Professional Documents
Culture Documents
A S SE MB L Y S EQ U E N C E S A N D
START-UP INSTR UCTIONS
FOR TH E
EVA CUATION AREA
V RI -6 -27 -0 4- 30 -3 0- 06
V RC-1 -2 7-0 4 -19 -1 9- 27
CCS -L -3- 6-1 5 -23 -0 28
CCP -1 -6 -15 -1 0- 24 -0 29
DB R-0 2 9-2 4 -3- 15 -L -E
V RL -6- 27 -0 4- 42 -4 2-1 1
TEC- 09 4- 31 0- 06 -2 -R
PR C-0 93 -0 94 -0 6-2 -B
V RE -03 -0 4- 26 -2 6- 34
PW I- 16 8- 09 4- 00 -C-1 8 1
PR C-0 90 -0 94 -0 6-2 -B
PR C-0 90 -0 94 -0 6-2 -B
rev.
date
description
compiled
checked
approved
00
April, 2006
First Issue
MUM
MUM
UMAC
SERVICE
MUM Department
INDEX
1.0 - ASSEMBLY SEQUENCES FOR THE EVACUATION AREA 1
1.1 - INTERMEDIATE ROLLER TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.2 - CUTTING ROLLER TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.3 - CROPS END COLLECTING CAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.4 - SAMPLES COLLECTING CAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.5 - NOSE AND TAIL DEBURRING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.6 - DISCHARGE ROLLER TABLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.7 - BLOOMS ELEVATOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.8 - PAWL COLLECTING PLATE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.9 - TRANSPORT ROLLER TABLE (W.B. AREA). . . . . . . . . . . . . . . . . . . . . . . 15
1.10 - WALKING BEAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.11 - PAWL COLLECTING PLATE (W.B.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1.12 - PAWL COLLECTING PLATE (SLOW COOL) . . . . . . . . . . . . . . . . . . . . . 21
2.0 - CONNECTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2.1 - SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2.2 - ELECTRICAL CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
April, 2006
P. 1
Of 2
April, 2006
P. 2
Of 2
SEC. 1.0
April, 2006
P. 1
Of 22
Pos.
1.1 intermediate
roller table
Type: VRI-6-27-04-30-30-06
Component/Unit
01
Metal structure
02
03
04
05
06
Motor unit
07
1) Metal stucture
Sling properly the cross member and put it on the foundations by means of a
suitable lifting device. Check verticality and flatness of the cross member and, if
necessary, insert some shimming plates according to the elevation values as per
drawing.
Carry out the final fastening to the foundations.
Make sure that the tie rods are properly tightened by means of a suitable
dynamometric wrench; for the tightening values see the data on the drawings
and/or the values in DANIELI standard n. 2.4.603.
Carry out the operations described above for each cross member.
2) Roller supporting frame
Sling properly the first length of the roller table and place it on the first two cross
members, previously fastened, by means of a suitable lifting device.
Sling the second length of the roller table, made up of a series of rollers and of
the pressure roller system, and place it on the other two cross beams by means
of a suitable lifting device.
Check the longitudinal alignment and the correct installation of the two crop ends
of the roller table; check verticality and flatness of the roller table and the roller
tangent level (this value is indicated in the CCM assembly drawing).
Carry out the final fastening on the rest cross members.
Make sure that the bolts are properly tightened by means of a suitable
dynamometric wrench; for the tightening values see the data on the drawings
and/or the values in DANIELI standard n. 2.4.603.
Carry out the operations described above for each casting line.
3) Movable roller sliding guides
Sling properly the roller supports and the movable roller sliding guides and place
them on the previously fastened frame by means of a proper lifting device.
Check the correct installation, the longitudinal alignment and the roller tangent
level.
Check the roller table verticality and flatness and carry out the final fastening to
the rest cross members .
April, 2006
P. 2
Of 22
SEC. 1.0
SEC. 1.0
Make sure that the bolts are properly tightened by means of a suitable
dynamometric wrench; for the tightening values see the data on the drawings
and/or the values in DANIELI standard n. 2.4.603.
Carry out the operations described above for each casting line.
4) Movable car and car moving cylinder
Sling the previously assembled movable car, place it into its seat with a suitable
lifting device and make sure that it is perfectly centered.
Sling the car moving cylinder and put it into the relevant rest seat with a suitable
lifting device.
Carry out the final fastening.
Make sure that the bolts are properly tightened by means of a suitable
dynamometric wrench; for the tightening values see the data on the drawings
and/or the values in DANIELI standard n. 2.4.603.
5) Pressure unit moving cylinder
Sling properly the cylinder and place it on the relevant rest seat by means of a
suitable lifting device. Stretch the cylinder and check its position.
At the end of the check, fasten the pressure unit cylinder according to the
tightening values in DANIELI standard n. 2.4.603.
