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Summary of Contents for TYROLIT Hydrostress PPH40RR Series
- Page 1 Operating Instructions Spare Parts List Drive Unit PPH40RR*** Index 000 10983813 en / 18.7.07...
- Page 2 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 © 2007 TYROLIT Hydrostress AG, CH-8330 Pfäffikon ZH All rights reserved, in particular the copying and translation rights.
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Page 3: Table Of Contents
Operating Instructions Overview Overview Page Introduction Congratulations!- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Validity of these Operating Instructions - - - - - - - - - - - - - - Standards - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Delimitation of the system - - - - - - - - - - - - - - - - - - - - - - - - Product description... - Page 4 Overview Operating Instructions Corrective maintenance Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1 Storage - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4 Transport Transport - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1 Safety instructions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1...
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Page 5: Introduction
Any repair work must be carried out by trained personnel only. If you need more details about how to keep your TYROLIT Hydrostress AG system in perfect condition, please contact our after-sales service for fur- ther information. -
Page 6: Validity Of These Operating Instructions
Introduction Operating Instructions Validity of these Operating Instructions This manual is only valid for the following system: Drive Unit PPH40RR*** Standards These Operating Instructions have been prepared in accordance with the CE Machinery Directive Appendix I and with the relevant standards in force at the time of printing. -
Page 7: Product Description
Operating Instructions Product description Product description Application The Drive Unit PPH40RR*** has been designed as a component for the fol- lowing concrete processing systems: • Hydraulic wall saw systems • Hydraulic diamond wire saw systems • Hydraulic core drilling systems •... -
Page 8: Information Sign
Product description Operating Instructions Information sign Attached to the plastic hood is an information sign containing the following information: • Hose connections (For a description see "Chapter 5" 5.3.2.1, 5-2) • Pressure stages (For a description see "Chapter 5" 5.4.3, 5-8) •... -
Page 9: Ec Declaration Of Conformity
Operating Instructions Product description EC Declaration of Conformity Description Hydraulic drive unit Type designation Drive Unit PPH40RR*** Year of construction 2007 We declare under our own liability that this product complies with the fol- lowing directives and standards: 1.6.0.1 Directive applied: Machinery Directive 2006/42/EC EC EMC Directive 89/336/EC EC Low Voltage Directive 73/23/EC... -
Page 10: Technical Data
Product description Operating Instructions Technical data 1.7.1 Dimensions 82 cm 56 cm Fig. 1-3 Dimensions 1.7.2 Weight Operating weight 255 kg 1.7.3 Tyres Wheel Ø 30 cm Operating pressure 3 bar PPH40RR*** / 000... -
Page 11: Hydraulics
Oil cooling Oil cooler: Water/oil heat exchanger 1.8.6 Couplings and hoses Plug-in couplings Type FD and FF, non-drip Hoses Length 8m (filled with hydraulic oil) 1.8.7 Oil quality TYROLIT Hydrostress AG recommends: Hydraulic oil: HLP/ISO VG 46 PPH40RR*** / 000... -
Page 12: Electrical Equipment
Product description Operating Instructions Electrical equipment Information Electrical data are only valid for the installed loads 3 P / LNPE 400 VAC / 50 Hz 1.9.1 Different voltages For countries where different mains networks operate the following types are available: Drive Unit PPH40RR*** 380-420 V 50 Hz... -
Page 13: Water
Operating Instructions Product description 1.9.2.3 Protection class IP 65 1.9.2.4 Internal control voltage (valve control) 24V / DC 1.9.2.5 Secondary socket Connections 2 sockets 230V / 10A with fault current tripping at 10 mA 1.10 Water Pressure min. 2 bar to max. 6 bar Quantity min. -
Page 14: Country List For Radio Transmission Frequency
Product description Operating Instructions 1.13 Country list for radio transmission frequency Country Frequency Country Frequency Australia Mexico Belgium New Zealand Bolivia Netherlands Brazil Norway Brunei Austria Bulgaria Poland China Portugal Denmark Puerto Rico Germany Romania Finland Russia France Sweden Greece Switzerland Great Britain Singapore... -
Page 15: Safety Instructions
