depth of incision 600 Maximum depth of incision 500 Set-up 5 cm 2 2 2 2 1 1 1 1 15 15 18 18 20 21 21 27 10 cm 6 5 4 4 3 3 3 2 20 22 25 26 28 29 32 37 15 cm 14 10 7 7 5 5 4 3 23 25 29 31 32 35 39 45 20 cm - 18 12 11 9 8 7 5 - 28 33 34 37 39 44 51 25 cm - - 19 17 13 12 10 7 - - 35
Set-up 5.4 FZ Choosing the saw motor Choose the motor like this: Choosing the appropriate saw motor results in...
FZ Set-up FZ + DK (35 PS Wisconsin) / DK.1 (27 PS Kubota) / DK.
Set-up 5.5 FZ Changing the saw motor Removing the saw motor Connecting the hoses 1) Push the hose coupling on or into its counterpart until you hear it "click" 2) Turn the locking ring of the coupling into its secured position Never connect or disconnect hoses when the unit is running. Always make sure that the hoses are properly connected. Always secure them by turning the locking ring.
FZ 5.6 Set-up Fixing the tracks on concrete Pay attention to the following instructions. Inappropriate fixing leads to serious hazards! Always use: – Tensioning blocks (6) with all screws (5) – Dowel bolts with: Ø 15 mm and 8 kN of traction (see "Accessories") – Screws (5): length = 50 mm – two track bases for the first track, one for all further tracks Fig. fz4-2b.
Set-up FZ Procedure 1) Mark the cutting line 2) Mark the dowel line in sections of 22 cm (for flush cutting 24 cm) 3) Mount the tracks (1) to the track bases (9). 5.
FZ Set-up Procedure Mount wall saw head without saw blade 1) Unscrew adjusting grips completely 2) Mount wall saw head 3) Fasten the adjusting grips so that there is no play 4) Check between machining for tightly fastened grips. 5.8 Mounting blade and blade guard or flush cutting flange If the saw blade is not mounted correctly it can get loose and harm people seriously! Use only the screws specified for this purpose and meeting the prescribed length and quality requirements.
Set-up FZ Mounting saw blade and blade guard Mounting saw blade and flush cutting flange Fig. fz4-5.tif 6DZ EODGH 6DZ EODGH FRYHU 5DGLDO FDP $OOHQ KHDG VFUHZV 0 [ %ODGH KXE 1) Fasten the saw blade with six screws 8VH RQO\ WKHVH VFUHZV 0 [ TXDOLW\ ',1 2UGHU QR , 2) Check the blade angle and readjust track bases 3) Mount the blade guard: Radial cam must engage into the guideway in the middle of the bladeguard Fig. fz4-6.
FZ Set-up After flush cutting Remount the cover plate to the blade guard. 5.9 Connecting the power unit Fundamentals Never connect or disconnect hoses when the unit is running. – Connect couplings with elbow pieces to the wall saw system – Connect straight couplings to the po- wer unit – Keep the couplings clean Connect both ends of the hose package. Thus the hose couplings are kept clean and will not be damaged during transport.
Set-up FZ Connecting the hoses Turn the pressure valve at the power unit to zero The following hose connections are to be established: Wall saw system Power unit Saw motor Main circuit Swivelling motor Feed circuit Feed motor Feed circuit Water connection Water connection Fig. fz5-2.
FZ Sawing 6 Sawing 6.1 Before sawing 6.2 The first cut Never saw without blade guard. Pay attention to the following instructions: – Check the moving sense of the wall saw head and the swivelling arm – The toothing of the track must be clean – Make a "trial run " along the whole length of the tracks and make sure that the hoses are not clogged Fig. fz6-1.