Place the signalling limit switch and make sure that it is installed in the correct
way; moreover, make sure that the cylinder is properly connected to the hydraulic
system.
Note: before installing the roller table on the structure, preassemble the cylinder
on it if the yard conditions allow this operation.
6) Motor unit
Check the correct assembly of the roller rotation unit (motor and reduction gear); this
check must be carried out on the ground.
Place and install the rotation unit in the settled position according to the
instructions of the Manufacturers documentation enclosed with this manual.
Note: before installing the roller table on the structure, preassemble the gear
motor on it if the yard conditions allow this operation.
7) Systems on the machine
Connect the following systems to the intermediate roller table:
motor electric feeding;
cooling system;
hydraulic system;
pneumatic system;
lubrication system.
For all systems, see the instructions in the Manufacturers documentation.
April, 2006
P. 3
Of 22
1.2 - cutting
roller table
Pos.
Type: VRC1-27-04-19-19-27
Component/Unit
01
Metal structure
02
Disk roller support and positioning of the movable roller sliding guides
03
04
Shaped roller
05
Motor unit
06
07
1) Metal structure
Sling properly the supporting frame and put it on the foundations by means of a
suitable lifting device. Check its verticality and flatness and, if necessary, insert
some shimming plates.
Carry out the final fastening to the foundations.
Make sure that the tie rods are properly tightened by means of a suitable
dynamometric wrench; for the tightening values see the data on the drawings
and/or the values in DANIELI standard n. 2.4.603.
2)
April, 2006
P. 4
Of 22
SEC. 1.0
SEC. 1.0
4) Shaped roller
Usually it is already assembled on the movable car; at any rate, it must be
preassembled on the car before the car is installed.
Sling the shaped roller and put it into the relevant seat by means of a suitable
lifting device.
Carry out the same operations for each shaped roller.
5) Motor unit
Check the correct assembly of the roller rotation unit (motor and reduction gear); this
check must be carried out on the ground.
Place and install the rotation unit in the settled position according to the
instructions of the Manufacturers documentation enclosed with this manual.
Make sure that the bolts are properly tightened by means of a suitable
dynamometric wrench; for the tightening values see the data on the drawings
and/or the values in DANIELI standard n. 2.4.603.
6) Guards and safety devices
Install the required guards and safety devices on each cutting roller table as
shown in the relevant assembly drawings.
7) Systems on the machine
Connect the following systems to the cutting roller table:
motor electrical feeding;
cooling system;
hydraulic system
lubrication system.
For all systems, see the instructions in the Manufacturers documentation.
April, 2006
P. 5
Of 22
Pos.
1.3 - crops
end collecting
car
Type: CCS-L-3-6-15-23-028
Component/Unit
01
Sliding rails
02
03
04
1) Sliding rails
Install the rails on the foundations according to the procedures in the manual
Installation general rules - NGI" and to the sequence indicated in the
Manufacturers documentation.
Before tightening the locking devices and carrying out the aligning operations,
make sure that the required elevation values are respected (if necessary, use
some shims).
2) Capstan unit and driving tightener
Assemble all the parts of the capstan unit (if not already assembled).
Position the capstan unit and the driving tightener and fasten them to the
foundations according to the Manufacturers documentation enclosed with this
manual.
Make sure that the bolts are properly tightened by means of a suitable
dynamometric wrench; for the tightening values see the data on the drawings
and/or the values in DANIELI standard n. 2.4.603.
3) Crops end collecting car
Sling properly the crop end collecting car, already assembled with all its parts, and
place it on the previously fastened sliding rails by means of a suitable lifting
device.
Install the rope on the capstan unit and connect it to the car and to the tightener
by means of the proper clamps and thimble.
4) Crop end collecting boxes
Sling properly the crop end collecting box by means of the eyebolts and place it
on the car with a suitable lifting device; pay attention to the box centering with
respect to the car .
Check that the bumpers are working in the correct way.
Carry out the operations described above for each box.
April, 2006
P. 6
Of 22
SEC. 1.0
1.4 - samples
collecting car
Pos.
Type: CCP-1-6-15-10-24-029
Component/Unit
01
Sliding rails
02
03
1) Sliding rails
Install the rails on the foundations according to the procedures in the manual
Installation general rules - NGI" and to the sequence indicated in the
Manufacturers documentation.
Before tightening the locking devices and carrying out the aligning operations,
make sure that the required elevation values are respected (if necessary, use
some shims).
2) Capstan unit and driving tightener
Assemble all the parts of the capstan unit (if not already assembled).
Position the capstan unit and the driving tightener and fasten them to the
foundations according to the Manufacturers documentation enclosed with this
manual.
Make sure that the bolts are properly tightened by means of a suitable
dynamometric wrench; for the tightening values see the data on the drawings
and/or the values in DANIELI standard n. 2.4.603.
