TYROLIT Hydrostress AU User manual

Operating Instructions
Spare parts list
10988314 en / 13.10.10
AU Drive Unit
Index 004

Operating Instructions
10988314 en / 13.10.10
Manufacturer's address:
TYROLIT Hydrostress AG
Witzbergstrasse 18
CH-8330 Pfäffikon
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 © 2009 TYROLIT Hydrostress AG, CH-8330 Pfäffikon ZH
All rights reserved, in particular the copying and translation rights.
The reprinting of these Operating Instructions, includingextracts, is prohib-
ited. No part of these Operating Instructions may be reproduced in any
form whatsoever or be processed, copied or distributed using electronic
systems without the written permission of TYROLIT Hydrostress AG.

Operating Instructions Overview
AU / 004 I (II)
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
1 Product description 1
1.1 Application - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1
1.2 Safety measures - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1
1.3 Operating instructions for connectable equipment- - - - - - - 1
1.4 Name plate - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1
1.5 EC declaration of conformity - - - - - - - - - - - - - - - - - - - - - - 2
1.6 Technical data - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3
1.7 Hydraulics - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4
1.8 Electrical system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5
1.9 Noise exposure (noise level)- - - - - - - - - - - - - - - - - - - - - - 6
1.10 Scope of supply- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6
2 Safety instructions 1
2.1 General- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1
2.2 General safety rules- - - - - - - - - - - - - - - - - - - - - - - - - - - - 1
2.3 Safety principles - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2
2.4 Responsibility - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3
2.5 Generally applicable warnings of residual dangers - - - - - - 5
3 Design and function 1
3.1 General- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1
3.2 Design AU Drive Unit - - - - - - - - - - - - - - - - - - - - - - - - - - - 2
3.3 Function - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4
4 Operating elements and displays 1
4.1 Controls - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1
4.2 Displays - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2
5Operation 1
5.1 Personnel qualifications - - - - - - - - - - - - - - - - - - - - - - - - - 1
5.2 System requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - 1
5.3 Connectable pressing tools- - - - - - - - - - - - - - - - - - - - - - - 1
5.4 Preparatory operations- - - - - - - - - - - - - - - - - - - - - - - - - - 2
5.5 Procedure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5
6 Servicing 1
6.1 Servicing and maintenance table- - - - - - - - - - - - - - - - - - - 1
7 Corrective maintenance 1
7.1 Troubleshooting- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1
7.2 Storage- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2

Overview Operating Instructions
II (II) AU / 004
8 Transport 1
8.1 Transport- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1
8.2 Safety instructions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1
8.3 Crane shackles and transport handles - - - - - - - - - - - - - - - 2
9 Disposal 1
9.1 General - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1
9.2 Disposal regulations - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2
9.3 Disposal- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2

Operating Instructions Introduction
AU / 004 0-1
0 Introduction
0.1 Congratulations!
You have decided to purchase a tried and tested TYROLIT
Hydrostress AG system and have thus acquired a highly sophisticated and
reliable state-of-the-art unit.
Thanks to the emphasis we place on quality assurance, your TYROLIT
Hydrostress AG system is another top-of-the-range Swiss product:
• High performance
• Reliable operation
• High portability
• Easy handling
• Low maintenance costs
Only original TYROLIT Hydrostress AG spare parts can guarantee quality
and interchangeability.
In the case of neglected or inappropriate maintenance, we will be unable
to accept the warranty commitment as specified in our terms of delivery.
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
further information.
We hope that working with your TYROLIT Hydrostress AG system will be
a problem-free and fault-free experience.
TYROLIT Hydrostress AG
Management
Copyright © TYROLIT Hydrostress AG, May 2009
TYROLIT Hydrostress AG
Witzbergstrasse 18
CH-8330 Pfäffikon
Switzerland
Phone +41 (0) 44 / 952 18 18
Fax +41 (0) 44 / 952 18 00

Introduction Operating Instructions
0-2 AU / 004
0.2 Validity of these Operating Instructions
This manual is only valid for the following system:
AU drive unit
0.3 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.
0.4 Delimitation of the system
These Operating Instructions describe the use of the AU drive unit.

Operating Instructions Product description
AU / 004 1-1
1 Product description
1.1 Application
The AU drive unit has been designed as a component for concrete
pressing systems:
The applicable mandatory limitations on use and other parameters are
contained in Chapter 1 "Technical data" 1.6, 1-3
1.2 Safety measures
Any use other than for the intended purpose (see Chapter 1.1, 1-1)
constitutes abuse or misuse.
1.3 Operating instructions for connectable
equipment
In order to ensure safety in the workplace and in danger areas, as well as
the safe operation of connectable equipment, the relevant Operating
Instructions must in all cases be followed.
1.4 Name plate
Fig. 1-1 Name plate

