AU DU PONT DE LUTTRE 74-1190 BRUSSELS BELGIUM PHONE: 322 34 83 162 FAX: 322 34 83 136 OPERATING MANUAL Electric Fully Automatic Floor Saw FS 1218 EX
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Important information before you start! When the machine is delivered, the wheels are locked in a transportation position and all electricity is disconnected. 1. Wheel lock The automatic feeding system is active when the wheel lock (1) is in right position. The wheels are thereby locked and function as trans security lock. To employ manual feeding and unlock the wheels, turn the handle (1) to left position. With the handle turned right, it is impossible to move the machine without electricity. 2. Main electricity fuse The electricity system has a separate main fuse. The machine cannot be used before the main fuse (2) is turned into operating position. Do not operate any electric system before you have carefully read and carried out the electrically instructions at page 5 to 8. 3. Battery and the 12 V main switches All battery cables are disconnected from the battery (4) when you receive the machine from the factory. The 12 V main switch is placed within the saw (3). The cables have to be connected and the main switch must be turned on before the winch and the hydraulic system may be used. NOTE: For your own and others security, please employ the mentioned technical locking systems when You leave the machine at a construction site, The machine is stored and The machine is transported to a new site. 3
1.0 Technical information FS 1218 EX This model has an 18.5 kw electric motor and a blade shaft capacity of 950 rpm. The model is well suited for Diamond blades between Ø 800 mm and Ø 1200 mm. All Diamant Boart floor saw machines are designed for using wet cutting Diamond blades. When ordering Diamond blades, contact your dealer and refer to the technical data listed below. Be sure to use correct type of blades. Incorrect blade may cause bad or non-cutting results. Incorrect use may also result in vibration, damaged parts and overheating of the motor. Do not use diameter of the blade larger than necessary for the actual job situation. We recommend pre-cutting with an Ø 800 mm blade, segments with 5 mm, before using Ø 1000 mm or Ø 1200 mm. Technical data FS 1218 EX Motor output kw/hp 18.5/25 Electricity * * Blade guard Ø 1200 Cutting depth (maximum) mm 510 Blade shaft Rpm 950 Blade flange connection 0/mm Combi 25,4/60 L x W x FT cm 160x81x117 Weight kg 465 * Different electric systems possible see separate machine card and electric form. 4
2.0 Electrical system IMPORTANT! This electric floor saw is available with different electrical systems. Be absolutely sure that you have ordered and received the correct system on your machine. It must correspond with the electrical power supply in your working area. Do not connect any electrical power, touch any buttons or operate any of the electrical systems before you have carefully read and understood all the instructions covered by this operating manual! If you have never operated a similar machine before, please carrying out the test procedures before you start working with the machine. The electrical data will be found on the machine card and electrical diagram. If you have the incorrect electrical system on your machine, take immediate action, and contact your dealer! Do not improvise! Electricity is very dangerous! ELECTRICAL DIAGRAMS. This machine is equipped with electrical systems in accordance with your order and specifications. Wiring diagrams are separately enclosed with the machine. Information about voltage, and document numbers for wiring diagram is placed on the top of the operating panel. Before use, always make sure that this information corresponds with the electrical power supply in the working location. Whenever new diagrams or other electrical service is required, be sure to specify the exact information s on the machine labels as indicated below. 5
3.0 Operating panel The fully automatically machines are basically operated from the operating panel on top of the frame. This manual explains all the buttons, lamp and switches for each technical operation, with references to the illustration below. If you have never operated a similar machine before, or you have moved to a new working area with new supplying electricity, it is essential to carry out the test procedure before connecting any electricity or operate any buttons. The test procedure is explained on the next page. Explanation of the buttons 1. Reversing switch. To choose correct motor running direction. 2. Emergency stop. Push down and all electricity are cut of. 3. Yellow lamp. Is turned on when electricity is connected to the machine. 4. GREEN - Start button main motor. Automatic star/delta start. 5. RED - Stop button main motor. 6. GREEN - Lamp. Is turned on when the main motor are running 7. RED - Lamp. Turns on when main motor are overloaded. 8. GREEN - Start button feeding motor. Automatic star/delta start 9. 9. RED - Stop button feeding motor. 10. GREEN - Lamp. Is turned on when the feeding motor running 11. RED - Lamp. Turns on when feeding motor are overloaded. 12. Lowering hydraulic cylinders. 13. Raising hydraulic cylinders.14. Activating of rear wheel hydraulic cylinder. 15. Connector. Input of electricity. (16. Correct motor running direction.) 6