3) Crops end collecting car
Sling properly the crop end collecting car, already assembled with all its parts, and
place it on the previously fastened sliding rails by means of a suitable lifting
device.
Install the rope on the capstan unit and connect it to the car and to the tightener
by means of the proper clamps and thimble.
April, 2006
P. 7
Of 22
SEC. 1.0
Pos.
Type: DBR-029-24-3-15-L-E
Component/Unit
01
02
03
Tail blade
04
April, 2006
P. 8
Of 22
SEC. 1.0
Pos.
1.6 discharge
roller table
Type: VRL-6-27-04-42-42-11
Component/Unit
01
Frame supports
02
Supporting frame
03
Rollers
04
Motor unit
05
06
1) Frame supports
Sling one support at a time and put them into the relevant seats with a proper
lifting device. Check the frame verticality and flatness; if necessary, insert some
shimming plates.
Check the machine longitudinal alignment with respect to the central line and
carry out the final fastening to the foundations.
Make sure that the tie rods are properly tightened by means of a suitable
dynamometric wrench; for the tightening values see the data on the drawings
and/or the values in DANIELI standard n. 2.4.603.
2) Steel structure support for shaped rollers
Sling the beams in the correct way and put them on the previously fastened
supports by means of a proper lifting device. Check their verticality and flatness
and, if necessary, introduce some shimming plates.
Carry out the final fastening to the foundations.
Make sure that the tie rods are properly tightened by means of a suitable
dynamometric wrench; for the tightening values see the data on the drawings
and/or the values in DANIELI standard n. 2.4.603.
Carry out the operations described above for each beam.
3) Rollers
Sling the roller with support in the correct way and put it into the relevant seat with
a proper lifting device.
Carry out the same operations for each roller.
4) Motor unit
Check the correct assembly of the roller rotation unit (motor and reduction gear); this
check must be carried out on the ground.
Place and install the rotation unit in the settled position according to the
instructions of the Manufacturers documentation enclosed with this manual.
Check the correct tightening of the bolts by means of a proper dynamometric
wrench; for the tightening values see the data on the drawings and/or the values
in DANIELI standard n. 2.4.603.
April, 2006
P. 9
Of 22
SEC. 1.0
SEC. 1.0
April, 2006
P. 10
Of 22
1.7 - blooms
elevator
Pos.
Type: TEC-094-310-06-2-R
Component/Unit
01
Metal structure
02
03
Chain wheels
04
05
Trolley
06
Motor unit
1) Metal stucture
Sling properly the cross member and put it on the foundations by means of a
suitable lifting device. Check verticality and flatness of the cross member and, if
necessary, insert some shimming plates according to the elevation values as per
drawing.
Carry out the final fastening to the foundations.
Make sure that the tie rods are properly tightened by means of a suitable
dynamometric wrench; for the tightening values see the data on the drawings
and/or the values in DANIELI standard n. 2.4.603.
Carry out the operations described above for each cross member.
2) Supports for chain wheels
Sling properly the supports and place them on the previously fastened frame by
means of a proper lifting device.
Check the correct installation, the longitudinal alignment and the wheels tangent
level.
Check the wheels verticality and flatness and carry out the final fastening to the
rest cross members .
Make sure that the bolts are properly tightened by means of a suitable
dynamometric wrench; for the tightening values see the data on the drawings
and/or the values in DANIELI standard n. 2.4.603.
3) Roller
Usually it is already assembled; at any rate, it must be preassembled before the
car is installed.
Sling the shaft and put it into the relevant seat by means of a suitable lifting
device.
Carry out the same operations for each shaft.
4) Chain and chain adjuster
Install (if not already installed) the chain adjuster on the frame.
Assemble all the parts of the chain and connect it between them.
Verify the correct working of the chain adjuster. Lubricate it if necessary.
Make sure that the bolts are properly tightened by means of a suitable
dynamometric wrench; for the tightening values see the data on the drawings
and/or the values in DANIELI standard n. 2.4.603.
April, 2006
P. 11
Of 22
SEC. 1.0
SEC. 1.0
5) Trolley
Assemble one trolley per time and install them on the relative seats with a proper
lifting system. Make sure that the guiding wheels are perfectly aligned inside the
sliding guides. Check the horizontal alignment between the trolleys and connect
them to the chains.
Make sure that the bolts are properly tightened by means of a suitable
dynamometric wrench; for the tightening values see the data on the drawings
and/or the values in DANIELI standard n. 2.4.603.
6) Motor unit
Check the correct assembly of the roller rotation unit (motor and reduction gear); this
check must be carried out on the ground.
Place and install the rotation unit in the settled position according to the
instructions of the Manufacturers documentation enclosed with this manual.
Check the correct tightening of the bolts by means of a proper dynamometric
wrench; for the tightening values see the data on the drawings and/or the values
in DANIELI standard n. 2.4.603.
April, 2006
P. 12
Of 22
Pos.
