Post on 29-Nov-2015
Service Manual
FRIATEC Aktiengesellschaft
Technical Plastics Division
Steinzeugstraße 50
D-68229 Mannheim
Tel +49 621 486 0
Phone +49 621 486 1837 oder 2030
Service-Hotline +49 621 486 1533
www.friatools.de
info-friatools@friatec.de
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FRIATOOLS® Scraper Tools
- Confidential -
Edition 2, 03.01.2013 - CONFIDENTIAL Revision 00
Register
1 Introduction
2 FWSG 63
3 FWSG 225/315
4 FWSG 630/710
5 FWSGS
6 FWSGA
7 FWSG SE
8 FWSG RA
9 Spare Parts
10 Miscellaneous
1 Introduction
Ausgabe 2, 07.02.2012 Revision 00 1-1
1 Introduction
1.1 Information about this Service Manual
Validity
This service manual is valid for scraper tools as indicated in chapter 1.3
Content that relates only to individual types of devices are marked accordingly.
Applicable documents
• operating manuals of the scraper tools and mechanical tools (current revision status to be
found on the homepage FRIATEC / FRIATOOLS under downloads)
• testing instructions TQ5090
Target group
This service manual is exclusively for service technicians who are authorized by FRIATEC.
Requirement for an authorization is a specific training performed by FRIATEC, which the
service technician must have completed successfully.
Use
This service manual contains the following information to the scraper tools and mechanical
tools:
• brief descriptions of the components
• maintenance and repairs
• final testing
• parts ordering information
Representation of elements in this service manual
Symbol Meaning
Prerequisite for the execution of an action.
Instructions consisting of an action step..
1.
2.
Instructions consisting of multiple action steps. The sequence of steps
must be followed.
Tab. 1: Representation of elements in this service manual
1 Introduction
Ausgabe 2, 07.02.2012 Revision 00 1-2
Meaning of the warnings and symbols
Symbol Meaning
DANGER indicates a hazardous situation, which, if not avoided, will
result in death or serious injury.
WARNING indicates a hazardous situation, which, if not avoided,
could result in death or serious injury.
CAUTION indicates a hazardous situation, which, if not avoided,
may result in minor or moderate injury.
NOTICE indicates a property damage message.
INFOMRMATION indicates application tips and other useful
information.
Tab. 2: Meaning of the warnings and symbols in this service manual
1.2 General safety hints
Risk of injury at the blade!
When replacing the blade or working in the area of the blade beware of risk of injury through the cutting
edge.
Crushing!
Risk of injury from moving parts.
1 Introduction
Ausgabe 2, 07.02.2012 Revision 00 1-2
1.3 General tool description and tool types
FRIATEC AG scraper tools are used for the removal of the oxidic layer which builds up during storage on the surface of HD-PE pipes (HD-PE = high density polyethylene) and PE-X pipes (PE-X = chemically crosslinked polyethylene).
The removal of this surface is an imperative measure in preparing for fault free fusion. Incomplete removal of the oxidic layer may lead to a leaky connection.
Observe nominal chip thickness and wear limit!
The size of the annular gap between pipe and fitting is vital for the quality of the
electrofusion. The smaller the annular gap, the better the conditions are for a successful
fusion. Therefore, removal of oxidic layer should – depending on the type of scraper tool –
not exceed the indicated wear limit and be somewhere within the nominal chip thickness.
Type Order-
No.
Application Dimensions
FWSG 63 613305 Scraper tool for tube end processing d 20 to 63 mm
FWSG 225 613311 Scraper tool for tube end processing d 75 to 225 mm
FWSG 63/225 613316 Scraper tool set for tube end
processing d 20 to 225 mm
FWSG 315 no longer available
Scraper tool for tube end processing d 75 to 315 mm
FWSG 630 L
no longer available
Scraper tool for scraping the entire
coupler length for slide-on couplers
and for scraping half the coupler
length for simple fusions.
d 250 to 630 mm
FWSG 630 S no longer available
Scraper tool for scraping half the
coupler length for simple fusions and
for scraping of nozzle fittings.
d 250 to 630 mm
FWSG 710 L 613642
Scraper tool for scraping the entire
coupler length for slide-on couplers
and for scraping half the coupler
length for simple fusions.
d 250 to 710 mm
FWSG 710 S 613639
Scraper tool for scraping half the
coupler length for simple fusions and
for scraping of nozzle fittings.
d 250 to 710 mm
1 Introduction
Ausgabe 2, 07.02.2012 Revision 00 1-3
Type Order-
No.
Application Dimensions
FWSG 800/900 L no longer available
Scraper tool for scraping the entire coupler length for slide-on couplers and for scraping half the coupler length for simple fusions.
IMPORTANT! If a FWSG 800/900 scraper tool arrives at a service station. The service stations have to send the scraper tool to Friatec Mannheim to make the service and maintenance.
d 250 to 800/900 mm
FWSG XL 613645
Scraper tool for scraping of large pipes.
IMPORTANT! If a FWSG XL scraper tool arrives at a service station. The service stations have to send the scraper tool to Friatec Mannheim to make the service and maintenance.
d 800 to 1200 mm
FWSGS 110 no longer available
Scraper tool for saddle parts d 50 to 110 mm
FWSGS 180 no longer available
Scraper tool for saddle parts d 110 to 180 mm
FWSGS 225 no longer available
Scraper tool for saddle parts d 180 to 225 mm
FWSGA no longer available
Scraper tool for outlets and pipe ends d 32 to 63 mm
FWSG SE 613562–613571
Dimension-bound scraper tool for pipe
ends and saddle parts d 63 to 315 mm
FWSG RA 613580-613583
Dimension-bound compact scraper
tool for pipe ends and outlets. d 32 to 63 mm
Tab. 3: Specification of the scarping tool types
Please refer to the appropriate chapters for specific service, repair and inspection steps.
1 Introduction
Ausgabe 2, 07.02.2012 Revision 00 1-4
1.4 Warranty
Devices/Parts Warranty time
New devices. 12 months
Devices from the second-hand shop No warranty
Spare parts, installed at the service. 6 months
Blades and parts which prematurely wear
because of multiple use and external influences (sand, soil etc.). In
addition, parts that have been damaged intentionally or through
negligence
No warranty
Tab. 4: Warranty times
1.5 Legal Notice
The confidential information contained in this service manual are property of the FRIATEC
AG. Any reproduction, disclosure, publication or unauthorized use of this service manual
and/or of its contents are expressly prohibited without the written agreement of FRIATEC.
FRIATEC has endeavored to the best of our knowledge and conscience, to reflect the
information contained in dies manual correctly. However, no guarantee on the reliability or
accuracy of this information is given, FRIATEC assumes no responsibility or any liability for the
accuracy or suitability of the information or for any errors or omissions. If you experience any
problems using this service manual, please contact FRIATEC directly.
Technical modifications reserved.
2 FWSG 63
Ausgabe 2, 07.02.2012 Revision 00 2-5
2 FWSG 63
2.1 Maintenance guidelines FWSG 63
Visual inspection:
unit number
contamination
completeness
mechanical damage
If the scraper tool does not present any noticeable problems start by inspecting the mechanics
and wear parts.
Guide rollers:
Do the rollers run smoothly? Is knurling clearly visible and tangible? Is the bearing bushing worn? If the rollers are too worn and the interaction between roller and axis cannot be corrected using the shim ring, these must be replaced (see replacement of guide rollers).
Rollers:
The rollers must run smoothly. If there is considerable mechanical damage or corrosion they must be replaced (see replacement of rollers).
Spindle inspection:
For this the machine is completely extended. This should be possible without applying much force and to the extent where it can be clamped onto a 63mm pipe. If there is resistance, the spindle must be taken out and cleaned, and replaced if necessary (see replacement of spindle).
Adjustable head:
Is it possible to loosen the clamping handle? If so, it should be easy to move the adjustable head to and from the dimension setting. If adjustment is not possible this can be corrected later when setting the carriage.
2 FWSG 63
Ausgabe 2, 07.02.2012 Revision 00 2-6
Fig. 1: Adjustment of the infeed
Blade holder:
It should be possible to push the blade holder into the housing and for it to extend again automatically. It is necessary to move the blade holder backwards and forwards whilst pushing in order to determine whether it is worn. If it gives too easily it must be replaced. If the blade holder is stuck in the housing the blade holder must be taken apart and cleaned. With mechanical damage, the faulty parts must be replaced.