Observance of the safety instructions The Drive Unit PPH40RR*** has been inspected before being shipped and is delivered in perfect condition. TYROLIT Hydrostress AG does not accept any liability for damage which is caused by failure to observe the instruc- tions and information provided in the Operating Instructions. -
Page 16: Safety Principles
Safety instructions Operating Instructions Safety principles 2.3.1 Delimitation of the safety concept The Drive Unit PPH40RR*** does not affect the safety concept of the con- nected systems, equipment and installations. 2.3.2 Safety elements Protection from live electrical parts All functional units containing parts which carry hazardous voltages are shock-protected by suitable covers. -
Page 17: Responsibility
Responsibility 2.4.1 Authorised personnel Work on or with the TYROLIT Hydrostress AG machines or systems may only be performed by authorised personnel. Personnel are considered by TYROLIT Hydrostress AG to be authorised if they meet the necessary training and know-how requirements and they have been assigned a pre- cise functional role. - Page 18 • Has trained as a concrete cutting expert or has professional experience. • Has received an introduction (basic training) to the operation of the TYROLIT Hydrostress AG machines and systems from a service engi- neer. • Has read and understood Chapter 2 "Safety instructions".
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Page 19: Generally Applicable Warnings Of Residual Dangers
Operating Instructions Safety instructions Generally applicable warnings of residual dangers Danger Electric shock due to defective electronic equipment. The electrotechnical equipment must be checked prior to each use and from time to time during prolonged use. Defective parts, such as e.g. cables and plugs, must be replaced immediately in the de- energized state by electrotechnically trained personnel. - Page 20 Safety instructions Operating Instructions PPH40RR*** / 000...
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Page 21: Design And Function 1 3.1 Design
Operating Instructions Design and function Design and function Design Fig. 3-1 Main components 1 Hood 10 Oil tank 2 Wheel 11 Electric motor 3 Electrical box 12 Electrical connection 4 Oil level indicator 13 Pump assembly 5 Transport handle with hose bracket 14 Power supply unit 6 Water valve 15 Hydraulic unit... -
Page 22: Function
Design and function Operating Instructions Function 3.2.1 Hydraulic circuit diagram Fig. 3-2 Hydraulic circuit diagram Electric motor 18 Leak-oil nipple Pump assembly 19 Coupling Proportional valve 0-260 bar 20 Nipple Check valve 21 Coupling Pressure relief valve 22 Nipple Pressure gauge 0-400 bar 23 Coupling Oil and water cooler 24 Water valve... - Page 23 Operating Instructions Design and function 3.2.2 Wiring diagram Fig. 3-3 Wiring diagram 1 Elec. box EMERG. STOP 2 Reversing switch 10 Hour counter 3 Auxiliary contact 11 Phase sequence relay 4 Contactor 12 Time relay 5 Thermal relay 13 Connector CEE 63/5 6 Interlock 14 Safety socket 7 Circuit breaker...
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Page 24: Radio Remote Control
Design and function Operating Instructions Radio remote control 3.3.1 Design Fig. 3-4 Remote controller 1 Controls 2 Plastic housing 3.3.1.1 Accessories Fig. 3-5 Accessories 1 2x interchangeable battery 2 Battery charger 3 Cable insert 4 Battery insert Warning The battery charger is exclusively for recharging the interchangeable re- chargeable battery. -
Page 25: Controls And Displays 1 4.1 Controls
Operating Instructions Controls and displays Controls and displays Controls Fig. 4-1 Controls 1 Safety socket 7 Suspension shackle 2 Schuko-socket 8 Water valve 3 Forward/reverse switch 9 Remote controller 4 Device protective switch 10 Water and hydraulic couplings 5 EMERG. STOP 6 Cable connection of remote controller 4.1.1 Radio remote control... -
Page 26: Electric Controls
Controls and displays Operating Instructions Electric controls 4.2.1 Secondary sockets The Drive Unit PPH40RR*** is equipped with 2 x 230V / 10 A secondary sockets with fault current tripping at 10 mA. The secondary sockets may only be used with a neutral conductor. Fig. - Page 27 Operating Instructions Controls and displays 4.2.2 Forward/reverse switch If the phase position of the power supply to the site is wrong, the phases can be turned. 4.2.3 Device protective switch The device protective switch protects the secondary sockets and thereby protects the devices connected to the sockets.
