Repair Manual and Spare Parts List
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1 Hydraulic Drive Unit Type Techn. Doc. No. 362 and Accessories for Pipe Cutting Machine Darstellung kann vom Original abweichen Repair Manual and _Inst_en_Version_03
2 Repair General In general, observe the safety regulations and instructions: refer to the operation and maintenance manual. The disassembly and re-assembly is done only according to the technical drawing. In case of damages, our service is at your disposal. Do not disassemble the tool until you know whether the problem is in one of the modules. Then only disassemble the tool as necessary to repair as required. Keep contaminants such as dirt and grit away from the internal parts at all times. Always identify and correct the cause of the problem prior to re-assembling. Further wear and tool failure can result, if the original cause is not corrected. Information for exact identification of the problem is given in the unit Troubleshooting of the operation manual. Notice: The particular installation direction of the parts mentioned in the following process instructions is indicated in the drawings and the parts lists at the end of this instruction. Spare Parts Only genuine Spitznas spare parts may be used. There is no warranty for damages and liability is disclaimed by Spitznas, if non-original spare parts and accessories are used. Disassembly Preparation of the hydraulic drive unit for disassembly Clean the exterior of the drive unit. Disconnect energy supply and secure against restart. Disconnect hydraulic hoses. Take cutting tool item 11, respectively item 12 (page 6) out of the tool holder item 8, 9 (page 8) and store it at a safe place. Remove drive unit item 1 (page 5) by pulling the ball lock bolts items 5 and 6 (page 8). Disassembling modules of the drive unit Loosen 4 x M6 item 17 (page 14) and remove drive motor item 1 from the gear item 2 (page 8). Loosen 4 x M6 item 39 (page 14) and remove guard item 3 (page 8) _Inst_en_Version_03 Page 1 of 34
3 Disassembling motor Send complete drive motor item 1 to the manufacturer. After having repaired the drive motor, a performance test must be done. Disassembling gear Before, 4 x M6 item 17 have been loosened and drive motor item 1 has been removed. (see paragraph disassembling the modules of the drive unit) Remove snap ring item 37 (page 14), pull out lever item 35 together with items 33, 34 and 36. Continue disassembling, if necessary by knocking out the grooved cylindrical pin item 36. Loosen 4 x M6 item 29, pull the gear rim item 14 with the parts items 8, 9, 10, 11, 12, 13, 15 and 26 out of the gear housing item 1. Remove snap ring item 6 and pull pinion shaft item 2 with items 5 and 4 out of gear housing item 1. Loosen 4 x M5 item 32 and pull gear cover item 30 with the inner parts items 16, 19 and 24 out of gear housing item 1. Continue disassembling according to the component drawings, if necessary. Re-assembly The re-assembly is done in the reverse order. Observe the following: Clean all parts before re-assembling. It is recommended to replace O-rings, bearings, radial shaft sealing rings and other sealings by new parts. Hydraulic diagram Hydraulic Motor Pressure control valve Gear shift valve Back pressure valve In general, it is recommended to replace all wear parts during repair _Inst_en_Version_03 Page 2 of 34