2 FWSG 63
Ausgabe 2, 07.02.2012 Revision 00 2-7
Scrape result:
The length of the scraped surface area must be determined and the chip thickness measured. If the measurements are within the tolerance range, no adjustment will be necessary. Otherwise an adjustment or blade replacement must take place. NB: If it is not possible to turn screws in the adjustable head because they have been secured with too much adhesive, please do not apply force. The adhesive will need to be heated using a hot-air blower in order to loosen the screws.
Contamination:
Generally, scraper tools need to be cleaned at each service. It is particularly important to ensure that the moveable parts are able to move smoothly and that the knurls in the guide rollers are free from deposits. Contaminated or clogged guide rollers have a negative effect on handling and often lead to a poor scrape result (typical thread). Therefore the guide rollers should be cleaned using a wire brush, and axes as well as moveable parts should be cleaned using the FRIATEC maintenance spray.
Completeness/damage:
Missing and mechanically damaged parts must be replaced.
Final inspection:
On completion of the service each scraper tool must undergo a final inspection according to test plan (TQ5090) by the operator and released if the result is positive.
2.2 Individual repair measures FWSG 63
2.2.1 Replacement of FWSG 63 blade holder
Replacement is necessary when the blade is worn or suspension is no longer guaranteed. 1
st step
Remove the blade.
INFORMATION
2 FWSG 63
Ausgabe 2, 07.02.2012 Revision 00 2-8
2nd
step
Loosen both screws on flange of blade holder and remove blade holder.
3rd
step
Clean the drilled area.
4
th step
Also remove the blade from the new blade holder and insert into the tool. It must be aligned in such a way that the blade can be mounted from the front..
2.2.2 Replacement of FWSG 63 star handle
Replacement due to mechanical damage.
1st
step
Extend the scraper tool completely.
2
nd step
Remove the split pin using a split pin drift.
3
rd step
Remove the star handle, using a plastic hammer if necessary.
INFORMATION
2 FWSG 63
Ausgabe 2, 07.02.2012 Revision 00 2-9
4th
step
Rotate aluminium sleeve of tools by a quarter of a rotation and insert new handle. Prepare tapping (graining) and drill a through hole using a 3mm drill.
5th
step
Remove star handle (it is recommended to mark the place for reinsertion) and remove drill chips from scraper tool.
6th
step
Insert star handle and drive in split pin.
2.2.3 Replacement of FWSG 63 handhold
Replacement necessary if there is mechanical damage.
1
st step
Knock out split pin using split pin drift and and remove handhold.
2
nd step
Also remove handhold support if necessary. For this the screw on the inside needs to be loosened.
3
rd step
Attach new handhold and drive in split pin. It is advisable to pull out the eye of the handhold very slightly using an implement, e.g. a thin split pin drift, in order to achieve an improved alignment of the bore holes when driving in split pin.
INFORMATION
2 FWSG 63
Ausgabe 2, 07.02.2012 Revision 00 2-10
2.2.4 Replacement of FWSG 63 clamping handle
Replacement is necessary if there is mechanical damage.
1
st step
Lift clamping handle, loosen the screw using a screwdriver or allen key and take off handle.
2
nd step
Turn new handle a little by hand, then lift and tighten. If required, the flat washer with the disc spring may be replaced.
2.2.5 Replacement of guide rollers with FWSG 63 axis
Replacement is necessary if worn or knurling is worn
For this you have to dismantle the shift head.
Extend the scraper tool completely before you start your work.
1
st step
The shift head will have to be dismantled for this procedure. Extend the scraper tool completely before starting the work.
INFORMATION
INFORMATION
2 FWSG 63
Ausgabe 2, 07.02.2012 Revision 00 2-11
2nd
step
Loosen retaining ring using external circlip gripper and take out guide rollers including axis. If axis does not come out easily it will have to be knocked out. Please hold on to any shim rings obtained during dismounting.
3
rd step
Before the new axis is inserted the bore hole in the shift head must be cleaned. For this we recommend using a reamer.
4th
step
Reassemble the tool in reverse order. When assembling the shift head do not forget the shim rings and make sure the retaining ring is engaged correctly. It must be possible to rotate the guide rollers easily without too much play. Use rings provided to compensate any imbalances.
2 FWSG 63
Ausgabe 2, 07.02.2012 Revision 00 2-12
2.2.6 Replacement of FWSG 63 rollers
Replacement is necessary if these are worn or mechanically damaged.
1
st step
Remove retaining ring and take off roller with shim rings. .
2
nd step
Sollte sich die Achse von Hand nicht entnehmen lassen, muss diese mit einem Splintentreiber ausgeschlagen werden.
3
rd step
Clean the bore hole using a reamer.
4
th step
Now knock in the axis central. Assembling of the flat washer run rolls, flat washer retaining ring on one axes side. (Attention! Due to stability reasons you have to mount the wider run roll on the side from the blade). 5
th step
Give a slight hit (axial) with the plastic hammer on the mounted side of the axis.The run roll must then be turnable only heavily. 6
th step
Assembling of the second axis side flat washer – run roll – flat washer - retaining ring. Now give a slight hit with the plastic hammer on the last mounted side. The rolls must be easily turnable without major play. If neccessary take up a compensation.
INFORMATION
2 FWSG 63
Ausgabe 2, 07.02.2012 Revision 00 2-13
2.2.1 Replacement of FWSG 63 thread spindle
Replacement is necessary if it is worn, slow moving or mechanically damaged.
1
st step
Knock cylinder bolt out from lower part of tool.
2
nd step
Drive out split pin at star handle and remove handle.
3
rd step
Loosen thread pin from the side.
4
th step
Knock out thread spindle from lower part.
5
th step
Remove aluminium sleeve including thread spindle and brass sleeve and clean. If there is mechanical damage, the relevant parts must be replaced.
INFORMATION
2 FWSG 63
Ausgabe 2, 07.02.2012 Revision 00 2-14
6th
step
It is possible now to clean the guide rod running parallel and to check it for any damage.
7th
step
When reassembling the spindle, its thread should be lightly greased. If the counterbore at the brass sleeve is squashed towards the positioning, it must be countersunk again using a drill (3.1mm) to ensure that the thread pin on the side protects the sleeve. To finish off, mount lower part and star handle.
2.2.2 Dismounting FWSG 63 blade holder
Replacement is necessary if there is mechanical damage or they are worn.
1
st step
Hook blade holder into vice ensuring the flange bears down flange. Carefully strike out brass bush including fastener using a plastic hammer.
2nd
step
Attach blade holder on reversed flange, press a little bit together and loosen grub screw. NB: Blade holder is under clip pressure. Slowly give in to pressure, otherwise there is a danger of parts of the blade holder scattering uncontrollably.
2.3
Illustration shows blade holder for FWSG 63 when dismantled. The blade holders of the other tools vary only in component size.
INFORMATION
2 FWSG 63
Ausgabe 2, 07.02.2012 Revision 00 2-15
2.4 Test report final inspection FWSG 63
Once assembly is complete, it is necessary to check mobility of telescope axis, sliding
clamp carriage, clamping roller, knife block, blade holder and spindle.
All tools must undergo a visual check.
It is necessary to carry out scraping tests using every scraper tool, for the following pipe
dimensions:
40 mm and 63 mm for FWSG 63
General features :
tools complete (unit number)
settings complete and legible
attach one green sticker „FWSGE4“ to base plate behind feed blocking device
attach one sticker „FRIATEC Logo“ to base plate above handhold
Functional tests:
mobility and fit
of telescope leverage across the entire extension length (by turning star handle)
of blade suspension
of all rollers
adjustability of feed depending on pipe diameter
scraper tests
clamping
clamp tool onto pipe using 1.5 Nm torque
apply scraper 5-10 mm from cutting edge
scraping 100% inspection
avoid pulling and pushing pressure in axial direction
scrape 15 rotations
2 FWSG 63
Ausgabe 2, 07.02.2012 Revision 00 2-16
ensure consistent scraping result
pipe max. min.
d63 PE100 42 mm 26 mm
d40 PE100 42 mm 26 mm
analysis
chip thickness : 0.15 mm – 0.25 mm
surface
complete and consistent scraping result
The scraper tests also serve for the adjustment of the scraper tool.
Table of nominal swarf thickness
Type of scraper tool nominal chip thickness (mm) wear limit (mm)
FWSG 63 0.15 - 0.25 0,3
Tab. 5: Nominal swarf thickness FWSG 63 The chip removal must be consistent, i.e. the oxidic layer in the pipe area to be fused must
be scraped completely.