Sawing 6.3 FZ After the first cut Do not saw with the highest admissible pressure of the power unit in sections where only concrete is sawed. Stay about 40 bar below. If the blade encounters reinforcement the pressure will then not exceed the admissible maximum. Further infeed After the first cut further infeed can be more than 5-10 cm. The depth of cut depends on the power of the connected power unit, the size of the saw blade the quality of the diamond segments and the quality of the concrete.
FZ 6.4 Sawing End of machining 1) Turn off power unit and unplug mains 2) Relieve pressure from the hydraulic circuits 3) Clean wall saw system, e.g.
Troubleshooting 7 FZ Troubleshooting Proceed systematically when looking for the cause of defects. for this purpose also use the hydraulic scheme. Before calling us, please observe the following: – The better you describe the defect, If you cannot find the defect or eliminate the faulty condition, please contact our after-sales service.
FZ Troubleshooting Trouble Cause Remedy &RXSOLQJ OHDNV &RXSOLQJ LV GHIHFWLYH 5HSODFH WKH VHDOLQJ &RXSOLQJ LV GHIHFWLYH 5HSODFH FRXSOLQJ :DOO VDZ KHDG GRHV QRW PRYH RYHU WUDFN MRLQWV 7UDFNV DUH QRW IOXVK 7UDFNV DUH ZDUSHG 7UDFNV DUH QRW DOLJQHG 0RXQW WKH WUDFNV FRUUHFWO\ 1R ZDWHU DW WKH VDZ EODGH :DWHU YDOYH DW WKH SRZHU XQLW LV FORVHG 2SHQ ZDWHU YDOYH :DWHU KRVH LV QRW FRXSOHG FRUUHFWO\ &RQQHFW ZDWHU KRVH FRUUHFWO\ SXVK ORFNLQJ ULQJ IRUZDUG :DWHU SUHVVXUH LV WRR ORZ :DWHU SUHVVXUH
Maintenance 8 Maintenance 8.1 Maintenance table FZ Service the system within the indicated intervals in order to ensure: – Safety of the operator – Best performance – Best reliability Disconnect the system from the power unit before servicing.
FZ 8.2 Maintenance Checking tension of toothed belt 2) Turn screw (2) with fork wrench until tension is correct Fig. fz7-3b.tif 3) Fasten all 8 Screws (1). 4) Mount rubber seal and belt cover 8.4 Replacing guiding devices Fig. fz7-1a.tif 1) Remove the rubber seal of the blade flange 2) Remove the belt cover 3) Check the tension 8.3 Tensioning the toothed belt Fig. fz7-2.tif Fig. fz7-1c.
Maintenance 8.5 FZ Replacing feed motor Fig. fz7-3.tif 8.6 Replace swivelling motor Fig. fz7-4.
FZ 8.7 Maintenance Refilling lubricant Use MOBIL GLYGOYLE exclusively. Swivelling gear 1) Remove blade guard bolt (4) 2) Turn the wall saw head upside down 3) Remove the old lubricant 4) Fill in 900 g of lubricant Feed gear Fill in half of the lubricant on each side of the main bearing. 5) Mount blade guard bolt (4). Fig. fz7-1c.tif 1) Loosen 3 screws (3) 2) Remove feed gear 3) Remove old lubricant from gear 4) Clean gear inside Fig. fz7-5.
Repairing 9 FZ Repairing Components other than the described may only be replaced by authorized personnel trained at HYDROSTRESS or equally qualified personnel. Contact HYDROSTRESS or an authorised HYDROSTRESS-representation if other personnel is to repair the system.
FZ 10 Transport, placing out of service, storing, disposal Transport, placing out of service, storing, disposal 10.1 Transport The wall saw system is a high-tech product. Protect it against damage during transport: – Remove blade guard – Do not place anything on or against the wall saw head, the blade guard or the tracks – Protect the toothing of the track against damage The wall saw system weighs more than 30 kg. Carry it carefully and if possible not alone in order to prevent injury. 10.