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Page 28: Displays
Controls and displays Operating Instructions Displays Fig. 4-5 Displays 1 Hour counter 4 Pressure gauge of main motor 2 Pilot lamp (radio & battery) 5 Oil level indicator 3 Pressure gauge of feed motors 4.3.1 Hour counter The hour counter allows for precise observance of the service intervals. Fig. - Page 29 Operating Instructions Controls and displays 4.3.3 Pressure gauge Fig. 4-8 Pressure gauge 1 Pressure gauge of main motor (0 bar to 400 bar) 2 Pressure gauge of feed motors (0 bar to 250 bar) 4.3.4 Oil level indicator MAX. MIN. Fig.
- Page 30 Controls and displays Operating Instructions PPH40RR*** / 000...
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Page 31: Operation
The Drive Unit PPH40RR*** is one of a series of drive products available from TYROLIT Hydrostress AG. In order to allow expansion of your Drive Unit PPH40RR*** with suitable devices to create an hydraulic saw or drilling system with optimum per- formance, please talk to TYROLIT Hydrostress AG. PPH40RR*** / 000... -
Page 32: Preparatory Operations
Operation Operating Instructions Preparatory operations 5.3.1 Visual inspection Before starting work always complete the following visual inspections: • Is the power supply earthed, fitted with a neutral conductor and a resid- ual current circuit breaker? • Does the mains network have fuse protection for a minimum of 63 A? •... - Page 33 Operating Instructions Operation 5.3.2.2 Hose connections Fig. 5-1 Hose connections 1 Couplings of main motor 2 Water connection 3 Couplings of feed motor 1 4 Couplings of feed motor 2 5 Leak-oil connection (hydraulic motor Gr.3) Proceed as follows: • Visual inspection Check: –...
- Page 34 Operation Operating Instructions 5.3.3 Radio remote control provision Information The transmitter and receiver are a pair of matched units. They cannot be used with other devices. 5.3.3.1 Power sources The radio remote control can be operated using a rechargeable battery, disposable battery or via cable.
- Page 35 Operating Instructions Operation 5.3.4 EMERGENCY STOP In danger situations the EMERGENCY STOP button must be pressed im- mediately. Fig. 5-3 EMERGENCY STOP 1 EMERG. STOP on the Drive Unit PPH40RR*** 2 EMERG. STOP on the radio remote control Deactivating EMERGENCY STOP Information If the EMERG.
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Page 36: Working
Operation Operating Instructions Working 5.4.1 Starting the Drive Unit PPH40RR*** Information The Drive Unit PPH40RR*** should only be switched on in a level and upright position. If the surface has an incline, secure the drive unit to pre- vent rolling away. Proceed as follows: •... - Page 37 Operating Instructions Operation Information If the Drive Unit PPH40RR*** is switched off after the electric motor has once been started up, in order to start up again it is only necessary to press the main switch on the remote controller just once more. •...
- Page 38 Operation Operating Instructions 5.4.3 Selecting the pressure stage Once the Drive Unit PPH40RR*** has been started properly, you can select the pressure stage. Fig. 5-6 Selecting the pressure stage Proceed as follows • Set the pressure stage selector switch to the desired pressure stage and turn the main motor potentiometer from 0 to 100%.
- Page 39 Operating Instructions Operation 5.4.5 Feed movements The feed motors for the travel motion and the swivelling can only be con- trolled individually by means of the feed joystick. Fig. 5-8 Feed A Travel feed B Swivel feed 5.4.6 Feed locking So that the joystick does not have to be held in position during the travel feed motion, the travel feed can be locked.