Chip thickness must be checked using a slide guage and recorded in a test report.
For reporting the test plans contained in the manual must be used.
3 FWSG 225/315
Ausgabe 2, 07.02.2012 Revision 00 3-17
3 FWSG 225/315
3.1 Maintenance guidelines FWSG 225/315
Visual inspection:
unit number
contamination
completeness
mechanical damage
If the scraper tool does not present any noticeable problems start by inspecting the mechanics and wear parts.
Telescopic axis:
This must work smoothly, and above all it must be possible to extend the telescope completely. If this is not the case, this may be due to excessive contamination or mechanical damage (see replacement of telescopic axes and guiding pipe).
Rollers/housing:
Do the rollers run smoothly? Are the knurlings clearly visible and tangible? Is the bearing bushing worn? If the rollers are too worn and interaction between roller and axis cannot be corrected using the shim ring, these must be replaced (see replacement of guide rollers).
Rollers/end plate:
Are the rolls smooth running? Are the knurlings clearly visible and tangible? Is the bearing bush worn? If the rollers are too much worn out and interaction between roller and axis cannot be corrected using the shim ring, these must be replaced (see replacement of guide rollers/end plate).
Slide-on sleeve/blade block:
Does the blade block sit tightly on the slide-on sleeve? If necessary, this must be re-glued. It must be possible to move the slide-on sleeve easily to its end position by turning the handle. If this is difficult, the slide-on sleeve must be dismantled and checked for wear and tear or damage (see replacement of slide-on sleeve).
Drive:
The drive as well as the threaded spindle which are both situated inside the handle, must move easily by turning back and forth inside the slide-on sleeve. If this is not the case, or if the slide-on sleeve is faulty, the spindle must be replaced. The handle must be checked for wear and tear, i.e. the handle in the aluminium support sleeve must not present too much movement (see replacement of drive).
3 FWSG 225/315
Ausgabe 2, 07.02.2012 Revision 00 3-18
Blade holder:
It must be possible to push the blade holder into the housing and for it to extend automatically. Whilst pushing, the blade holder must be moved back and forth to determine whether it is worn. If there is too much play, the blade holder must be replaced. If the blade holder is stuck in the housing, it must be taken apart and cleaned. If there is mechanical damage, the faulty parts must be replaced (see replacement of blade holder).
Clamping element:
If the tool is equipped with a belt pulley, the customer should be offered a sliding clamp carriage and have the benefits explained. By turning the star handle the clamping element should move easily up and down. If there is a mechanical fault, it must be dismounted and the faulty parts replaced. Disassembly is shown in the section on replacement of star handle.
Scrape result:
For this you need to extend the blade block. The tool must be clamped onto a suitable pipe in such a way that all four rollers sit on the pipe and scraping can take place. It is important to remove the oxidic layer completely. Chip thickness must be within tolerances indicated (check test plan).
Contamination:
Generally speaking, scraper tools should be cleaned when serviced. It is important to ensure that moveable parts can move easily and that knurlings of roller or guide rollers are free from deposits. Contaminated or damaged rollers will make handling more difficult and often result in a poor scraping result. Rollers and guide rollers should be cleaned using a wire brush, axes or moveable parts should be cleaned using the FRIATEC maintenance spray.
Completeness/damage:
Missing and mechanically damaged parts must be replaced. If service costs exceed 150 Euro, the customer must be provided with a quote. The customer should also be informed if the scraper tool no longer works due to lack of care, wrong handling or storage.
Final inspection:
On completion of the service each scraper tool must undergo a final inspection according to test plan (TQ5090) by the operator and released if the result is positive.
Revision 01
3 FWSG 225/315
Ausgabe 2, 07.02.2012 Revision 00 3-19
3.2 Individual repair measures FWSG 225/315
3.2.1 Replacement of FWSG 225/315 blade holder
Replacement is necessary if it is worn or spring travel is no longer guaranteed.
1
st step
Remove blade.
2nd
step
Loosen allen screws at flange and remove blade holder.
3rd
step
Remove scraper blade from new blade holder and insert blade holder. Take note of which direction the slitter holder is pointed. 4
th step
Remount blade.
3.2.2 Replacement of FWSG 225/315 telescope axes
Replacement is necessary if there are clearly visible signs of wear and tear or if there is mechanical damage, and if there are deposits of dirt including oxidation.
Cleaning of borehole using reamer
Dismantling the telescope axes takes place according to the description in the section „Replacement of guide roller housing“. However, in addition, the following needs to be observed: if it is not possible to pull the telescope axes out by hand, they have to be driven out using a suitable drift punch. The boreholes must then be cleaned using a reamer (see illustration). Otherwise insertion of new axes may not be possible or tight axes will recur after only a short time.
INFORMATION
INFORMATION
3 FWSG 225/315
Ausgabe 2, 07.02.2012 Revision 00 3-20
3.2.3 Replacement of rollers – FWSG 225/315 end plate
Replace if necessary if they or knurlings are worn.
1
st step
Loosen both screws of the telescope axes.
2
nd step
Pull out end plate together as well as guide rods (long and short). Please look after the flat washers as you will need them again for reassembly.
3
rd step
Pull off guide rollers and replace them with new rollers. If the telescope axes present clear signs of wear in the area in question, they must be replaced.
4
th step
Reassemble the tool in reverse order. When you tighten the screws please ensure that the rollers can be rotated easily without too much play. If necessary use shim rings to compensate.
3.2.4 Replacement of FWSG 225/315 drive
Replacement is necessary if there is mechanical damage or they are worn.
1
st step
Loosen both screws of the telescope axes.
INFORMATION
INFORMATION
3 FWSG 225/315
Ausgabe 2, 07.02.2012 Revision 00 3-21
2nd
step
Pull out end plate as well as guide rods (long and short). Please hold on to flat washers as you will need them for reassembly.
3
rd step
Remove guide rollers.
4
th step
Turn the handhold until both slide-on sleeve and slitter block have reached your hand..
5
th step
Loosen the screws from the aluminium support sleeve and take off handle.
6
th step
Pull off rubber section handle from handle sleeve, cut open if necessary. Also remove supporting sleeve.
7
th step
Clamp handle sleeve in and drive split pin out using a split pin drift. Before the splint drift is pulled out, it is important to hold on to the thread spindle.
3 FWSG 225/315
Ausgabe 2, 07.02.2012 Revision 00 3-22
8th
step
Now pull out splint pin drift and take out spindle.
9th
step
Insert new spindle and reassemble in reverse order.
3.2.5 Replacement of FWSG 225/315 star handle
Replacement is necessary if there is mechanical damage.
1
st step
Drive out split pin.
2
nd step
Remove star handle together with the flat washer.
INFORMATION
3 FWSG 225/315
Ausgabe 2, 07.02.2012 Revision 00 3-23
3rd
step
Remove the retaining ring at the axis of the clamping element.
4
th step
Pull out the axis and take out the whole clamping element.
5
th step
Clamp clamping element into a vice. Rotate existing borehole of brass sleeve until it is horizontal. Apply new star handle, which has already centre punched in the upper third of the aluminium socket, and flat washer plus shim ring (e.g. 0.3 mm from the FWSG 63 guide rollers) and drill a clearance hole using a 3mm drill (position shim ring between star handle and flat washer).
6th
step
When pulling off the star handle it is very helpful to mark the star handle and the brass sleeve to help find the overlapping boreholes when driving split pins in later. Reassemble the tool in reverse order. At this point please remove the shim ring required for drilling.
3.2.6 Replacement of rollers FWSG 225/315 housing
Replacement is necessary if rollers or knurlings are worn.
1
st step
Loosen both screws of the telescope axis.
INFORMATION
3 FWSG 225/315
Ausgabe 2, 07.02.2012 Revision 00 3-24
2nd
step
Pull out the end plate together with guide rods (long and short). Do not lose flat washers as you will need them later for reassembly.
3
rd step
Pull off the guide roller end plate.
4
th step
Remove black closing caps on the back of the tool.
5
th step
Take out retaining ring using external circlip gripper.
6
th step
Pull out telescope axis and remove guide roller housing. Should the telescope axis jam a little knock out the telescope axis carefully using a drift punch. If the telescope axis has is clearly worn it must be replaced.
7
th step
Clean the borehole and retainer of the guide roller inside housing. 8
th step
Guide new guide roller into retainer and insert telescope axis into the borehole and roll. Now reassemble the tool in reverse order. NB! The retaining ring of the telescope axis must lock into place. Check by pulling hard on the telescope axis.