Transport, placing out of service, storing, disposal FZ 10.3 Disposal The wall saw system consists of the following materials: – Cast and rolled aluminum – Bronze – Steel – Rubber – Rubber / nylon - tissue – Synthetic lubricant – Plexiglass Consider the local regulations for disposal in your country.
FZ 11 Accessories Accessories The supplied tool kit provides the following: – 3UHVVXUH UHOLHI YDOYH – )OXVK FXWWLQJ IODQJH ZLWK DOOHQ KHDG FRXQWHUVXQN VFUHZV – 7UDFN HQG VWRSSHU – 6HYHUDO VHDOV – 7RROV IRU UHSODFLQJ WKH VDZ PRWRU Available on request: – VDZ PRWRUV VL]H FFP BBBBBBBBBBBBBBBBBBBBBBBBBBBBBBBBB2UGHU QR BBBBBBBBBB 00 – VDZ PRWRUV VL]H FFP BBBBBBBBBBBBBBBBBBBBBBBBBBBBBBBB2UGHU QR BBBBBBBBBB 00 – 7UDFNV PP BBBBBBBBBBBBBBBBBBBBBBBB
Spare parts list 12 FZ Spare parts list 12.1 Order indications For spare part orders we need the following indications: – Type of machine according to type pla- te (for example FZ Index 003) – ber of machine according to type plate (for example 2136) – Stock number of spare part according to spare parts list (for example 08W775648-02) For orders, inquiries and information please refer to your appropriate branch office (indicated below).
FZ Spare parts list 12.2 Table of contents (Spare parts) Fig. fz11-0.
Page 42 FZ31294 Fig.
Page 43
Page 44 FZ31294 Fig.
FZ31294 HS # Diamond Products # Page 45 1 2 3 4 5 7 8 9 10 XXKL02Z20001000102Z201I107S201I113G4- 000001002854310538510802010100070130602011626- 41 00 01 01 00 00 14 00 06 Plexiglas Schild 11 12 13 14 15 0001000105O104W204R3- 5385454067000500000506205- 02 01 25 00 10 3400678 3400343 3400501 3400521 3400588 Worm Gear Distributor Bushing O-ring Stop-Shaft nut Ball bearing 16 17 18 19 20 000104R30001000105O1- 5406706206542975385501100- 02 10 02 06 35 3400343 3400589 3400522 3400505 3400679 D
Page 46 FZ31294 Fig.
FZ31294 31 32 33 34 35 01I1000201I1000105O1- 0602053962050205412400080- 11 02 00 01 25 3400708 3400260 n/a 3400262 3400520 Allen Screw Driving gear FZ Allen screw Water hose DZ/FZ O-ring 1 1 2 1 2 36 37 38 39 40 04Z3000001I101I205S2- 0330760021060350601600400- 00 01 00 00 70 3400267 3400986 3400920 3400709 3400032 Angular ball bearing Blade hub FZ 60mm Allen head screw Allen screw Shaft seal 1 1 12 4 1 41 42 43 44 45 01I105O1000001A10001- 0801800300600210504553855- 00 30 05 00 07 3400788
Page 48 FZ31294 Fig.
FZ31294 61 62 63 64 65 0001000105O199MS- 53854538550042254612- 03 03 30 00 66 67 68 69 70 000101I199MS0001- 54310060205456553855- 02 11 01 02 71 72 73 74 75 05S202S204R1000102S2- 0030004717069065455302110- 70 50 00 02 50 3400719 3400514 3400269 3400403 3400515 Shaft seal Seeger Circlip1 Ball bearing Worm wheel Seeger Circlip 1 1 1 76 77 78 79 80 05O1000104R1000201I1- 0016053854069065385906060- 25 06 00 01 00 3400271 3400720 3400269 3400635 n/a O-ring Sealing Plug Ball bearing Feed Motor
Page 50 FZ31294 Fig.