4.0 Test procedure of the electrical system Bring the machine to a stable position in a clear area. Any person not involved in the test should leave the area nearby the machine. Check before test: That no blade is mounted On the blade shaft. That all covers and guards are mounted on the machine. That the movable frame is lowered to the ground. Step 1. 1. Connect the power supply to the input plug (15) and the yellow lamp (3) will turn on to indicate correct supply of electricity. Be sure to use a safety cable with undamaged plugs. 2. Check that the emergency stop (2) is pulled over to the operating position. 3. Turn the reversing switch (1) to position 1 that indicates that you have chosen an unknown running direction for the motor. (Wrong direction are not important for this test) 4. Push the start button (4) and the main motor start to run in the first step start position. Wait for 6-8 seconds and the system turn automatically over to the second and final start position. The green lamp (6) will now turn on indicating that the motor is working correct. Look and listen to ensure that everything works perfectly. 5. Stop the machine by pushing the stop button (5). Step 2. 6. When the machine has come to a complete stop, turn the reversing switch (1) to position 2 and repeat the start procedure described in item 4 above. The motor running direction shall now be opposite of test 1. 7. When the machine runs smoothly, push down the emergency stop (2). All electricity hall be cut off and the motor will stop. Final step. Correct motor running direction (16) is very important for all further operation of the If you have problems with this test, please call for professional assistance. Do not try to open the electric system. Touching the components inside the electric system is hazardous! 7
5.0 Correct running direction Never start to work with the machine before you have chosen correct running direction. The running control procedure has to be carried out when: - Electricity has been connected to the machine. - The machine has been moved to a new working area with new electrical power supply. The motor and blade shaft must always run forward as arrow (16) illustrated below. Control procedure including all elements of start and stop, must be carried out in accordance with the test procedure at page 7, and carried out without any blade mounting on the blade shaft. Running direction control: Carry out the test procedure step 1 page 7 Observe which way the motor and blade shaft are running. If incorrect direction, continue with step 2. Never change direction when the main motor is running. 5.1 Running direction feeding motor Remark: The forward feeding motor is connected to the main electricity. It is essential that correct main running direction be chosen for the machine. It is impossible to operate the feeding system, with wrong motor direction. The problem often occurs when the motor has been changed, and the wiring has been connected wrong. In case see page 21 for service of the feeding system. 8
6.0 12 volt battery system The fully automatic machines have a 12-v system where the battery and a safety main switch are located inside the frame, and an Ammeter located outside upper rear cover. The battery is fully loaded at delivery. Connect the battery cables to the battery electrodes. Red to minus and black to plus. Turn the safety switch over to the position on and the 12 v systems are ready to be used. Read instructions for the hydraulic systems and wire winch carefully before you start to use any of the 12 V automatic systems. The main switch shall always be turned of during breaks in the work, transportation or storage. 6.1 Battery charger The current electric system inside the operating panel has a battery charger built- in. Whenever electricity is connected to the input plug (15 at page 6) the charger automatically loads the battery. The Ammeter indicates that the charger is in work. Note: When there is no reaction at the Ammeter see page 20. Remember that the battery system is operating the lowering and raising frame, support wheel and wire winch system. Heavy use can empty the battery faster than the charger is loading the battery. In this case it only takes a short brake for extra charging of battery. Long time storage of the machine can also make influence on the battery condition. An overnight charging can be recommended. Note: A battery that is damaged or in bad condition is not indicated by the ammeter. For service and troubleshooting of the battery and battery charger: See page 20 9