4 Lubricant Fill-up the gear with 25 g of grease. Grease SPITZNAS reference number: (400 g); (100 g) After finishing the assembly, a functional check of the drive unit must be done. (see technical specification of the operation and maintenance manual). Tighten all screws and nuts according to the instructions, when re-assembling. Tightening torques Item Description Torque Remark 5 Socket head screw M6 18 Nm Page Socket head screw M8 24 Nm Page Socket head screw M6 18 Nm Page Socket head screw M6 18 Nm Page Counter sunk screw M5 12 Nm Page Socket head screw M6 18 Nm Page 14 8 Socket head screw M5 12 Nm Page 19 8 Socket head screw M5 12 Nm Page _Inst_en_Version_03 Page 3 of 34
5 Pipe cutting machine, assy. Item Qty. Description Part and drawing number Remarks 1 Hydraulic drive unit see separate list Accessories: 2 Guide carriage small see separate list 3 Chain tensioner small see separate list 4 Tensioning chain L = 950 mm 5 Guide carriage large see separate list 6 Chain tensioner large see separate list 7 Chain link Tightener see separate list 9 Tool set see separate list 11 Circular saw blade 180 mm Diamond 12 Circular saw blade 180 mm Carbide metal 13 1 Bevelling cutter Bevelling cutter Bevelling cutter Metal carrier box _Inst_en_Version_03 Page 4 of 34
6 Pipe cutting machine, assy _Inst_en_Version_03 Page 5 of 34
7 Pipe cutting machine, assy _Inst_en_Version_03 Page 6 of 34
8 Drive Unit Item Qty. Description Part and drawing no. Remarks 1 1 Drive motor see separate list 2 1 Gearbox see separate list 3 1 Guard + water connection see separate list 4 1 Adjustment device Ball lock bolt Ball lock bolt Rotary sleeve see separate list 8 1 Adapter Adapter Feeding pipe Pivot screwing Hydraulic hose set _Inst_en_Version_03 Page 7 of 34
9 Drive Unit _Inst_en_Version_03 Page 8 of 34
10 Hydraulic Drive Motor Item Qty. Description Part and drawing no. Remarks 1 1 Hydraulic motor Drive shaft Flange Coupling Socket head screw Connecting plate Connection nipple O-Ring * 9 2 O-Ring * 10 3 Socket head screw * Wear parts to be stored in case of continuous use _Inst_en_Version_03 Page 9 of 34
11 Hydraulic Drive Motor Section A-A Consider position of rotor and square _Inst_en_Version_03 Page 10 of 34
12 Twist Throttle Item Qty. Description Part and drawing no. Remarks Valve housing, assy Rotary sleeve Pressure rod Threaded pin Snap ring Gate Valve insert, assy item Snap ring Socket head screw Washer Governor piston valve Spring plate Slide Sleeve Guide Pressure spring Locking washer O-Ring * O-Ring * O-Ring * Threaded pin O-Ring * O-Ring * Locking screw Adjusting washer Adjusting washer Safety valve, assy * Wear parts to be stored in case of continuous use _Inst_en_Version_03 Page 11 of 34
13 : Twist Throttle Set pressure 120 bar Glued with Loctite _Inst_en_Version_03 Page 12 of 34
14 Part and drawing number. Gearbox two-stage Item Qty. Description Part and drawing no. Remarks 1 1 Gearbox housing Pinion shaft, assy item Pinion shaft Pressure piece Snap ring Grooved ball bearing * 6 1 Snap ring Spur gear, assy item Spur gear Side pressure piece Needle sleeve * 1 Planet carrier, assy item Planet carrier Bearing needle * 12 3 Needle cage * 13 3 Planet wheel Gear rim Grooved ball bearing * 16 1 Grooved ball bearing * 17 4 Socket head screw Output shaft Gear rim Grooved ball bearing * 25 2 Grooved ball bearing * 26 3 Snap ring Shaft seal * 29 8 Socket head screw Gearbox cover Counter sunk screw Eccentric disc Cylinder pin Lever Grooved cylindrical pin Snap ring Spring pressure piece Socket head screw Bushing * Wear parts to be stored in case of continuous use _Inst_en_Version_03 Page 13 of 34
15 Gearbox two-stage Glued with Loctite 243 glued Insert with surface seal _Inst_en_Version_03 Page 14 of 34
16 Gearbox two-stage glued _Inst_en_Version_03 Page 15 of 34