FZ31294 91 92 93 94 95 01I102S104R1000104V1- 06016- 11 02512- 50 61805- 00 53854- 01 QJ304- 00 3400346 3400807 3400258 3400808 3400295 Allen head screw Seeger cirglip Ball bearing Worm Gear Ball Bearing 1 1 1 96 97 98 99 100 04X104W1000100010001- 0000400004538565385653856- 00 00 02 03 01 3400511 3400041 3400351 3400352 3400353 Sheet Metal nut lock Spanner Nut Carrier Shaft Holding sleeve 1 101 102 103 104 105 03T1000102Z101I101G1- 0231053856040300601605008- 09 04 00 11 45 3400357 3400354 3
Page 52 FZ31294 Fig.
FZ31294 99MS- 54236- 01 3400252 1 2 3 4 5 000101I2000202Z10001- 5385606012519740403053856- 02 00 01 00 03 3400103 3400617 3400355 3400352 6 7 8 9 10 01I101I4000101G103T1- 0601605016538560500802310- 11 21 04 45 09 11 0001- 53856- 01 Carriage Guide Complete Butterfly Handle 3400351 Carrier Allen head screw Prisma Parallel pin Shaft 8 4 2 2 3400346 3402111 3400354 3402110 3400357 Allen head screw Countersunk head screw Butterfly Handle Set screw Disk spring 8 2 2 2 4 3400353 Holding slee
Page 54 FZ31294 Fig.
FZ31294 99MS- 54565- 01 3400331 Feed motor 1 2 3 4 5 07M1 00020002000407S1- 00006 54374543745404600372- 32 01 02 01 38 3400160 3400634 3400658 3400652 3401032 Hydraulic motor Motor flange Connection flange Screw type nipple Nipple 1 1 1 2 1 6 7 8 07S1- 0037101I2- 0501201I1- 06020- 38 00 11 3401031 n/a 3400708 Coupling Allen screw Allen screw 1 4 Page 55
Page 56 FZ31294 Fig.
FZ31294 99MM- 32005- __ Saw motor Size 2 1 2 3 4 5 07S108D114D401I101I1- 00801????? 685790604506030- ?? 12 34 00 00 3401022(FD)3400140(Bruning) 3/4'Coupler 3400360(1/2") 3400276(3/4") Sealing Ring 3400371 Screw-type connection piece 3400921 Allen head screw 3400085 Allen head screw 1 2+2 2 2 2 6 7 8 9 10 01F107Fl05O107M205S1- 0600061210001903220500180- 50 12 25 __ 78B n/a 3400142 3400302 3400180 (30cc) 3400249 Spring washer Motor flange O-Ring Motor Shaft seal 8 1 1 1 1 11 12 13 14 15 02S20
Page 58 FZ31294 Fig.
FZ31294 99MM- 34008- __ Saw motor Gr. 3 cpl.
Page 60 FZ31294 Fig.
FZ31294 99MS- 54126- 00 Blade protection Ø 800, 3 pc.
Page 62 FZ31294 Fig.
FZ31294 99MS- 53693- 10 Blade Guard Ø 1000, 3 pc.
Page 64 FZ31294 Fig.
FZ31294 NA 99MS-54514- 00 3400206 Flush cut flange compl. US 1 2 3 5/16" X 1" Flat Hd.
Page 66 FZ31294 Fig.
FZ31294 Steel V-track 1 2 3 4 5 99MS99MS99MS99MS99MS- 0070001100014000180002200- 11 11 11 11 11 3400478 2500304 2500382 2500383 2500303 V-track compl. 27" V-track compl. 43" V-track compl. 55" V-track compl. 70" V-track compl.
Page 68 FZ31294 Fig.
FZ31294 99MS- 53675- 20 3400480 Steel V-Track Foot 1 2 3 4 5 00010001000101S10001- 5347853478534791206553478- 05 06 08 00 04 3400167 3402107 n/a 3400168 3400283 Clamping strap Cap nut Spring Hex head cap screw V-track base 1 1 1 1 1 6 7 8 9 10 000101S199MS01S10001- 5204416040534791213053479- 08 00 02 00 02 3400581 3400582 3400569 3400400 3400866 Spacer Hex head cap screw Fixing block, compl.