7.0 Support wheel This machine has an extra support wheel (1) to eliminate manual lifting of the machine when moving, turning or up lining for correct cutting direction. The wheel is connected to a hydraulic cylinder operated by three buttons (2) at the top panel. 27 Press button 13 and 14 simultaneously to lower the support wheel. When it reaches the floor the rear part of the machine will be lifted up. Moving and turning operations will now go very smoothly. To replace the machine back to operating position, press button 12 and 14 simultaneously and the support wheel will be raised back to the upper position. Always keep this wheel in upper position when not in use to eliminate damage. This is particularly important at situation as loading, unloading and transport of the machine. 10
8.0 Automatic feeding system The machine has an Electric Hydrostatic feeding system offering you fully adjustable speed control forward as well as backwards from the 0-position. The electric motor for this feeding system is wired to the main electricity.the feeding unit is depended on the choice of correct running direction of the machine. (see page 8 and 21) Operating: Place the operating feeding handle (1) in an upright position. This is the non-moving position. Move handle (2) to the right position to connect the feeding gear to the rear wheels. (Remark that the machine some times needs to be manually moved a little bit forward or backward to complete this gear connection). Push the electric start button (4) on the operating panel to activate the Hydrostatic feeding system. Stand on the step-plate (6) behind the machine to put pressure on the rear wheel. Push the operating handle (1) forward or backward for movement. Always deactivate feeding system by pushing the stop button (5) when not in use, and particularly when leaving the machine. 11
9.0 Automatic lowering and raising blade frame. On the push buttons (13 and 14) on operating panel you can chose between lowering and raising movement of the blade frame. This automation is operated by the hydraulic system that can be adjusted for smooth and controlled feeding of the diamond blade, see page 13. If you have never operated a similar machine before, please carry out a test before you start working with this feeding system. Simply push button 13 for upward movement, and button 14 for downwards These switches are the non-locking type, and as soon as you release the button, all movement will stop. If you have operating problems, see page 9 and 20 for the battery/battery charger or page 22 and 23 for the hydraulic system. 12
10.0 Lowering and raising speed control In- and out feeding speed control of the Diamond Blade is very important. The fully automatic machines make you able to adjust individually the lowering and raising speed of the blade frame. Standard settings are normally slow in-feeding speed, and some quicker out-feeding speed see illustration below: The machine is adjusted to standard setting at delivery. Size of blade and different quality of concrete or other materials can make it necessary to adjust the feeding speed somewhat. Adjust the speed by turning one or both of the buttons illustrated below. 13
11.0 Tools The tools are placed in a separate tool holder inside the saw frame: The C-wrench (1) is used to open the out flange (3) when removing the diamond blade from the blade spindle. The standard wrench (2) is used to lock &e spindle when removing the blade flange. This wrench fits to a slot on the spindle between the blade and the right side of the movable frame (4). Please note that the slot is situated in the centre of the movable frame on some models. 12.0 Inner blade flange The blade shaft is designed with an inner blade flange in both ends for mounting Diamond blades with Ø 25, 4 mm and Ø 60 mm centre holes. 1 Inner blade flange 2 Spindel for 0 25,4 mm centre hole 3 Distance washer for 0 60 mm centre hole 4 Screws Diamant Boart delivers the machine adjusted for Ø 60 mm centre hole. If Ø 25,4 mm centre hole is required, simply remove the distance washer (3). 14
13.0 Outer blade flanges The outer blade flanges for mounting the diamond blade to the blade shaft are placed at a flange holder inside the rear door. Remark that the right side flange has left thread, and the left side flange has right thread, these are respectively marked L and R. LOCKING Before mounting the blade be sure, that you have chosen the blade flange with correct thread. Place the blade on the blade shaft and fasten the flange by following the arrows above. UNLOCKING Block the blade shaft with the standard wrench and use the especially C-wrench (1) to unlock the outer blade flange. Observe which side of the blade shaft you are working on to ensure that you are turning the wrench in correct direction, shown by the arrows! Unlocking in wrong direction damage the flange and wrench, as well as the blade shaft. - Never let the blade flange stay mounted on the blade shaft if not engaged in the work. - After use, always place the blade flanges back in the flange holder inside the frame. - Never leave or store the saw with tools or blade flanges mounted to the machine. - Always keep the flange systems lean. Damaged parts must be replaced immediately. 15