17 Guard with water connection Item Qty. Description Part and drawing no. Remarks 1 1 Guard, assy Splash guard, assy Star handle Threaded pin Tension sleeve Cup spring Pivot lock, assy item Pivot ring piece Gasket * 13 1 Hollow screw Gasket * 15 1 Ball valve with handle Connection Connection nipple Hose coupling with tensioning screw * * Wear parts to be stored in case of continuous use _Inst_en_Version_03 Page 16 of 34
18 Part and drawing number. Guard with water connection _Inst_en_Version_03 Page 17 of 34
19 Adjustment device Item Qty. Description Part and drawing number Remarks 1 1 Sleeve Intermediate piece Scraper ring H * 4 1 Threaded head glued in place 5 1 Eye bolt Scraper ring H * 7 1 Spring washer Socket head screw Threaded pin glued in place 10 1 Rotary knob Bolt Bushing glued in place 13 1 O-Ring * _Inst_en_Version_03 Page 18 of 34
20 : Adjustment device _Inst_en_Version_03 Page 19 of 34
21 : Adapter for blade, assy Item Qty. Description Part and drawing number Remarks 1 1 Adapter for blade Clamp disc Nut Adapter ring ø22,2 u. 30 mm _Inst_en_Version_03 Page 20 of 34
22 Adapter for blade, assy _Inst_en_Version_03 Page 21 of 34
23 : Adapter for bevelling cutter, assy Item Qty. Description Part and drawing number Remarks 1 1 Adapter for bevelling cutter Feather key Spacer disc for 45 bevelling cutter Spacer disc for 60 bevelling cutter Spacer disc for radius cutter Capstan nut _Inst_en_Version_03 Page 22 of 34
24 : Adapter for bevelling cutter, assy _Inst_en_Version_03 Page 23 of 34
25 : Guide carriage small Item Qty. Description Part and drawing number Remarks 1 1 Carriage Wheel bolt I Wheel bolt II Wheel I * 5 2 Wheel II * 6 2 Hook Nut Ball lock bolt Bushing glued in place * Wear parts to be stored in case of continuous use _Inst_en_Version_03 Page 24 of 34
26 Guide carriage small _Inst_en_Version_03 Page 25 of 34
27 : Chain tensioner small Item Qty. Description Part and drawing number Remarks 1 Chain tensioner Pos Sleeve Eye bolt Scraper H * 4 6 Cup spring O-Ring * 6 1 Threaded head glued in place 7 1 Spring washer Socket head screw Rotary knob Bolt glued in place 11 1 Tensioning chain (21 link) Chain lock Washer * Wear parts to be stored in case of continuous use _Inst_en_Version_03 Page 26 of 34
28 : Chain tensioner small _Inst_en_Version_03 Page 27 of 34
29 : Guide carriage large Item Qty. Description Part and drawing number Remarks 1 1 Carriage Wheel bolt Wheel bolt II Wheel I * 5 2 Wheel II * 6 1 Hook Nut glued in place 8 2 Ball lock bolt Bushing glued in place * Wear parts to be stored in case of continuous use _Inst_en_Version_03 Page 28 of 34
30 Guide carriage large _Inst_en_Version_03 Page 29 of 34
31 Chain tensioner large Item Qty. Description Part and drawing number Remarks 1 1 Rotary sleeve Eye bolt Eye bolt II Screwed lock pin glued in place 5 1 Threaded head Pressure spring Nut Wheel bolt Locking washer Wheel Washer Scraper H * 13 1 Tensioning chain (19 links) *Wear parts to be stored in case of continuous use _Inst_en_Version_03 Page 30 of 34
32 Chain tensioner large _Inst_en_Version_03 Page 31 of 34
33 : Tightener Set Item Qty. Description Part and drawing number Remarks 1 1 Spindle nut Spindle nut Spindle Tensioning segment small Tensioning segment small _Inst_en_Version_03 Page 32 of 34
34 Tightener Set _Inst_en_Version_03 Page 33 of 34
35 Tool Set Item Qty. Description Part and drawing number Remarks 1 Spanner AF Spanner AF Spanner AF Spanner AF Spanner AF Pin spanner _Inst_en_Version_03 Page 34 of 34
36 Translation of the original manual compiled:
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