P r od u c t d e s c r i p t i o n
O p e r a t i n g l n s t r u c t i o n s
1 . 5 E C d e c l a r a t i o n o f c o n f o r m i t y
D e s c r i p t i o n
T y p e d e s i gna t i o n
H y d r au l i c d r i v e u n i t
A U d r i v e u n i t
W e d e c l a r e u n de r o u r o w n l i ab i l i t y t h a t t h i s p ro d u c t c o m p l i e s w i t h t h e
f o ll o w i n g d i r e c t i v e s a n d s t a nd a r d s :
1 . 5 . 0 . 1 D i r e c t i v e a p p l i e d :
2 0 0 6 / 4 2 / E G
2 0 1 4 / 30 / E U
2 0 1 2 / 1 9 / E U
1 . 5 . 0 . 2 S t a nd a r ds a pp li e d :
E N 1 2 10 0 : 2 0 1 0
E N 6 0 20 4 - 1 : 20 0 6
E N I S O 4 4 1 3 : 20 10
T Y R O LI T H y d r o s t r e s s A G
W i tz b e r g s t r a ss e 1 8
CH - 8 3 3 0 P fä ff i k o n
S w i tz e r l a n d
P fä ff i k on , 1 5 . 1 2 . 2 0 2 1
R o l a n d K ä g i
O p e r a t i o n s + R & D M a c h i n e s
1 - 2
A U / 0 0 4

Operating Instructions Product description
AU / 004 1-3
1.6 Technical data
1.6.1 Dimensions
Fig. 1-2 Measurements in mm
1.6.2 Weight
Operating weight 95 kg
1.6.3 Tyres
Wheel Ø 42 cm
Operating pressure 3 bar
758
420
514
966
543
228

Product description Operating Instructions
1-4 AU / 004
1.7 Hydraulics
1.7.1 Hyrdaulic circuits
3 closed circuits
- High pressure circuit max. 2,000 bar
- Pressure booster circuit max. 80 bar
- Low pressure circuit max.150 bar
1.7.2 Flow rates and pressure
30 l/h 2,000 bar
1.7.3 Connection options
With high-pressure 4-way distributor 4 pressing-tools
With special accessory max. 8
1.7.4 Press force
max. 2,000 bar
1.7.5 Radial piston pump
Primary outlet 14.4 l/min, 80 bar
Secondary outlet 2.4 l/min, 150 bar
1.7.6 Oil tank
Oil tank volume: 13 litres
Filter quality: 25 µm
1.7.7 Return oil filter
Type: Filter screen
1.7.8 Oil quality
TYROLIT Hydrostress AG recommends:
Hydraulic oil: HLP/ISO VG 46

Operating Instructions Product description
AU / 004 1-5
1.8 Electrical system
1.8.1 Motor
Electric motor Air cooled
Power supply 3P / PE 380-420V / 50Hz
Current consumption 10 A at maximum load
3 x 200 V 50 Hz / 60 Hz
3 x 230 V 50 Hz
3 x 400 V 50 Hz
3 x 460 V 60 Hz
Output 2.2 kW
Speed at 50 Hz 2,850 rpm
at 60 Hz 3,480 rpm
1.8.1.1 Motor protection
Electrical protection Thermal relay
1.8.1.2 Cooling
Air cooling
1.8.1.3 Protection class
IP 44
Information
Electrical data are only valid for the installed loads
3 P / LNPE 400 VAC / 50 Hz
Warning
A danger will arise if the AU drive unit is operated with a different
mains network voltage.
The details on the name plate must correspond to the mains
network values (voltage and frequency).
Damage may be caused to the unit if it is connected to a different
voltage; there is also a risk of fire and personal injury.

Product description Operating Instructions
1-6 AU / 004
1.9 Noise exposure (noise level)
Depending on the working environment and the connected device, the
AU drive unit can produce high noise levels during operation.
1.9.0.1 Noise level measurement
Noise level measured at the ear of the operator 0.5 m from the AU drive
unit; noise power level according to ISO 3744; drive unit only; highest value
taken from all operating states at full load; mean values from three series
of measurements.
Noise level 83 dB (A) noise power level 92 dB (A)
1.10 Scope of supply
• AU drive unit
• Operating Instructions / Spare parts list
Danger
Noise danger
When operating the AU drive unit, the wearing of hearing
protection is mandatory at all times.
If this instruction is not followed irreparable hearing damage may
result.