14.0 12 volt winch system The 12 V winch system is only to be used for loading, unloading or moving the machine at very uneven ground surfaces. This winch system shall under no circumstances be used to feed the machine when sawing. The winch unit (1) is located in front of the basic frame. The wire rope are passing down through the bottom part and out between the front wheels where the hook (2) is to be found. SAFETY PRECAUTION WINCHING - SPOOLING MOVING PART HAZARD To Prevent Serious Injury And Property Damage: Do not operate winch before you have read and understood the operator s manual. Stand clear of wire rope and bad during operation. Keep others away. Always inspect the condition of the winch and wire rope, before operating winch. Do not exceed winch s rated capacity. Never touch wire rope or hook while in tension. To Prevent Serious Injury: Keep hands clear of wire rope, hook and fairlead opening during operation and when spooling. Always use a rag or cord to hold hook when spooling under no load. Wear heavy leather gloves when handling wire rope. Never winch with less than 5 wraps of wire rope around drum. 16
14.1 Pulling out wire rope manual The clutch knob, located on the winch housing opposite the motor, controls the clutch position. When the clutch is in free spool, the gear train and wire rope drum are uncoupled, allowing the drum to rotate freely for pulling out the wire. To prevent damage, always fully engage or fully disengage the clutch knob. Clutch for free spool WARNING Do not disengage clutch if winch is under load or wire rope is in tension. 14.2 In and out spooling automatic The spooling switch is located on the winch motor. When clutch above is engaged, the gear train is coupled to the wire rope drum, and power may be transferred from the winch motor. When turning the spooling switch to the right or left the motor activates for automatic in- as well as out spooling. Operating problems: Remember that the winch is operated by the 12-v battery system. Long and heavy usage can empty the battery faster than the charger is loading the battery. More information on battery and battery charger see page 9 and 20.
15.0 Maintenance and inspection For the safety of yourself and others, always keep the machine in good condition. Missing and damaged parts have to be replaced or repaired immediately. Never do maintenance the machine while the electricity is connected! It is very important to clean the machine after use because of the thick layer of concrete that will be left on the machine. This layer will keep for a long time, which in turn will cause a corrosive attack. The layer may also prevent the machine from working properly. Cleaning the electric motor is especially important since a layer of concrete reduces the motors air-cooling ability, which may cause overheating, overload and failure. Motor - loss of output The motor has a maximum output limit. In addition to the output required for the sawing, the total output is used for: - Running the motor and the ball bearing friction, -Friction in the V-belts, and -Friction in the shaft bearing. If the V-belt and/or shaft bearings are not properly adjusted, this may cause a significant loss of output left for the sawing. Therefore, keep these parts in good condition and change shaft bearings when it shows signs of wear. Control the V-belts - In the beginning, V-belts must be checked after one day of use, and if necessary tightened properly. - Check the V-belts periodically. Loose V-belts will cause wear and tear, and skidding causes loss of output for the sawing spindle. -If one V-belt breaks, change all of them. Missing V-belts or uneven V-belt sets causes loss of output. - When changing V-belts, make sure that the spindle, pulley and the motor is adjusted perfectly on the centre line. Nonparallel V-belts cause wear and tear on the new V-belts. - 18 -
16.0 12 V Battery, service and troubleshooting If the battery is impossible to recharge: - Check that the power is correct and connected to the input plug 15 page 6. - Check that the battery cables are fully connected to the electrodes. - The ammeter shows that the charger is working, but the battery is impossible to recharge? Check that the battery is not damaged or in bad condition. - The Ammeter does not work? Check that the fuse inside the charger is OK. See instruction below. Temperature, unstable use or long storing is discharging the battery. This influence on the lifetime of the battery, and change to a new and fresh battery can be necessary. When change, remark that the new battery needs to have the electrodes (plus and minus) as illustrated 16.1 Charger - problem shooting The battery charger located inside the main electric panel, have in-built a safety fuse (2) in case of overload or other electric problems. When charging and the Ammeter (3) do not make any reaction is the problem normally located at this fuse. Before you start to check the charger fuse: Un-plug all electricity!! Remove the top cover for operating panel. The battery charger is located at left side frame. The in-built fuse has to be found as illustrated below. Unscrew cap (1) and change the fuse (2) when necessary. - 19 -