3 FWSG 225/315
Ausgabe 2, 07.02.2012 Revision 00 3-25
3.2.7 Replacement of FWSG 225/315 slitter block with sliding sleeve
Replacement is necessary if there is mechanical damaged or the sliding sleeve presents clear signs of wear.
1
st step
Loosen both screws of the telescope axis.
2
nd step
Pull out the end plate with guide rods (long and short). Hold on to flat washers as you will need them again later for reassembly.
3
rd step
Pull off guide rollers.
4
th step
Turn the handhold until you are holding sliding sleeve as well as slitter block in your hand.
5th
step Dismantle blade holder. Loosen torque screw of blade and remove blade. Loosen both allen screws at the flange and take out blade holder.
INFORMATION
3 FWSG 225/315
Ausgabe 2, 07.02.2012 Revision 00 3-26
6th
step Insert new blade holder into new blade block. Attach sliding sleeve at thread spindle and screw on by turning handle. 7
th step
Reassemble tool in reverse order.
3.2.8 Replacement of belt pulley with FWSG 225/315 clamping slide
Replacement if requested by customer.
1
st step
Loosen mounting nut of belt pulley and pull off belt pulley.
2
nd step
Remove hexagon head screw.
Take out retaining ring using clip from bolt of clamping lever.
3
rd step
Place clamping slide into receiver and fasten using set screw..
INFORMATION
3 FWSG 225/315
Ausgabe 2, 07.02.2012 Revision 00 3-27
3.2.9 Replacement of FWSG 225/315 cylinder bolt
Replacement is necessary if worn or safety of housing no longer assured. It is advisable to check whether it is possible to rotate the bolt by 180º. If the bolt is partly polished it must be replaced.
1
st step
Clamp cylinder bolt into vice.
2
nd step
Pull off tools from bolt by rotating and pulling on housing at the same time.
3
rd step
Grease new bolt, attach and drive in using hammer.
3.2.10 Dismounting FWSG 225/315 blade holder
Replacement is necessary if there is mechanical damage or they are worn.
1
st step
Hook blade holder into vice ensuring the flange bears down flange. Carefully strike out brass bush including fastener using a plastic hammer.
INFORMATION
INFORMATION
3 FWSG 225/315
Ausgabe 2, 07.02.2012 Revision 00 3-28
2nd
step
Attach blade holder on reversed flange, press a little bit together and loosen grub screw. NB: Blade holder is under clip pressure. Slowly give in to pressure, otherwise there is a danger of parts of the blade holder scattering uncontrollably.
3.3
Illustration shows blade holder for FWSG 63 when dismantled. The blade holders of the other tools vary only in component size.
3.3.1 Removal of the bonded guide tube
Fig. 2: Removal of the bonded guide tube
3 FWSG 225/315
Ausgabe 2, 07.02.2012 Revision 00 3-29
3.4 Test report final inspection FWSG 225/315
Once assembly is complete, it is necessary to check mobility of telescope axis, sliding
clamp carriage, clamping roller, knife block, blade holder and spindle.
All tools must undergo a visual check.
It is necessary to carry out scraping tests using every scraper tool, for the following pipe
dimensions:
160mm or 225 mm for FWSG 225
160mm for FWSG 315
General features:
tools being complete (unit number)
settings are complete and legible
attach one red sticker „FWSGE3“ to blade block
attach one sticker „FRIATEC Logo“ to end plate
Functional tests:
mobility and fit
of telescope leverage across the entire extension length
of blade suspension
of all rollers
extend blade holder to maximum scrape length
scraper tests
with FWSG 225 – d160 PE100
with FWSG 315 – d160 PE100
analysis
chip thickness : 0.20 mm – 0.35 mm
surface
complete consistent scraping result
3 FWSG 225/315
Ausgabe 2, 07.02.2012 Revision 00 3-30
Table of nominal swarf thickness
Type of scraper tool nominal chip thickness (mm) wear limit (mm)
FWSG 225/315 0.20 - 0.35 0,4
Tab. 6: Nominal swarf thickness FWSG 225
The chip removal must be consistent, i.e. the oxidic layer in the pipe area to be fused must
be scraped completely.
Chip thickness must be checked using a slide guage and recorded in a test report.
For reporting the test plans contained in the manual must be used.
4 FWSG 630/710
Ausgabe 2, 07.02.2012 Revision 00 4-31
4 FWSG 630/710
4.1 Maintenance guidelines FWSG 630/710
Visual inspection:
unit number
contamination
completeness
mechanical damage
If the scraper tool does not present any noticeable problems start by inspecting the mechanics and wear parts.
Guide rollers:
Do the rollers run smoothly? Are the knurlings clearly visible and tangible? Is the bearing bushing worn? If the rollers are too worn, they must be replaced (see replacement of guide rollers).
Rollers:
The rollers must run smoothly. If there is considerable mechanical damage or they are worn, they must be replaced (see replacement of rollers).
Spindle inspection:
It must be possible to move the knife block (applies only to FWSG 630 L and FWSG 710 L) back and forth easily on the spindle by turning the handle. The spindle with knife block (with FWSG 630 S and FWSG 710 S only) must be easily extendable by turning the handle.
Telescope axis:
It must be possible to extend the telescope axis (with FWSG 630 S and FWSG 710 S only) to the desired size. If this is difficult, it must be disassembled and checked, and if necessary the telescopic axes must be replaced.
Blade holder:
It must be possible to push the blade holder into the housing and for it to extend again automatically. Whilst pushing, the blade holder must be moved back and forth in order to determine whether it is worn. If there is too much play it must be renewed. If the blade holder is stuck in the housing it must be disassembled and cleaned. If there is mechanical damage the faulty parts must be replaced.
4 FWSG 630/710
Ausgabe 2, 07.02.2012 Revision 00 4-32
Clamping element:
The height adjustment of the clamping element must be easy to handle. By turning the star handle, the clamping element, sliding clamp carriage) must move up or down depending on which way the handle is turned. If this is difficult, it must be cleaned using the FRIATEC maintenance spray. Parts with mechanical damage must be replaced.
Scrape result:
The tool must be clamped on to a pipe and scraping must be carried out. The oxidic layer must be removed across the entire scrape area without any gaps. Chip thickness must be determined using the slide gauge. If necessary the blade must be replaced and the scraping repeated.
Contamination:
Generally speaking all scraper tools should be cleaned at each service. It is important to ensure that moveable parts can be moved easily and the knurlings of guide rollers are free from deposits. Dirty or worn guide rollers make handling more difficult and often result in poor scrape result. Therefore the guide rollers should be cleaned using a wire brush, and the axes or moveable parts should be cleaned using FRIATEC maintenance spray
Completeness/damage:
Missing and mechanically damaged parts must be replaced. If costs are likely to exceed 200 Euro, a quote must be provided to the customer. The customer needs to be informed if the fact that his scraper tool has stopped working is clearly due to lack of care, faulty handling or storage.
Final inspection:
On completion of the service each scraper tool must undergo a final inspection according to test plan (TQ5090) by the operator and released if the result is positive.
4.2 Individual repair measures FWSG 630/710
4.2.1 Demounting FWSG 630/710 L
1st
step
Loosen all three screws from end plate and pull off.
4 FWSG 630/710
Ausgabe 2, 07.02.2012 Revision 00 4-33
2nd
step
Push in lock bolt of blade block and pull off from spindle.
3
rd step
Loosen fastening screw of cross-beams and remove both cross-beams.
4
th step
Loosen grub screw of handle and remove it.
5th
step
Strike thread spindle out of tool body using light blows with a plastic hammer.
4 FWSG 630/710
Ausgabe 2, 07.02.2012 Revision 00 4-34
6th
step
Loosen and remove fastening screw of guide rod.
7
th step
Hook cross-beam into vice making sure the roller bears on the splits of the vice. Knock out cross- beam of roller using a split pin drift, which fits into the borehole of the cross-beam.
8
th step
Dismantle second roller using a plastic hammer (ensure the roller sits flush).
Damaging of the rollers when reassembling!
When reassembling rollers please make sure the knurled roller is mounted first, as the
smooth runner might be damaged on knocking in of cross-beam.
4.2.2 Demounting FWSG 630/710 S
1
st step
Loosen both screws of telescope axis.
4 FWSG 630/710
Ausgabe 2, 07.02.2012 Revision 00 4-35
2nd
step
Pull off end plate with guide rods (long and short). Hold on to flat washers as you need them later for reassembly.