1.8 - pawl
collecting
plate
Type: PRC-093-094-06-2-B
Component/Unit
01
Supporting frame
02
03
04
05
06
1) Supporting frame
Sling the whole frame and put it on the foundation plates with a proper lifting
device.
Check the verticality and flatness of each frame and, if necessary, insert some
shimming plates. Carry out the final fastening.
Make sure that the tie rods are properly tightened by means of a suitable
dynamometric wrench; for the tightening values see the data on the drawings
and/or the values in DANIELI standard n. 2.4.603.
2) Pawl moving cylinder
Sling properly the cylinder and put it into the relevant seat with a suitable lifting
device.
Carry out the final fastening.
Make sure that the tie rods are properly tightened by means of a suitable
dynamometric wrench; for the tightening values see the data on the drawings
and/or the values in DANIELI standard n. 2.4.603.
3) Support for shaft with levers
Sling properly the support and put it on the frame with a suitable lifting device.
Check the verticality and flatness of each support and, if necessary, insert some
shimming plates. Carry out the final fastening.
Sling the shaft with levers and put it on the previously positioned supports.
Check the verticality and flatness of each support and, if necessary, insert some
shimming plates. Carry out the final fastening.
Make sure that the tie rods are properly tightened by means of a suitable
dynamometric wrench; for the tightening values see the data on the drawings
and/or the values in DANIELI standard n. 2.4.603.
4) Pawl supporting frame
Assemble the whole frame according to the relevant installation drawings.
Position and fasten the billet translation pawl and the billet sliding blocks on the
previously assembled frame.
Sling them and put them into the relevant seat with a proper lifting device.
Carry out the final fastening of the whole frame and the relevant devices.
April, 2006
P. 13
Of 22
SEC. 1.0
SEC. 1.0
Make sure that the tie rods are properly tightened by means of a suitable
dynamometric wrench; for the tightening values see the data on the drawings
and/or the values in DANIELI standard n. 2.4.603.
Connect the lever bottom part with the moving cylinder and the top part with the
car, to the relevant locking pins, as shown in the relevant installation drawings.
5) Guards and safety devices
Install the required guards and safety devices, as shown in the relevant assembly
drawings.
6) Systems on the machine
Connect the following systems to the pawl collecting table of each casting line:
hydraulic system;
lubrication system.
For all systems, see the instructions in the Manufacturers documentation.
April, 2006
P. 14
Of 22
1.9 - transport
roller table
(w.b. area)
Pos.
Component/Unit
01
Frame supports
02
Supporting frame
03
Rollers
04
Motor unit
05
06
1) Frame supports
Sling one support at a time and put them into the relevant seats with a proper
lifting device. Check the frame verticality and flatness; if necessary, insert some
shimming plates.
Check the machine longitudinal alignment with respect to the central line and
carry out the final fastening to the foundations.
Make sure that the tie rods are properly tightened by means of a suitable
dynamometric wrench; for the tightening values see the data on the drawings
and/or the values in DANIELI standard n. 2.4.603.
2) Steel structure support for shaped rollers
Sling the beams in the correct way and put them on the previously fastened
supports by means of a proper lifting device. Check their verticality and flatness
and, if necessary, introduce some shimming plates.
Carry out the final fastening to the foundations.
Make sure that the tie rods are properly tightened by means of a suitable
dynamometric wrench; for the tightening values see the data on the drawings
and/or the values in DANIELI standard n. 2.4.603.
Carry out the operations described above for each beam.
3) Rollers
Sling the roller with support in the correct way and put it into the relevant seat with
a proper lifting device.
Carry out the same operations for each roller.
4) Motor unit
Check the correct assembly of the roller rotation unit (motor and reduction gear); this
check must be carried out on the ground.
Place and install the rotation unit in the settled position according to the
instructions of the Manufacturers documentation enclosed with this manual.
Check the correct tightening of the bolts by means of a proper dynamometric
wrench; for the tightening values see the data on the drawings and/or the values
in DANIELI standard n. 2.4.603.
April, 2006
P. 15
Of 22
SEC. 1.0
SEC. 1.0
April, 2006
P. 16
Of 22
1.10 - walking
beam
Pos.
Type: PWI-168-094-00-C-181
Component/Unit
01
02
03
Fixed frame
04
Movable frame
05
Translation cylinder
06
07
08
09
April, 2006
P. 17
Of 22
SEC. 1.0
SEC. 1.0
4) Movable frame
Sling the movable frame previously assembled with each one of its details, and
put it on the relevant supports with a proper lifting device. Check the frame
verticality and flatness and, if necessary, insert some shimming plates according
to the values in the drawings.
Carry out the final fastening of the whole structure.
Make sure that the tie rods are properly tightened by means of a suitable
dynamometric wrench; for the tightening values see the data on the drawings
and/or the values in DANIELI standard n. 2.4.603.