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Page 40: After The Work
Operation Operating Instructions 5.4.7 Shutting down the Drive Unit PPH40RR*** Proceed as follows • Switch off the electric motor (main switch of radio remote control) • Shut off the cooling water (Water On/Off button of radio remote control) • Close the water valve on the Drive Unit PPH40RR*** •... -
Page 41: Servicing
If there is a risk of frost, blow out the water, see "Chapter 6" 6.1.1, Mechanical Retighten accessible screws and nuts Major service May only be carried out by TYROLIT Hydrostress AG First service after or an authorised representative 100 operating hours After every 200 operating hours, thereafter... - Page 42 Use the TYROLIT purge pump No. 10982667. 6.1.2 Oil change 6.1.2.1 Oil quality TYROLIT Hydrostress AG recommends: Hydraulic oil: HLP / ISO VG 46 Other hydraulic oils can be used if they comply with the following specifica- tions: Pour point: -42°...
- Page 43 Operating Instructions Servicing 6.1.2.2 Replacing hydraulic oil In order to replace the hydraulic oil you will need: • A collecting pan for the used hydraulic oil with a capacity of approx. 15 litres • Open-ended spanner, size across flats 18 mm for the oil drain plug •...
- Page 44 Servicing Operating Instructions Bleeding the system Information Air must be bled from the system whenever the tank has been complete- ly emptied and refilled. Proceed as follows: • Open tank cover • Fill oil to maximum mark • Do not refit the tank cover, yet •...
- Page 45 Motor runs in wrong direction Change direction of rotation with for- running and valves are open ward/reverse switch For drive unit with monitoring Inform TYROLIT Hydrostress AG after-sales service Defective pump Have pump replaced by TYROLIT Hydrostress AG or an authorised representative...
- Page 46 Operating Instructions Fault Possible cause Solution The hydraulic oil is cloudy, light in Defective oil cooler Inform TYROLIT Hydrostress AG colour and the tank overflows after-sales service Warning: Do not continue operating the unit, otherwise hydraulic ele- ments could be damaged...
- Page 47 Water valve on feed line is closed Open water valve Insufficient water pressure Check water circuit see "Chapter 1" 1.10, Defective water valve Inform TYROLIT Hydrostress AG after-sales service Water filter is blocked Clean the filter or inform TYROLIT Hydrostress AG after sales service If you are unable to remedy a fault, please call our service centre (see man- ufacturer's address on the reverse of the title page).
- Page 48 Corrective maintenance Operating Instructions Storage The Drive Unit PPH40RR*** consists partially of material which can cor- rode. If you take the unit out of service for an extended period, proceed as follows: • Blow out the water from the water lines •...
- Page 49 Operating Instructions Transport Transport Transport The Drive Unit PPH40RR*** is a high-quality, technical device. Protect it against transport damage: • Do not place any parts on or against the Drive Unit PPH40RR*** • Protect the Drive Unit PPH40RR*** from impacts •...
- Page 50 Transport Operating Instructions Crane shackles and transport handles Fig. 8-1 Crane shackles and transport handles 1 Crane shackles 2 Transport handles with hose bracket Danger Danger of falling parts. When crane transport is used, the Drive Unit PPH40RR*** must be transported alone, without the radio remote control and hoses.
- Page 51 Operating Instructions Disposal Disposal General The operator can recycle or dispose of the Drive Unit PPH40RR*** himself provided that he observes the statutory provisions. In order to dismantle the unit correctly and to properly separate the materials, some knowledge of mechanical procedures and knowledge about the differentiation of waste materials is necessary.
- Page 52 Disposal Operating Instructions Disposal regulations The usual national and regional regulations and directives must be ob- served when disposing of the Drive Unit PPH40RR***. Disposal of the Drive Unit PPH40RR*** To allow proper disposal, the components of the Drive Unit PPH40RR*** must be dismantled.
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