3
rd step
Push in lock bolt of handle and pull off blade block with thread spindle.
4. Schritt Unscrew both telescope axes by hand.
5. Schritt Loosen the four allen screws of clamp jacket and remove.
6. Schritt Pull off handle.
4 FWSG 630/710
Ausgabe 2, 07.02.2012 Revision 00 4-36
7. Schritt Hook in telescope axis into vice ensuring the roller bears down flush. Use a split pin drift to drive out telescope axis carefully.
8. Schritt Dismantle second roller using a plastic hammer (make sure the roller bears down flush).
Damaging of the rollers when re-assembling!
When reassembling rollers please make sure the knurled roller is mounted first, as the
smooth runner might be damaged on knocking in of cross-beam.
Knock out guide pasted!
Knock out guide tube if damaged, as it is pasted into the body of the tool.
4 FWSG 630/710
Ausgabe 2, 07.02.2012 Revision 00 4-37
4.2.3 Dismounting FWSG 630/710 blade holder
Replacement is necessary if there is mechanical damage or they are worn.
1
st step
Hook blade holder into vice ensuring the flange bears down flange. Carefully strike out brass bush including fastener using a plastic hammer.
2nd
step
Attach blade holder on reversed flange, press a little bit together and loosen grub screw. NB: Blade holder is under clip pressure. Slowly give in to pressure, otherwise there is a danger of parts of the blade holder scattering uncontrollably.
4.3
Illustration shows blade holder for FWSG 63 when dismantled. The blade holders of the other tools vary only in component size.
4.3.1 Replacement of locking bolt for FWSG 630/710
When replacing the locking bolt the drilled hole in the knife block must be cleaned every time and rubbed using a reamer. The reason for this that the drilling operation in the knife block is affected by dirt.
INFORMATION
4 FWSG 630/710
Ausgabe 2, 07.02.2012 Revision 00 4-38
4.3.2 Clear out of the FWSG 710 L in the last third while scrape procedure
During scrape procedure it can be possible that the scraping tool clear out from the pipe end. The reason for this is that while mounting/repairing the rod the tool is moving.
Before assembling the tool you must observe following steps!
apply the clamping carriage in demounted condition on a flat area.
the ball-bearing of the clamping-carriage must overlie without space on the area.
if required adjust the ball-bearing via plastic hammer.
Adjusting of the cross bar:
place the tool on a flat desk top so that the body fit on the desk top and the rolls
overlie.
tighten the screws of the cross bar hand-screwed and check if the runners
(guide rolls) overlie without space on the desk top.
tighten up the screws of the cross bars hard over cross. It must be pointed out
that the runners (guide rolls) furthermore overlie on the desk top.
4.3.3 Scraper tool FWSG 800/900
If a FWSG 800/900 Scraper arrived at a service station. The service stations have to send the scraper to Friatec Mannheim to make the service and maintenance.
4.3.4 The guide rod with scale is wrong assembled.
In the year 2010 where FWSG 710 scraper delivered where the guide rod with scale that rewards installed. On every FWSG 710L who was produced in the year 2010 is to check if the scale is on the right position. If the scale is on the wrong position you have to turn around the guide rod with scale. If necessary you have to change the guide rod with scale.
4 FWSG 630/710
Ausgabe 2, 07.02.2012 Revision 00 4-39
4.4 Test report final inspection FWSG 630/710
Once assembly is complete, it is necessary to check mobility of telescope axis, sliding
clamp carriage, clamping roller, knife block, blade holder and spindle.
All tools must undergo a visual check.
It is necessary to carry out scraping tests using every scraper tool, for the following pipe
dimensions:
250 mm or 315 mm for FWSG 630/710
General features: tools being complete (unit number)
settings being complete and legible
attach one blue sticker „FWSGE5“ to blade block
Functional tests:
mobility and fit
of suspension in base support of blade block
of blade block on thread spindle by turning the handhold and activating the release button
of all rollers
of sliding clamp carriage in grid
scraper tests
d250 PE100
d630
analysis
chip thickness : 0.30 mm – 0.45 mm
surface
complete and consistent scraping result
4 FWSG 630/710
Ausgabe 2, 07.02.2012 Revision 00 4-40
Table of nominal swarf thickness
Type of scraper tool nominal chip thickness (mm) wear limit (mm)
FWSG 630/710 0.30 - 0.45 0,5
Tab. 7: Nominal swarf thickness FWSG 630/710
The chip removal must be consistent, i.e. the oxidic layer in the pipe area to be fused must
be scraped completely.
Chip thickness must be checked using a slide guage and recorded in a test report.
For reporting the test plans contained in the manual must be used.
5 FWSGS
Ausgabe 2, 07.02.2012 Revision 00 5-1
5 FWSGS
5.1 FWSGS 110/180/225 maintenance guidelines
Visual inspection:
tool number
contamination
completeness
mechanical damage
If the scraper tool does not present any obvious problems, the mechanics and the wear parts
should be inspected first.
Locking bolt:
The cap nut must be tightly attached. The unlocking mechanism must work easily and
automatically snap into place once the dimension has been set. It must be replaced if
there is any damage and/or faulty function (see replacement locking bolt).
Clip pressure:
Check the clip pressure using the slide gauge. The distance between the blade block and
the tool housing must be measured. The distance must amount to 31.5mm. If necessary
release the cover sheets and adjust distance and consequently the clip pressure by
turning the socket screws.
Rollers of the cutter head:
The rollers must run smoothly and be clean. If worn too much, they must be replaced (see
replacement of rollers).
Adjustment of the dimension:
The ranges must run smoothly and be adjustable without catching. If necessary oil lightly
and/or file lightly using a flat mill file.
Ball bearing rollers:
These rollers must be smooth-running and clean. Replace if necessary.
Screw connections:
Test for tightness.
5 FWSGS
Ausgabe 2, 07.02.2012 Revision 00 5-2
Scrape result:
There must not be any chatter marks once scraping is complete. The chip thickness must
be within the tolerance range (see TQ5090 quality control plan).
Final inspection:
On completion of the service, each scraper tool must be subject to a final check by the
machine operator and released if the result is positive.
5.2 Individual repair measures FWSGS 110/180/225
5.2.1 Exchange locking bolt FWSGS 110/180/225
Exchange necessary, if mechanical damaged or by disfunction.
1
st Step
Loose locking bolt with a flat wrench size 13.
2
nd Step
Unscrew and remove locking bolt.
3
rd Step
Screw in and tighten the new locking bolt with a flat wrench.
INFORMATION
5 FWSGS
Ausgabe 2, 07.02.2012 Revision 00 5-3
5.2.2 Exchange plain roller FWSGS 110/180/225
Exchange necessary, if worn out or mechanical damaged.
1
st Step
Remove sticker.
2
nd Step
Unscrew both allen screws.
3
rd Step
5.2.3 Remove blade block.
4
th Step
Remove retaining ring.
5th
Step
Push the axis out with a split pin drift.
INFORMATION
5 FWSGS
Ausgabe 2, 07.02.2012 Revision 00 5-4
6th
Step
Remove axis.
7th
Step
Drive out the axis from the roll, mount new roll and assemble the tool in reverse order again. When mounting of the blade block you have to pay attention that you don´t tighten the screws too much. You must be able to upend the blade block from one side to the other side without getting stuck. Glue on the sticker for the scrape direction
Pay regard to the scrape direction of the arrow!
5.3 Test report final inspection FWSGS 110/180/225
General features:
tools complete (unit number)
settings complete and legible
atach one yellow sticker „FWSGE6“ to base plate below blade block
for FWSGS 110 and 180)
attach one curry coloured sticker „FWSGE7“ to base plate below blade block
(for FWSGS 225)
attach one sticker „FRIATEC Logo“ to spacer
Functional tests:
mobility and fit
of all rollers
of dimension adjustment
mobility of FWSGS 110 and FWSGS 180 swivel-head
functioning of locking bolt
INFORMATION
5 FWSGS
Ausgabe 2, 07.02.2012 Revision 00 5-5
adjustment of clip/camber (measured from bottom edge of compensator up to
top edge of spacer)
8 mm with FWSGS 110 and FWSGS 180
10 mm with FWSGS 225
scraper tests
FWSGS 110: d50 PE100/d110 PE100
FWSGS 180: d110 PE100/d180 PE100
FWSGS 225: d180 PE100/d225 PE100
analysis (average of 3 measuring points radially in centre of chip)
first scraping, chip thickness:
FWSGS 110: 0.10 – 0.30 mm
FWSGS 180: 0.10 – 0.30 mm
FWSGS 225: 0.10 – 0.30 mm
last scraping
0.4 mm with FWSGS 110/180 and
0.5 mm with FWSGS 225
surface
complete consistent scraping of saddle area.