Page 70 FZ31294 Fig.
FZ31294 99MS-52044-01 n/a 1 2 3 4 5 01I10001000101S101M1- 080205204452044121102000- 11 07 01 73 00 n/a Allen head screw 3401849 Cover for track base n/a Track base Hexagon head cap screw 1 n/a Hexagon nut 1 6 7 8 9 01U2000101S10001- 12028520441605052044- 50 05 00 08 n/a 3400222 n/a 3400581 1 1 2 2 Washer Face plate for base Hexagon head cap screw Separator 1 1 1 Page 71
Page 72 FZ31294 Fig.
FZ31294 99MS- 53717- 01 3400868 1 2 3 4 5 00010001000100020002- 5347853478534795367953679- 05 06 08 01 02 3400167 3402107 n/a n/a n/a 6 7 8 9 10 000101S101S199MS01S1- 5204416040120655347912130- 08 00 00 02 00 11 12 13 14 15 00010001000106S20001- 5347953479534790401053479- 16 17 18 19 20 01G700010001000101I1- 0601253479534795347908025- Stair V-track Foot Clamping strap Cap nut Spring Receiver block Stepped track base 1 1 1 1 1 3400581 3400582 3400168 3400569 6kt-Schraube Trackbase sepera
Page 74 FZ31294 Fig.
FZ31294 99MS- 52477- 01 3400479 Swivel track base 1 2 3 4 5 01I10001000100010001- 0801652044523155231552315- 11 07 09 07 08 3402042 3401849 n/a n/a n/a Allen head screw Cover for track base Track bolt for swivelling base Retaining screw for swivelling Bolt seat of swivelling baset 6 7 8 9 10 0001000101S1000101S1- 5231552315160655231512070- 03 02 00 01 00 n/a n/a n/a 3403003 6kt.
Page 76 FZ31294 Fig.
FZ31294 99MS- 54612- 00 3400184 Bolt for blade guard 1 2 3 4 5 000105O101I103D20001- 5456600422080201001754566- 02 30 00 85 04 n/a 3400174 3401917 3400591 3401854 Bolt O-ring Allen screw Pressure spring Wedge 1 1 4 2 1 6 7 8 9 10 00010001000100010001- 5456654566545665385654566- 03 05 06 04 07 3401853 3401855 3400723 3400354 3400592 Wedge Fastening device Fastening device Wing shaped grip Locking screw 1 1 1 1 1 11 12 13 14 01I401Q101G101I1- 05016060080500805040- 21 00 45 00 3402111 34
Page 78 FZ31294 Fig.
FZ31294 1 2 3 4 99MS- 54615- 00 3400183 0001000401S101M1- n/a 3400062 n/a n/a 54590525820803008000- 02 01A 00 00 Blade guard holder in 2part Attaching pipe Clamp lever for AZ-S Hexagonal screw Nut hexagon 1 1 4 4 Page 79
Page 80 FZ31294 Fig.
FZ31294 99MS- 54613- 00 n/a Blade guard holder 1 2 3 4 5 000100010001000101I1- 5456653646536465364612020- 01 10 01 04 00 n/a n/a n/a n/a 3402144 Attaching pipe Buffer red Guide Pointer Allen head screw 1 1 1 1 1 6 7 8 9 10 01I101M206B106A101I1- 1204012000080300028504008- 00 00 00 00 00 n/a 3402015 3400243 3400244 n/a Allen head screw Hexagon nut Quick separating pin Fixing lever Allen head screw 1 1 1 1 2 11 0002- 54240- 01 n/a Locking device 1 Page 81
Page 82 FZ31294 Fig.
Page 83