5) Translation cylinder
Sling properly the cylinder and put it on the relevant rest seat with a proper lifting
device. Stretch the cylinder and check its correct position.
At the end of the check, fasten the cylinder.
Make sure that the tie rods are properly tightened by means of a suitable
dynamometric wrench; for the tightening values see the data on the drawings
and/or the values in DANIELI standard n. 2.4.603.
6)
Before installing the shaped blades, pay attention to devide correctly the blades for
fixed frame from the movable frame ones; this division is carried out according to
the different toothing of both blades.
Sling properly one shaped blade and put it on the frame small blocks. For
fastening the blades see the locked points and the dilatation ones, then fasten the
blade on the frames. Make sure that the tie rods are properly tightened by means
of a suitable dynamometric wrench; for the tightening values see the data on the
drawings and/or the values in DANIELI standard n. 2.4.603.
Carry out the same operations for each blade of the fixed frame.
7) Movable frame blades
Sling properly one shaped blade and put it on the frame small blocks. For
fastening the blades see the locked points and the dilatation ones, then fasten the
blade on the frames. Make sure that the tie rods are properly tightened by means
of a suitable dynamometric wrench; for the tightening values see the data on the
drawings and/or the values in DANIELI standard n. 2.4.603.
Carry out the same operations for each blade of the movable frame.
8) Guards and safety devices
Install the required guards and safety devices as shown in the relevant assembly
drawings.
9) Systems on the machine
Connect the following systems of the walking beam:
equipments electrical feeding;
hydraulic system;
lubrication system.
For all systems, see the instructions in the Manufacturers documentation.
April, 2006
P. 18
Of 22
Pos.
1.11 - pawl
collecting
plate (w.b.)
Type: PRC-090-094-06-2-B
Component/Unit
01
Supporting frame
02
03
04
05
06
1) Supporting frame
Sling the whole frame and put it on the foundation plates with a proper lifting
device.
Check the verticality and flatness of each frame and, if necessary, insert some
shimming plates. Carry out the final fastening.
Make sure that the tie rods are properly tightened by means of a suitable
dynamometric wrench; for the tightening values see the data on the drawings
and/or the values in DANIELI standard n. 2.4.603.
2) Pawl moving cylinder
Sling properly the cylinder and put it into the relevant seat with a suitable lifting
device.
Carry out the final fastening.
Make sure that the tie rods are properly tightened by means of a suitable
dynamometric wrench; for the tightening values see the data on the drawings
and/or the values in DANIELI standard n. 2.4.603.
3) Support for shaft with levers
Sling properly the support and put it on the frame with a suitable lifting device.
Check the verticality and flatness of each support and, if necessary, insert some
shimming plates. Carry out the final fastening.
Sling the shaft with levers and put it on the previously positioned supports.
Check the verticality and flatness of each support and, if necessary, insert some
shimming plates. Carry out the final fastening.
Make sure that the tie rods are properly tightened by means of a suitable
dynamometric wrench; for the tightening values see the data on the drawings
and/or the values in DANIELI standard n. 2.4.603.
4) Pawl supporting frame
Assemble the whole frame according to the relevant installation drawings.
Position and fasten the billet translation pawl and the billet sliding blocks on the
previously assembled frame.
Sling them and put them into the relevant seat with a proper lifting device.
Carry out the final fastening of the whole frame and the relevant devices.
April, 2006
P. 19
Of 22
SEC. 1.0
SEC. 1.0
Make sure that the tie rods are properly tightened by means of a suitable
dynamometric wrench; for the tightening values see the data on the drawings
and/or the values in DANIELI standard n. 2.4.603.
Connect the lever bottom part with the moving cylinder and the top part with the
car, to the relevant locking pins, as shown in the relevant installation drawings.
5) Guards and safety devices
Install the required guards and safety devices, as shown in the relevant assembly
drawings.
6) Systems on the machine
Connect the following systems to the pawl collecting table of each casting line:
hydraulic system;
lubrication system.
For all systems, see the instructions in the Manufacturers documentation.
April, 2006
P. 20
Of 22
Pos.
Type: PRC-090-094-06-2-B
1.12 - pawl
collecting
plate (slow
cool)
Component/Unit
01
Supporting frame
02
03
04
05
06
1) Supporting frame
Sling the whole frame and put it on the foundation plates with a proper lifting
device.
Check the verticality and flatness of each frame and, if necessary, insert some
shimming plates. Carry out the final fastening.
Make sure that the tie rods are properly tightened by means of a suitable
dynamometric wrench; for the tightening values see the data on the drawings
and/or the values in DANIELI standard n. 2.4.603.
2) Pawl moving cylinder
Sling properly the cylinder and put it into the relevant seat with a suitable lifting
device.
Carry out the final fastening.
Make sure that the tie rods are properly tightened by means of a suitable
dynamometric wrench; for the tightening values see the data on the drawings
and/or the values in DANIELI standard n. 2.4.603.