The chip removal must be consistent, i.e. the oxidic layer in the pipe area to be fused must be scraped completely.
Chip thickness must be checked using a slide guage and recorded in a test report.
For reporting the test plans contained in the manual must be used.
6 FWSGA
Ausgabe 2, 07.02.2012 Revision 00 6-1
6 FWSGA
6.1 Maintenance guidelines FWSGA
Visual inspection:
tool number
contamination
completeness
mechanical damage
checking of the adapter (if present)
Should the scraper tool not present any noticeable problems start by inspecting the mechanics
and wear parts.
Cutter head:
By turning the handle the cutter head must easily extend and retract up to the stop. If this is not the case the sliding parts must be disassembled and checked for dirt and damage (see also replacement of slide-on sleeve/telescopic rod/drive).
Dimension adjustment:
The ranges must run smoothly and be adjustable without catching. If necessary oil lightly and/or file lightly using a flat mill file.
Blade holder:
It must be possible to push the blade holder into the cutter head and extend out again automatically. If there is a fault with the blade holder, it is necessary to dismantle and clean it. If there is mechanical damage, it may be necessary to replace the blade holder (see replacement of blade holder).
Scrape result:
Guide adapter into pipe and fix. Clamp tool onto pipe and carry out test scrape. The oxidic layer must be thoroughly removed. If adapters are faulty, please contact service point Mannheim for further instructions.
Final inspection:
Every scraper tool must undergo final inspection on completion of service by the operator according to test plan (TQ5090) and released if result is positive.
6 FWSGA
Ausgabe 2, 07.02.2012 Revision 00 6-2
6.2 Individual repair measures FWSGA
6.2.1 Tight feed on soiled FWSGA
With very dirty tools it may become difficult for the blade block to extend or retract as the diameter of the sliding sleeve exceeds the tolerance range. In this case the sliding sleeve must be tested using the blade holder, cleaned if required, and the affected sleeve should be returned to FRIATEC AG.
6.2.2 Replacement of FWSGA blade holder
Replacement is necessary if this is worn or mechanically damaged.
1
st step
Loosen the grub screw while holding blade holder. NB! The blade holder may be catapulted away due to clip pressure (hold on tight).
2
nd step
Slowly give in to clip pressure and take out blade holder.
3
rd step
Clean the borehole (blow through using compressed air).
4th
step
Insert new blade holder and fix using grub screw ensuring that the blade holder is again suspended. 5
th step
Carry out scraping.
INFORMATION
6 FWSGA
Ausgabe 2, 07.02.2012 Revision 00 6-3
6.2.3 Replacement of FWSGA drive block
Replacement is necessary if there is mechanical damage or operational failure.
1
st step
Loosen grub screw of telescope rod and extract from milling head.
2nd
step
Unscrew sliding sleeve completely.
3rd
step
Loosen the three screws from the aluminium supporting sleeve and remove drive block.
4th
step Cut open and remove profile rubber film.
5th
step Push out split pin..
INFORMATION
6 FWSGA
Ausgabe 2, 07.02.2012 Revision 00 6-4
6th
step Remove threaded spindle.
7th
step Insert new threaded spindle and reassemble tool in reverse order.
6.2.4 Replace milling head/sliding sleeve/telescope rod
Replacement is necessary, if worn or mechanically damaged.
1
st step
Loosen grub screw of telescope rod and pull out rod.
2nd
step Unscrew milling head including sliding sleeve.
3rd
step Remove retaining ring of telescope rod.
INFORMATION
6 FWSGA
Ausgabe 2, 07.02.2012 Revision 00 6-5
4th
step Pull telescope out the back.
5
th step
In order to remove the sliding sleeve from the milling head, the grub screw must be loosened at the side and the sliding sleeve extracted using rotating movements. When inserting the new sliding sleeve do not forget to glue in.
6th
step Reassembling the tool takes place in reverse order.
6.3 Test report final inspection FWSGA
General features:
tools complete (unit number)
settings complete and legible
attach one red sticker „FWSGE3“ to base plate behind feed arrest
attach one sticker „FRIATEC Logo“ to base plate
Functional tests:
mobility and fit
of telescope leverage across the entire extension length
of blade carrier and suspension
of all rollers
check adjustability of pipe dimension with regards to adapter diameter
extend blade block to maximum scraper length
6 FWSGA
Ausgabe 2, 07.02.2012 Revision 00 6-6
scraper tests
clamping
scraping
ensure consistent scraper result
d32 with PE100
d63 with PE100
analysis
chip thickness : 0.15 mm – 0.25 mm
surface
completely consistent scraper result
The chip removal must be consistent, i.e. the oxidic layer in the pipe area to be fused must be scraped completely.
Chip thickness must be checked using a slide guage and recorded in a test report.
For reporting the test plans contained in the manual must be used.
7 FWSG SE
Ausgabe 2, 07.02.2012 Revision 00 7-1
7 FWSG SE
7.1 Maintenance instructions FWSG SE 63-315
Visual inspection:
Device number
Contamination
Completeness
Mechanical damages
If the scraper tool shows no findings, the mechanical and the wearing parts are to be
inspected.
Contamination:
In principal, scraper tools are to be cleaned during service, in particular it is to be ensured that the movable parts are freely moving and that the guide or guide rollers are free from any deposits. Dirty scraper tools impair the handling and often result in an inferior scraping result.
Clamping lever / clamping mechanism:
Activation without any impairment must be ensured (such that the device tightly sits on the pipe without being loose.
Rollers:
It must be possible to smoothly turn the ball bearings.
Blade block:
Remove the blade holder and clean the holes
Blade holder:
It must be possible to press the blade holder into the housing. The blade holder must then automatically return to its initial position. If the blade holder gets stuck in the housing, the blade holder must be disassembled and cleaned. In case of mechanical damage, the defective parts must be replaced. The blade adapter must be movable.
Scraping result:
Clamp the device onto a suitable pipe and perform
the scraping. The oxide layer must be completely removed. The swarf must be within the tolerance range (see test plan).
7 FWSG SE
Ausgabe 2, 07.02.2012 Revision 00 7-2
Final inspection:
On completion of the service each scraper tool must undergo a final inspection according to test plan (TQ5090) by the operator and released if the result is positive.
7.2 Individual repair measures FWSG SE
Repair instructions:
Clamping screw: Torque 65 cNm. Thread locker Loctite 241. The device may not be
used for at least 4 hours.
The screws of the rollers are to be secured with Loctite 241.
If retaining rings have to be removed, new ones must be used for re-assembly.
7.2.1 Deformation of the aglet on FWSG-SE
Due to complaints of different FWSG-SE scraper tools we established, that the aglet
deform with the length of time and the frequenzy of use of the unit and thus you can
not clamp the unit prober on the pipe anymore.
Therefore you must dismount the aglet, control it of deformation and replace it, if
necessary. (see drawing).
Fig. 3: Aglet FWSG SE
7 FWSG SE
Ausgabe 2, 07.02.2012 Revision 00 7-3
7.2.2 Description of assembly of the flat washer at the FWSG-SE
If the screw of the clamping handle will be removed it is possible that the enclosed flat
washer can fall out. When the flat washer be returned, it has to be check the position.
If the position of the flat washers is incorrect the pressure of the clamping handle could
be to high or to low.
Fig. 4: Drawing flat washers FWSG SE 63
7 FWSG SE
Ausgabe 2, 07.02.2012 Revision 00 7-4
Fig. 5: Drawing flat washers FWSG SE 75/90/110/125/140
7 FWSG SE
Ausgabe 2, 07.02.2012 Revision 00 7-5
Fig. 6: Drawing flat washers FWSG SE 160/180
7 FWSG SE
Ausgabe 2, 07.02.2012 Revision 00 7-6
Fig. 7: Drawing flat washers FWSG SE 200/225
7 FWSG SE
Ausgabe 2, 07.02.2012 Revision 00 7-7
Fig. 8: Drawing flat washers FWSG SE 250/280/315
7 FWSG SE
Ausgabe 2, 07.02.2012 Revision 00 7-8
7.3 Test report final inspection FWSG SE 63-315
General aspects:
Completeness of the devices (device number)
Completeness and legibility of the dimensions
Completeness and legibility of the blade numbering
Function tests:
Mobility and seat
of all rollers and guide rollers
of the blade block
Movability of the blade holder
Tight seat of the device on the pipe
Tight seat of the handles
Scraping tests
Pipes dimension-dependent PE80 and PE100
Evaluation
FWSG SE63: 0.15 - 0.30mm
FWSG SE > 63: 0.15 - 0.40mm
Surface
Complete scraping without interruptions
No chatter marks
The chip removal must be consistent, i.e. the oxidic layer in the pipe area to be fused must be scraped completely.