17.0 Service automatic feeding system The Electrical Hydrostatic Feeding System is a complete unit based on 3 basic components as electric motor (7), hydrostatic variator (8) and gear (9). When delivered the speed control is set to a correct limit. Do not change this! Service When delivered the hydrostatic unit (8) is filled with oil, tested and prepared to be used directly. Basically this is a locked system prepared for up to 2000 hours usage before an oil change is required. It is however recommended to control the oil level through the inspection glass (10), and refill if necessary. The oil input (11) is located outside frame (12). Change of oil: Remove cap (11). Open drain plug (13) to pour out the old oil. Refill new oil as recommended below. Recommended grade of oil: Esso INVAROL EP 46; 0,5 L 17.1 Trouble shooting Forward feeding do not work? 1. Did you connect the gear connection? (Item 2 page 11) 2. Did you start the feeding motor? (Item 4, page 11) 3. Did you choose correct motor running direction? (Item 16, page 8) 4. Check that main fuse is turned on. (Page 9) 5.Check that the chain between gear and rear wheel is undamaged. If further problem, call for assistance and refer to the information on the technical plate for motor as well as the variator shown at the illustration to the left. - 20 -
18.0 Hydraulic pump system service The 12-v hydraulic pump system is located inside the frame. 1. 12-v motor and pump unit. 2. Valve unit. 3. Oil container 4. Oil refill input 5. Magnetic valve Other parts, see spare part list. Service: Make a regular control of the oil level. IMPORTANT: Before the oil level control move the hydraulic cylinders (B + C) to the bottom position to bring the oil back to the oil container (3): Step 1. Raise the movable sawing frame to the maximum position (See page 13) and cylinder (B) will be at bottom position. Step 2 Raise the rear additional support wheel to the upper position (See page 10) and the cylinder (C) will be at bottom position. Step 3. Step 4. The oil container (3) shall now be about 3/4 filled, shown by arrow (A). If necessary, supply oil to correct level at the oil fill point (4) outside front of the frame. Recommended grade of oil: ESSO Univis N-46 or Shell Tellus T 46 Change of oil. We recommend change of oil at 100 hour working. NOTE: Be sure that both hydraulic cylinders, named above, are placed in bottom position, otherwise you get an oil overflow in the system when start using! 1. Remove the oil reservoir (3). 2. Pour out the old oil and replace the reservoir. 3. Fill in new oil as mentioned above. - 21 -
19.0 Hydraulic troubleshooting If the hydraulic system does not work, carry out the following control: 1. Are the battery cables connected to the battery? 2. Is the main switch for the 12 V systems switched on? 3. Is the battery fresh and recharged? 4. Is the oil level at the 3/4 spot on the oil reservoir? When all above seems to be correct, and it still does no work, the magnetic valve (3) can be out of order or blocked. Cleaning the valve. Step1. Remove part no. (1) and (2) and unscrew the magnetic valve no. (3). For best possible cleaning result we are recommended to use compressed air. Blow inside as well as outside the valve before all parts are replaced. Step 2.. Step 3. If cleaning does not give sufficient result, change the magnetic valve. If nothing above helps, you my have an electrical wiring problem, or some technical problem with the hydraulic unit. Call for assistance. - 22 -
20.0 Aluminium guide rails The aluminium guide rails are additional equipment and very suitable to used at all our Electric Floor Saws. The rails are very handy to be used to level up uneven floor surfaces for easier sawing, as well as moving the machine on difficult working areas, sandy ground e. g. For the fully automatic machines adapted with wire winch the rails are very suitable to be used for loading and unloading the machine. - Read and understand all instructions for using the winch, Page 16 and item 17 - Any person not involved in the work should leave the area nearby the machine. - When loading and unloading, do not stand or walk behind the machine, always have position beside of the machine. - 23 -
21.0 Noise level The drawing shows typical average values of noise level in Leq (db) measured in various directions at a distance of 1-2 m. The measurements are taken under normal, typical operation with standard tools (blade) in normal concrete. Please be aware that variations in tools (blade diameter) and other properties, the compositions of the material to be sawed, and the size and surfaces of work area, and surrounding, all affect the noise level. 22.0 Check before starting The working area must be completely cleared, well lit and all safety hazards removed. The operator must wear clothing appropriate to the work he/she is doing. The use of ear protection is mandatory. Any person not involved in the work should leave the working area. - 24 -