3) Support for shaft with levers
Sling properly the support and put it on the frame with a suitable lifting device.
Check the verticality and flatness of each support and, if necessary, insert some
shimming plates. Carry out the final fastening.
Sling the shaft with levers and put it on the previously positioned supports.
Check the verticality and flatness of each support and, if necessary, insert some
shimming plates. Carry out the final fastening.
Make sure that the tie rods are properly tightened by means of a suitable
dynamometric wrench; for the tightening values see the data on the drawings
and/or the values in DANIELI standard n. 2.4.603.
4) Pawl supporting frame
Assemble the whole frame according to the relevant installation drawings.
Position and fasten the billet translation pawl and the billet sliding blocks on the
previously assembled frame.
Sling them and put them into the relevant seat with a proper lifting device.
Carry out the final fastening of the whole frame and the relevant devices.
April, 2006
P. 21
Of 22
SEC. 1.0
SEC. 1.0
Make sure that the tie rods are properly tightened by means of a suitable
dynamometric wrench; for the tightening values see the data on the drawings
and/or the values in DANIELI standard n. 2.4.603.
Connect the lever bottom part with the moving cylinder and the top part with the
car, to the relevant locking pins, as shown in the relevant installation drawings.
5) Guards and safety devices
Install the required guards and safety devices, as shown in the relevant assembly
drawings.
6) Systems on the machine
Connect the following systems to the pawl collecting table of each casting line:
hydraulic system;
lubrication system.
For all systems, see the instructions in the Manufacturers documentation.
April, 2006
P. 22
Of 22
2.0 - CONNECTIONS
At the end of the machine assembly, connect carefully the users placed on these
machines to the relevant power mains and carry out all the preliminary checks
and the necessary adjustments and calibrations.
2.1 - systems
2.1 - SYSTEMS
The systems must be connected to the relevant power mains in accordance with
the instructions on the relative drawings indicated at the end of this instruction
manual.
Besides these instructions, see the relevant specification annexed to this
documentation.
The distribution pipes (except the flexible ones) on the machine can be easily
recognized according to their colour and to any applied mark (if not otherwise
indicated in the drawings, see DANIELI standard n. 2.1.001).
1)
2)
3)
4)
2.2 - electrical
connections
Before starting any operation, make sure that the involved sections for user feeding
are without voltage (the earthing knife switch is open).
Before the electrical connections, carry out the grounded connection of the machine
structure.
Make sure that the voltage and frequency values of the supply mains of the
equipment installed on the machine correspond to those indicated on the rating
plates of the electrical components.
a) Electric motor
At the end of the installation in the foundations, make sure that the earthing
of the motor casing has been carried out, by connecting the relevant
conductor (colour: yellow/green) to the terminal clamp.
Make sure that the motor feeding is in accordance with the data on the rating
plates. The feeding cables must be suitable to the rated current and to the
plant conditions (for example: ambient temperature, kind of cable installation,
etc...). Connect the feeding cables according to the instructions on the
diagram of the terminal board.
April, 2006
2.0 - CONNECTIONS
P. 1
Of 2
SEC. 2.0
Before carrying out the operations described below, the operators shall be perfectly
aware of the safety rules in force in the country and in the plant.
Check the correct inner connection of the windings according to the feeding
voltage values; if necessary, change them according to the diagram on the
terminal board.
Connect and tighten the feeding terminals to the relevant terminal clamps of
the terminal board: refer to the documentation and the marks applied on each
conductor. If not otherwise indicated, the following tightening torques refer to
the normal closure of the locking screws and nuts for electrical connections.
SEC. 2.0
Tightening torques
(in nm with tolerance of +/- 10% foir dimensions of the threads
Diameter
M4
M5
M6
M8
M10
M12
M16
M20
Torque N/m
1.2
2.5
4.0
8.0
13
20
40
80
April, 2006
2.0 - CONNECTIONS
P. 2
Of 2
Note: for the oil levels, for the correct preparation of the device and for further
checks, see the Manufacturers documentation enclosed with this manual.
When changing the oil, always use the previously used type. Never mix different oil
types; above all, do not mix synthetic oils with mineral ones or with other synthetic
oils. If mineral oil has to be changed with a synthetic one or vice versa, wash
thoroughly the toothed gearing with a suitble detergent.