Chip thickness must be checked using a slide guage and recorded in a test report.
For reporting the test plans contained in the manual must be used.
8 FWSG RA
Ausgabe 2, 07.02.2012 Revision 00 8-1
8 FWSG RA
8.1 6.1 Maintenance guidelines FWSG RA
Visual inspection:
Device number
Contamination
Completeness
Mechanical damages
Replacement of defective parts
Replacement of defective parts, after consultation with the customer.
Final inspection:
On completion of the service each scraper tool must undergo a final inspection according to test plan (TQ5090) by the operator and released if the result is positive.
8.2 Test description final inspection and testing FWSG RA
Scraping tests
Pipes dimension-dependent PE100
Evaluation
chip thickness : 0.15 mm – 0.25 mm
surface
Complete scraping without interruptions
The chip removal must be consistent, i.e. the oxidic layer in the pipe area to be fused must be scraped completely.
Chip thickness must be checked using a slide guage and recorded in a test report.
For reporting the test plans contained in the manual must be used.
9 Spare Parts
Ausgabe 2, 07.02.2012 Revision 00 9-1
9 Spare Parts
9.1 Spare Parts FWSG 63
Art.-No.: Description Illustration
626001 Tool body with DU-
bushing
626002 Set screw
adjustable head
626003 Set screw lateral
626004 Bottom part
626005 Guide rod
626007 Run roll-set
626008 blade (HM) 63
626013 Flange blade holder
626016 adjustable head
626018 Guide roll-set
626022 Release handle
626024 Disc spring release
handle
626025 Star handle 63/630
626026 Splint-pin star
handle (pack of 20)
626027 Lead screw 63
626028 Handhold
626030 Sticker FWSGE4
626031 Sticker dimension
range
626041 Guide bush
9 Spare Parts
Ausgabe 2, 07.02.2012 Revision 00 9-2
Art.-No.: Description Illustration
626003 Set screw lateral
626004 Bottom part
626005 Guide rod
626006 Cylinder bolt (2
pieces)
626007 Run roll-set
626008 blade (HM) 63
626009 Blade holder 63
626010 Torque screw
626011 Clip blade holder
63/225
626013 Flange blade holder
626014 Screw flange
626022 Release handle
626023 Flat washer release
handle
626024 Disc spring release
handle
626025 Star handle 63/630
626027 Lead screw 63
626028 Handhold
626029 Screw handhold
626030 Sticker FWSGE4
626031 Sticker dimension
range
626108 Split pin star handle
9 Spare Parts
Ausgabe 2, 07.02.2012 Revision 00 9-3
Art.-No.: Description Illustration
626018 Guide roll-set
627019 Axis guide rolls
627020 Retaining ring guide
roll
627021 Shim ring guide
rolls
9 Spare Parts
Ausgabe 2, 07.02.2012 Revision 00 9-4
9.2 Spare Parts FWSG 225/315
Art.-No.: Description Illustration
626104 Guide roll pair
(body)
626105 Cylinder bolt
626107 Star handle 225
626118 Clamping slide
complete
626130 Blade holder
complete
626131 End plate
626137 Guide rod long
626138 Guide rod short
626141 Guide roll pair (end
plate)
626145 Rubber profile
cover
9 Spare Parts
Ausgabe 2, 07.02.2012 Revision 00 9-5
Art.-No.: Description Illustration
626107 Star handle 225
626108 Split pin star handle
626109 Axis star handle
626110 Brass bushing star
handle
626111 Flat washer star
handle
626112 Eye screw star
handle
626113 Clamping lever with
DU-bushing
626114 Tension ring
clamping slide
626115 Bolt star handle
626116 Notched ring star
handle
626117 Clamping slide
complete
626118 Ball bearing
clamping slide
626119 Flat washer
clamping slide
626120 Screw clamping
slide
626121 Axis clamping lever
626122 Retaining ring
clamping lever
626123 Star handle 225
9 Spare Parts
Ausgabe 2, 07.02.2012 Revision 00 9-6
Art.-No.: Description Illustration
626104 Guide roll pair (body)
626115 Tension ring clamping slide
626123 Retaining ring clamping lever
626131 End plate
626132 Telescope axis FWSG 225
626133 Flat washer Telesc. axis + lead screw
626134 Spring washer telescope axis
626136 Screw telescope axis
626137 Guide rod long
626138 Guide rod short
626139 Spring washer guide rod
626140 Screw guide rod pack of 50)
626141 Guide roll pair (end plate)
9 Spare Parts
Ausgabe 2, 07.02.2012 Revision 00 9-7
Art.-No.: Description Illustration
626011 Clip blade holder 63/225
626013 Flange blade holder
626014 Screw flange (pack of 50)
626125 Sliding sleeve
626126 Blade (HM) 225
626127 Blade holder 225/630/710
626128 Guide bush with thread + Cylinder bolt
626130 Blade holder complete
626271 Screw guide groove
9 Spare Parts
Ausgabe 2, 07.02.2012 Revision 00 9-8
Art.-No.: Description Illustration
626133 Flat washer Telesc. axis + lead screw
626144 Handhold bush
626145 Rubber profile cover
626146 Lead screw 225
626147 Lead screw 315
626148 Clip lead screw
626150 Split pin lead screw
626273 Adjusting washer 0,5mm
9 Spare Parts
Ausgabe 2, 07.02.2012 Revision 00 9-9
Art.-No.: Description Illustration
626101 body
626104 Guide roll pair (body)
626105 Cylinder bolt (pack of 10)
626107 Star handle 225
626122 Axis clamping lever
626124 Slitter block with D-bushing
626125 Sliding sleeve
626126 Blade (HM) 225
626127 Blade holder 225/630/710
626131 End plate
626135 Telescope axis-set FWSG 315
626137 Guide rod long
626141 Guide roll pair (end plate)
626142 Back-up bush aluminium
626145 Rubber profile cover
626151 Tension roller with ball bearings
626152 Eye screw with nut and spring washer
626153 Nut belt pulley (pack of 50)
626154 Spring washer belt pulley (pack of 50)
9 Spare Parts
Ausgabe 2, 07.02.2012 Revision 00 9-10
9.3 Spare Parts FWSG 630/710
Art.-No.: Description Illustration
626025 Star handle 63/630/710
626202 Tensioning arm
626204 Clamping arm
626209 Clamping slide
626210 Ball bearing clamping slide
626213 Blade (HM) 630
626215 Blade holder complete
626220 Housing
626221 Cylinder bolt
626225 Handhold
626227 Threaded spindle 630/710
626228 Cross bar
626231 Roller pair knurled
626232 Roller pair flat
626233 Clamp screw 25mm (pack of 20)
626235 Guide rod with scales
626245 Screw distance washer
9 Spare Parts
Ausgabe 2, 07.02.2012 Revision 00 9-11
Art.-No.: Description Illustration
626025 Star handle 63/630/710
626210 Ball bearing clamping slide
626215 Blade holder complete
626217 Lock bolt
626221 Cylinder bolt
626225 Handhold
626238 Clamping arm short
626239 Clamping slide short
626241 Slitter block short with bushing
626242 Tool body short
626246 Handhold short
626247 Lead screw short
626249 Distance bush short
626250 Roller pair knurled short
626251 Roller pair flat short
626253 Counter bearing S
626254 Telescope tube with 3 DU-bushing
9 Spare Parts
Ausgabe 2, 07.02.2012 Revision 00 9-12
Art.-No.: Description Illustration
626227 Threaded spindle 630/710
626234 Clamp screw 30mm (pack of 20)
626241 Slitter block short with bushing
626252 Guide roller with scales short
626253 Counter bearing S
626025 Star handle 63/630/710
626108 Split pin star handle
626201 Threaded spindle star handle
626205 Cylinder bolt clamping arm
626206 Cylinder bolt clamping slide