Operating Instructions Safety instructions
AU / 004 2-1
2 Safety instructions
2.1 General
All persons who work on and with the AU drive unit have a duty to read and
understand the operating instructions.
2.1.1 Observance of the safety instructions
The AU drive unit has been inspected before being shipped and is
delivered in perfect condition. TYROLIT Hydrostress AG does not accept
any liability for damage caused by the failure to observe the instructions
and information provided in the operating instructions. This applies in
particular to:
• Damage caused by improper use and operator error.
• Damage caused by failure to observe safety-related information in the
operating instructions or shown on the warning signs attached to the
machine.
• Damage caused by defective or neglected maintenance work.
Independently performed conversions and alterations may affect safety
and are not permitted.
2.2 General safety rules
2.2.1 Statutory provisions
The generally applicable national and local safety and accident prevention
provisions and the supplementary operator regulations must be followed
and complied with.
2.2.2 Inspection and maintenance obligation
The operator is under an obligation to use the AU drive unit only when it is
in a perfect and undamaged condition. The maintenance intervals shown
in the Operating Instructions must be adhered to without fail. Malfunctions
and mechanical damage must be rectified without delay.
2.2.3 Spare parts
Only TYROLIT Hydrostress AG original spare parts may be used.
Otherwise, damage can be caused to the AU drive unit or other property
and may result in personal injury.
2.2.4 Power connections
The AU drive unit must be connected and coupled in accordance with the
operating instructions.

Safety instructions Operating Instructions
2-2 AU / 004
2.3 Safety principles
2.3.1 Delimitation of the safety concept
The AU drive unit does not affect the safety concept of the connected
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.
2.3.3 Removal of protective devices
Protective devices may only be removed if the unit has been switched off,
disconnected from the mains and is at standstill. Safety components, in
particular, may only be removed and refitted by authorised personnel, see
"Chapter 2" 2.4.1, 2-3.
Before switching the AU drive unit back on again, the safety elements must
be checked to ensure correct operation.
2.3.4 Safety measures (organisational)
2.3.4.1 Product monitoring obligation
Operating personnel must notify changes in operational behaviour or
safety-related components to a responsible person or the manufacturer,
immediately.
2.3.4.2 Location of the Operating Instructions
A copy of the Operating Instructions must be available to staff at all times
at the place of use of the equipment.

Operating Instructions Safety instructions
AU / 004 2-3
2.4 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
precise functional role.
The personnel qualifications for the corresponding work are contained in
the introduction under "General" of the respective chapters.
2.4.2 Manufacturer
TYROLIT Hydrostress AG or a company expressly nominated by
TYROLIT 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 from the operator information about the products.
2.4.3 Operator
The operator named by TYROLIT Hydrostress AG is the primary, legal
entity responsible for the designated correct use of the product and for the
training and assignment of the authorised personnel. Theoperator sets out
the mandatory skills and level of training of the authorised personnel for his
company.
2.4.4 Operator (user)
User is the term employed by TYROLIT Hydrostress AG to designate a
person who independently performs the following work:
• Sets up TYROLIT Hydrostress AG machines or systems for tasks
according 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.
2.4.5 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.

Safety instructions Operating Instructions
2-4 AU / 004
2.4.6 Qualification and training
2.4.6.1 Operator
• A technically trained person in a management position.
• Has relevant experience in personnel management and danger
assessment.
• Has read and understood the "Safety instructions" chapter.
2.4.6.2 Operator (user)
• Have trained as a concrete cutting expert or have professional
experience.
• Has received an introduction (basic training) to the operation of the
TYROLIT Hydrostress AG machines and systems from a service
engineer.
• Have read and understood Chapter 2 “Safety instructions”.
2.4.6.3 Service engineers
• Has specialist professional training (mechanical / electrotechnical).
• Has attended specialist courses at TYROLIT Hydrostress AG.
• Has read and understood the "Safety instructions" chapter.

Operating Instructions Safety instructions
AU / 004 2-5
2.5 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.
Failure to comply with this regulation may lead to serious physical
injury or death. Secondary damage such as fires may also occur.
Warning
Danger of allergic reactions if skin comes into contact with
hydraulic oil.
Persons who have an allergic reaction to hydraulic oil must wear
protective gloves and goggles when carrying out work where they
come into contact with hydraulic oil. Any areas of the skin affected
must be rinsed immediately with copious amounts of water.
Failure to observe this regulation may result in allergic reactions or
injury to the eyes.

Safety instructions Operating Instructions
2-6 AU / 004

Operating Instructions Design and function
AU / 004 3-1
3 Design and function
3.1 General
The AU drive unit is assembled from other TYROLIT components to form
a complete pressing system.
3.1.1 System components
Fig. 3-1 System components
1 Drive unit 4 Pressing tool
2 High-pressure hose 5 Pressing plate
3 Low-pressure hose
Warning
Danger from incorrect system components.
The AU drive unit should only be operated with original TYROLIT
Hydrostress AG- system components.
Failureto adhereto thisregulationmay resultinphysicalinjuryand
damage to property.
1
2
3
4
5

Design and function Operating Instructions
3-2 AU / 004
3.2 Design AU drive unit
3.2.1 Components
Fig. 3-2 Components
1 Pressure booster 10 Vent connection
2 Return connection (screw connection) 11 Oil tank
3 High-pressure connection (screw connection)12 Wheel
4 Low pressure gauge 13 Oil level indication
5 Control valve 14 Electrical box
6 High pressure gauge 15 Electric motor
7 Oil filler neck 16 Chassis
8 Mains cable
9Grip
1
6
7
3
8
4
9
10
12
13
14
15 16
2
5
11