Certain sizes of the reduction gear - see the Manufacturers technical documentation
- require the bearing lubrication. During the further lubrication, do not mix greases
with different soap bases. Grease is put inside the bearing by means of a pressure
greaser through the proper greaser union. For the type and quantity of lubricant
refer to the relevant lubrication table in the manual "Lubrication tables collection"
and/or to the Manufacturers documentation.
b)
Electric motor
Before carrying out the following operations, make sure that the reduction gear is
properly lubricated
If necessary, carry out the following checks after disconnecting the motor/
reduction gear from the machine driven by it.
make sure that all the foundation bolts are properly tightened;
make the motor rotate by hand and make sure that it rotates freely and with
no interferences;
make sure that the windings are earthed (by means of the tester-Megger);
April, 2006
P. 1
Of 11
SEC. 3.0
with the motor in the no-load operation mode, connect the required feeding
voltage and:
check the motor operation: sense of rotation;
make sure that there are no overheated parts, otherwise check the
windings and make sure that the terminals are properly tightened:
make sure that there are no vibrations or anomalous noise, otherwise
check the bearing conditions;
connect the motor to the relevant machine, by aligning and locking the
coupling according to the Manufacturers instructions.
Note: for further checks, refer to the Manufacturers documentation enclosed with
this manual.
SEC. 3.0
Certain sizes of the reduction gear - see the Manufacturers technical documentation
- require the bearing lubrication. During the further lubrication, do not mix greases
with different soap bases. Grease is put inside the bearing by means of a pressure
greaser through the proper greaser union. For the type and quantity of lubricant
refer to the relevant lubrication table in the manual "Lubrication tables collection"
and/or to the Manufacturers documentation.
c) Grease lubrication system
Centralized lubrication
Check the correct operation of the drive and control instruments, including
the alarm devices;
make sure that the filter on the pump is properly installed and clean;
fill the tank with the type and quantity of grease indicated in the relevant
lubrication table;
fill the pipings up to the various users as follows:
disconnect the ends of each line length with the various users;
select the manual operation of the electrical equipment and start the pump,
thus making the lubrication system work for some complete cycles until the
compact and even grease comes out of the opposite ends;
connect the ends of each line length to the relevant users;
pre-set the grease flow rate for each lubrication point from the feeder adjusting
turret.
The feeder flow rate depends on the standstill and the working time set on the timer
of the pump unit.
The quantity of reinstatement grease in the " Lubrication Table" is indicated in cm3/h;
lubricate the users. Pump the correct quantity of grease; remove the
exceeding grease and clean.
Note: Each feeder is provided with two outlets; if only one outlet is used, it is necessary
either to install a connecting bridge between them or to replace the closing plug on the
front side (depending on the kind of feeder); in this way, the flow rate at the feeder outlet
doubles (for further information, see the Manufacturers documentation).
When pumping the lubricant, carry out the following checks:
make sure that the feeders work properly, by checking the movement of the
small rod inside the turret;
make sure that all the points of the grease lubrication system, in particular the
farthest ones, are properly lubricated. If necessary, adjust the flow rate by
means of the relevant turret required for each outlet on each feeder;
April, 2006
P. 2
Of 11
make sure that there are no leaks in the feeding circuits, in particular on the
connections. If necessary, drain the air from the circuit by means of the
proper pressure switch bleeds.
Note: For further information about the motor pump and the relevant
instrumentation, see the Manufacturers documentation.
Manual lubrication
The lubrication of the components that require greasers is carried out by means
of a manual or wheeled pump provided with a proper quick coupling.
For the type and quantity of grease to be used for each component and/or device,
see the relevant lubrication table and/or the technical documentation of the
component Manufacturer.
SEC. 3.0
April, 2006
P. 3
Of 11
Start the machine, operating in the manual mode from the local control desk.
April, 2006
3.3.1 intermediate
roller table
P. 4
Of 11
SEC. 3.0
Make the no load tests complying strictly with the safety rules.
3.3.3 - samples
collecting car
SEC. 3.0
April, 2006
P. 5
Of 11
3.3.6 - discharge
roller table
April, 2006
SEC. 3.0
P. 6
Of 11
3.3.7 - blooms
elevator
April, 2006
3.3.8 - pawl
collecting
plate
P. 7
Of 11
SEC. 3.0
3.3.10 - walking
beam
SEC. 3.0
April, 2006
P. 8
Of 11
3.3.11 - pawl
collecting plate (w.b.)
April, 2006
SEC. 3.0
3.3.12 - pawl
collecting plate (slow
cool)
P. 9
Of 11
SEC. 3.0
Verify before to install the flexible hoses that they are complete free without
any restriction or clogged internal hoses.
Verify the presence of leakages at the maximum water and hydraulic pressure.
Check the hydraulic cylinders moviment without unusually noise and friction.
Verify the properly stroke.
Sequence checks from main pulpit and MMI.
Set the time for forward/backword hydraulic cylinders.
Verify the complete cycle time without load.
Verify the complet cycle time with load.