626207 Spring plate clamping arm
626210 Ball bearing clamping slide
626211 Flat washer clamping slide
626212 Screw clamping slide
626238 Clamping arm short
626239 Clamping slide short
626252
626227
626234
626241
626253
9 Spare Parts
Ausgabe 2, 07.02.2012 Revision 00 9-13
Art.-No.: Description Illustration
626215 Blade holder complete
626237 Sticker FWSGE5 (blue)
626241 Slitter block short with bushing
626247 Lead screw short
626248 Telescope rod short
626249 Distance bush short
626250 Roller pair knurled short
626251 Roller pair flat short
626252 Guide roller with scales short
626253 Counter bearing S
626254 Telescope tube with 3 DU-bushing
626256 Guide rod slitter block
626261 Cylinder bolt M10x20 DIN912
626262 Leans head screw M8x30 ISO738
626270 Set screw M18x1.5x10 DIN913
9 Spare Parts
Ausgabe 2, 07.02.2012 Revision 00 9-14
Art.-No.: Description Illustration
626217 Lock bolt
626218 Clip lock bolt
626246 Handhold short
626247 Lead screw short
626258 Retaining ring cleft
626265 Cylinder bolt M4x25 DIN912
9 Spare Parts
Ausgabe 2, 07.02.2012 Revision 00 9-15
9.4 Spare Parts FWSGA
Art.-No.: Description Illustration
626217 Lock bolt
626218 Clip lock bolt
626246 Handhold short
626247 Lead screw short
626258 Retaining ring cleft
626265 Cylinder bolt M4x25 DIN912
626133 Flat washer Telesc. axis + lead screw
626144 Handhold bush
626145 Rubber profile cover
626150 Split pin lead screw
626522 Lead screw
626535 Bear bush
626536 Clip thread shaft
9 Spare Parts
Ausgabe 2, 07.02.2012 Revision 00 9-16
Art.-No.: Description Illustration
626014 Screw flange
626237 Sticker FWSGE5 (blue)
626502 Base plate FWSGA
626506 Top part flank right with punching tool
626507 Spacer
626508 Surface axis
626512 Axis base plate
626514 Ball-bearing for axis base plate
626518 Clamp sleeve M3x18
626520 Pressure spring-set for base plate
626521 Fixing handle base plate
626529 Telescope axis complete
626531 Guiding bush
626534 Retaining ring 471-10x1
626538 Hexagon socket head cap screw M4x12
9 Spare Parts
Ausgabe 2, 07.02.2012 Revision 00 9-17
Art.-No.: Description Illustration
626503 Base part flank left with punching tool
626504 Base part flank right with punching tool
626509 Roll axis
626510 Ball-bearing for roll axis
626515 Cap nut M4
626516 Handle bar top
626517 Handle bar bottom
626519 Locking bail with cylinder bolt
626539 Serrated lock washer M4
626540 Countersunk socket screw M4x16
626541 Shim ring M8x0,4mm
9 Spare Parts
Ausgabe 2, 07.02.2012 Revision 00 9-18
9.5 Spare Parts FWSGS
Art.-No.: Description Illustration
626301 Spare blade (1xFWSGE 6)
626302 Locking bolt
626303 Ball-bearing for axis
626304 Axis bottom part
626306 Rod with ball
626307 Guiding roll blade block with ball-bearing
626308 Blade pair for bottom part
626309 Axis for dimension adjustment
626310 Cap nut for axis
626311 3x clip for blade block
626312 Axis for guide rolls
626313 Blade block
626314 Locking cap black
626315 Spacer
626316 Split pin for axis dimension adjustment
626317 Direction sticker
626319 Cylinder-head screw M5x40
626320 Lens head screw M6x14
626321 Countersunk screw M4x16
626322 Blade pair for upper part
626333 Seesaw axis
626334 Pendular axis
626337 Retaining ring 6
626338 Rod for blade holder block
626339 Shim ring 7x13x0.3
626341 Compensator
9 Spare Parts
Ausgabe 2, 07.02.2012 Revision 00 9-19
9.6 Spare Parts FWSG SE
Art.-No.: Description Illustration
626701 Scraper blade HSS for SG-SE 40-315
626711 Softline ball handle
626703 Blade holder complete excl. blade
626719 Clamping lever 225
626721 Clamping lever 63
626722 Clamping lever 75-180
626723 Clamping lever 250-315
626730 Roller
626731 Roller screw
626701
626711
626703
626730
626731
626719 626721 626722 626723
9 Spare Parts
Ausgabe 2, 07.02.2012 Revision 00 9-20
9.7 Spare Parts FWSG RA
Art.-No.: Description Illustration
626749 Scraper blade d32 and d40
626750 Scraper blade d50 and d63
626751 Torx screw for scraper blade
626752 Mandrel d 32
626753 Mandrel d 40
626754 Mandrel d 50
626755 Mandrel d 63
626756 Adjustment incl. screw (20St)
626757 Dowel for blade holder (20St)
626758 Knob d32-63
626763 Base body d32
626764 Base body d40
626765 Base body d50
626766 Base body d63
626767 Blade holder d32
626768 Blade holder d40
626769 Blade holder d50
626770
Blade holder d63
626771 Threaded spindle d32
626772 Threaded spindle d40
626773 Threaded spindle d50
626774 Threaded spindle d63
626775 Detent d32-63
626776 Screw for detent d32-63
626777 O-Ring for Mandrel d32
626777 626758
626775
626752 627753 626754 626755
626763 627764 626765 626766
626767 627768 626769 626770
626776
626771 627772 626773 626774
626749 627750
626751
10 Miscellaneous
Ausgabe 2, 07.02.2012 Revision 00 10-1
10 Miscellaneous
10.1 Tools and aids
Pos Tools Size / Gauges / (Art.No.) For scraper tool
1 Peen hammer 500 g All of them
2 Plastic hammer Ø35 mm blow-back proof All of them
3 Brass pin Ø25x150 63/225/315
4 Torque key 370/T8 All of them
5 Screwdriver 0.8x5.5 63
6 Special key 1800.015.22 225/315
7 Cross-screwdriver 2x250 225/315
8 Ring spanner (low cropped) 17 SW 315
9 Die wrench 5-12mm Size 3 All of them
10 Die wrench 7-20mm Size 5 All of them
11 Twist drill HSS Ø3 mm 63/225/315
12 Cone spot facer 90º ab Ø2.5 mm 63/225/315
13 Triangular scraper 75x8 63/225/315
14 Hexagon screwdriver with handhold
1.5/2.0/2.5/3.0/4.0/5.0 All of them
15 Machine reamer H7 Ø5. / 6 / 8 / 10 / 12 All of them
16 Machine reamer H7 Ø13 / 14 / 15 / 16 /20 All of them
17 Split pin drift (intersection) Ø6x50 225/315/630
18 Split pin drift (reworked) Ø1.9 / 2.9 / 4.9 63
19 Split pin drift (reworked) Ø5.9 / 7.9 630
20 Circlip pliers for retaining ring A 0 (A 5-A 10) 63/225/315
21 Circlip pliers for grip screw ZGG1 (G 3.5-G8) 63
22 Circlip pliers for retaining ring. long A 12 225/315
23 Parallel vice 100-120 mm All of them
24 Spare split corrugated and ground 100-120 mm All of them
25 Protective braces 100-120 mm All of them
26 Triangular file 150 mm / hack 2 All of them
27 Semicircular file 150 mm / hack 2 All of them
28 Sand paper Grain 400 All of them
29 Flat pliers (small) All of them
30 Bench drill All of them
31 Scriber plate All of them
32 Cleaner All of them
33 Lubricating grease All of them
34 Centre drill 1.5 mm All of them
35 Repair shop press 630
36 Drill Ø4.2 90º 63
37 Top for torque wrench 63
38 Adhesive LOCTITE 241 (626296-00) All of them
39 Adhesive LOCTITE 648 (626297-00) All of them
40 Adhesive KÖVULFIX (for vulcanised rubber)
(626298-00) 225/315
Tab. 8: Tool list
10 Miscellaneous
Ausgabe 2, 07.02.2012 Revision 00 10-2
Fig. 9: Special key FWSG 225
FRIATEC Aktiengesellschaft
Division Technische Kunststoffe
Steinzeugstraße 50
D-68229 Mannheim
Tel +49 621 486 0
Fax +49 621 486 1837 oder 2030
Service-Hotline +49 621 486 1533
www.friatools.de
info-friatools@friatec.de
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