April, 2006
P. 10
Of 11
April, 2006
SEC. 3.0
P. 11
Of 11
8.322138.G
Cooling system
8.322134.V
Guards
8.322133.R
8.322132.T/A03
8.322131.S
8.322129.F/A07
Drive unit
8.322129.F/A06
Drive unit
8.322128.E
8.322127.W
8.322126.V/A01
Photocells installation
8.322125.R/A01
Roller group
8.322123.S/A03
8.322118.C/A01
8.322112.W
8.322111.V/A01
Roller group
8.317430.D
8.317400.P/A02
8.317398.Q/A02
8.317392.B/A02
Basement group
8.317389.P/A02
8.277861.Q
Wheel assembly
8.277719.S
8.120067.F
Hydraulic system
8.120050.H/A02
Lever group
April, 2006
SEC. 4.0
To consult the drawings listed below, refer to the ones already in your possession.
P. 1
Of 7
8.120047.B/A03
8.089486.Z
Cooled support
8.089454.F/A08
Rotating joint
8.089454.F/A03
Rotating joint
6.146972.R
Devices location
6.062913.P
8.342610.Z
8.120816.T/A06
Capstain group
6.146984.Q
Devices location
6.062873.X
8.120163.C/A06
Capstain group
6.146985.H
Devices location
SEC. 4.0
Cooling system
8.342598.H
8.342594.E
Control flap
8.342589.Q
Guards
8.342588.P
8.342587.F
8.342586.E
8.333017.W
Hydraulic system
8.333016.V
Movable stop
8.322132.T/A04
8.322129.F
Drive unit
8.322125.R/A02
Roller group
8.322125.R/A01
Roller group
April, 2006
P. 2
Of 7
8.322123.S/A04
8.322111.V/A02
Roller group
8.317430.D
8.277861.Q
Wheel assembly
8.089486.Z
Cooled support
8.089454.F/A03
Rotating joint
6.146978.A
Devices location
8.342606.S
Deburring installation
8.342605.Z
Deburring installation
8.342602.V
Cooling system
8.342601.R
8.342600.F/A04
Drive unit
8.342600.F/A03
Drive unit
8.342596.G
Deburring installation
8.342593.D
Deburring group
8.304391.M
Support
6.146982.N
6.146981.M
Devices location
Guards
8.342631.H
Cooling system
8.342630.V
8.342629.X
8.342628.W
8.342626.M
Hydraulic system
8.342625.L
8.342594.E
8.333017.W
Hydraulic system
April, 2006
SEC. 4.0
P. 3
Of 7
8.333016.V
Movable stop
8.322129.F/A11
Drive unit
8.322111.V/A02
Roller group
8.106881.T
Mechanical connection
8.089454.F/A03
Rotating joint
6.146994.K
Devices location
Billets elevator
8.325902.B
Cooling system
8.325901.A
8.325900.M
Guards
8.325893.S
8.325892.Z
8.325891.X
Chain assembly
8.325890.B
Billet elevator
8.325882.W/A03
Trolley assembly
8.325882.W/A02
Trolley assembly
8.325882.W/A01
Trolley assembly
8.325881.V
6.155234.Z
6.155233.X
Devices location
Cooling system
8.342638.Z
Hydraulic system
8.342634.M
8.342623.H
8.342619.V
8.122277.C
Support
6.146989.V
6.146988.R
Devices location
April, 2006
SEC. 4.0
P. 4
Of 7
8.342646.Z
8.342641.T
Cooling system
8.342640.E
8.342639.S/A01
Roller group
8.342637.Q
8.322129.F/A05
Drive unit
8.317405.G/A04
Photocell group
8.317392.B/A03
Basement group
8.261001.M
Fixed stop
8.161343.L
Support
8.089486.Z
Support
8.089454.F/A02
Rotating joint
6.146990.T
Devices location
Walking beam
8.325732.F
Guards
8.325730.H
Walking beam
8.325676.P
Hydraulic system
8.325665.L
8.146980.A
Limit switches
8.146967.G
Limit switches
8.122201.F
8.097517.Q
Encoder group
6.147394.S
Motion diagram
6.147392.X
Devices location
April, 2006
SEC. 4.0
8.342653.X
P. 5
Of 7
Photocells group
8.342657.R/A01
Photocells group
8.342655.S
Photocells installation
8.342649.B
8.342648.A
Collecting plate
8.342638.Z
Hydraulic system
8.342634.M
8.122277.C
Support
6.146999.X
6.146998.W
Devices location
8.342658.C
8.342657.R/A03
Photocells group
8.342652.W
Cooling system
8.342649.B
8.342642.R
Collecting plate
8.342638.Z
Hydraulic system
8.342634.M
8.122277.C
Support
6.170878.H
Devices location
6.170877.A
April, 2006
SEC. 4.0
8.342659.D
P. 6
Of 7
4.2 - technical
components
SEC. 4.0
The catalogues concerning the main components and units supplied by DANIELI
& C., but manufactured by third parties, that require assistance and/or repair
during machine operation and maintenance, are collected in alphabetical order as
explained in the "Components Catalogues Collection - CCC" in volume 1,
position 0 of the same collection.
April, 2006
P. 7
Of 7