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This document is subject to DA NIE LI & C.

right of ownership and cannot be repr oduced

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

Doc. No. DPXXXX-HC11-M1001-KB0X1

SERVICE

MUM Department

DOC. No. DPXXXX-HC11-M1001-KB0X1 REV. 00


Assembly sequences and start-up instructions for the evacuation area
VRI-6-27-04-30-30-06 + VRC-1-27-04-19-19-27 + CCS-L-3-6-15-23-028 + CCP-1-6-15-10-24-029 +
DBR-029-24-3-15-L-E + VRL-6-27-04-42-42-11 + TEC-094-310-06-2-R + PRC-093-094-06-2-B +
VRE-03-04-26-26-34 + PWI-168-094-00-C-181 + PRC-090-094-06-2-B + PRC-090-094-06-2-B

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

3.0 - NO-LOAD TESTS AND SET-UP . . . . . . . . . . . . . . . . . . . . . . . . . 1


3.1 - FIRST LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3.2 - NO-LOAD TESTS AND SET-UP OF THE COMPONENTS
AND SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3.3 - NO-LOAD TESTS AND CHECKS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.3.1 - INTERMEDIATE ROLLER TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.3.2 - CROPS END COLLECTING CAR . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.3.3 - SAMPLES COLLECTING CAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.3.4 - CUTTING AND TRANSPORT ROLLER TABLE. . . . . . . . . . . . . . . . 5
3.3.5 - NOSE AND TAIL DEBURRING SYSTEM. . . . . . . . . . . . . . . . . . . . . 6
3.3.6 - DISCHARGE ROLLER TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.3.7 - BLOOMS ELEVATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.3.8 - PAWL COLLECTING PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.3.9 - TRANSPORT ROLLER TABLE (W.B. AREA) . . . . . . . . . . . . . . . . . . 8
3.3.10 - WALKING BEAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.3.11 - PAWL COLLECTING PLATE (W.B.) . . . . . . . . . . . . . . . . . . . . . . . 9
3.3.12 - PAWL COLLECTING PLATE (SLOW COOL) . . . . . . . . . . . . . . . . 9
2.4 - INSTRUMENTS AND TOOLS FOR CHECKS AND TESTS. . . . . . . . . . . . 11

April, 2006

P. 1
Of 2

DOC. No. DPXXXX-HC11-M1001-KB0X1 REV. 00


Assembly sequences and start-up instructions for the evacuation area
VRI-6-27-04-30-30-06 + VRC-1-27-04-19-19-27 + CCS-L-3-6-15-23-028 + CCP-1-6-15-10-24-029 +
DBR-029-24-3-15-L-E + VRL-6-27-04-42-42-11 + TEC-094-310-06-2-R + PRC-093-094-06-2-B +
VRE-03-04-26-26-34 + PWI-168-094-00-C-181 + PRC-090-094-06-2-B + PRC-090-094-06-2-B

4.0 - TECHNICAL DOCUMENTATION . . . . . . . . . . . . . . . . . . . . . . 1


4.1 - LIST OF DRAWINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
4.2 - LIST OF TECHNICAL COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

April, 2006

P. 2
Of 2

DOC. No. DPXXXX-HC11-M1001-KB0X1 REV. 00


Assembly sequences and start-up instructions for the evacuation area
VRI-6-27-04-30-30-06 + VRC-1-27-04-19-19-27 + CCS-L-3-6-15-23-028 + CCP-1-6-15-10-24-029 +
DBR-029-24-3-15-L-E + VRL-6-27-04-42-42-11 + TEC-094-310-06-2-R + PRC-093-094-06-2-B +
VRE-03-04-26-26-34 + PWI-168-094-00-C-181 + PRC-090-094-06-2-B + PRC-090-094-06-2-B

SEC. 1.0

1.0 - ASSEMBLY SEQUENCES FOR THE


EVACUATION AREA
GENERAL NOTES
Lift and move the machine parts with proper lifting means and slings; for the
cumbersome parts refer to the lifting points shown in the drawings of chapter
"Movement and transport of the components".
Use a suitable dynamometric wrench to tighten all the bolts: for the tightening
values see the data on the drawings and/or the values indicated in DANIELI
standard n. 2.4.603.

Fig.1.0.a - Top view of the evacuation area

April, 2006

1.0 - ASSEMBLY SEQUENCES FOR


THE EVACUATION AREA

P. 1
Of 22

1.1 - INTERMEDIATE ROLLER TABLE


MACHINE ASSEMBLY SEQUENCE
Machine: Intermediate roller table

Pos.

1.1 intermediate
roller table

Type: VRI-6-27-04-30-30-06

Component/Unit

01

Metal structure

02

Roller supporting frame

03

Movable roller sliding guides

04

Movable car and car moving cylinder

05

Pressure unit moving cylinder

06

Motor unit

07

Systems on the machine

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

1.0 - ASSEMBLY SEQUENCES FOR


THE EVACUATION AREA

P. 2
Of 22

SEC. 1.0

DOC. No. DPXXXX-HC11-M1001-KB0X1 REV. 00


Assembly sequences and start-up instructions for the evacuation area
VRI-6-27-04-30-30-06 + VRC-1-27-04-19-19-27 + CCS-L-3-6-15-23-028 + CCP-1-6-15-10-24-029 +
DBR-029-24-3-15-L-E + VRL-6-27-04-42-42-11 + TEC-094-310-06-2-R + PRC-093-094-06-2-B +
VRE-03-04-26-26-34 + PWI-168-094-00-C-181 + PRC-090-094-06-2-B + PRC-090-094-06-2-B

DOC. No. DPXXXX-HC11-M1001-KB0X1 REV. 00


Assembly sequences and start-up instructions for the evacuation area
VRI-6-27-04-30-30-06 + VRC-1-27-04-19-19-27 + CCS-L-3-6-15-23-028 + CCP-1-6-15-10-24-029 +
DBR-029-24-3-15-L-E + VRL-6-27-04-42-42-11 + TEC-094-310-06-2-R + PRC-093-094-06-2-B +
VRE-03-04-26-26-34 + PWI-168-094-00-C-181 + PRC-090-094-06-2-B + PRC-090-094-06-2-B

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

1.0 - ASSEMBLY SEQUENCES FOR


THE EVACUATION AREA

P. 3
Of 22

1.2 - cutting
roller table

1.2 - CUTTING ROLLER TABLE


MACHINE ASSEMBLY SEQUENCE
Machine: Cutting and transport 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

Movable car and car moving cylinder

04

Shaped roller

05

Motor unit

06

Guards and safety devices

07

Systems on the machine

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)

Disk roller supports and positioning of the movable roller sliding


guides
Sling properly the shaped 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 .
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 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.

April, 2006

1.0 - ASSEMBLY SEQUENCES FOR


THE EVACUATION AREA

P. 4
Of 22

SEC. 1.0

DOC. No. DPXXXX-HC11-M1001-KB0X1 REV. 00


Assembly sequences and start-up instructions for the evacuation area
VRI-6-27-04-30-30-06 + VRC-1-27-04-19-19-27 + CCS-L-3-6-15-23-028 + CCP-1-6-15-10-24-029 +
DBR-029-24-3-15-L-E + VRL-6-27-04-42-42-11 + TEC-094-310-06-2-R + PRC-093-094-06-2-B +
VRE-03-04-26-26-34 + PWI-168-094-00-C-181 + PRC-090-094-06-2-B + PRC-090-094-06-2-B

DOC. No. DPXXXX-HC11-M1001-KB0X1 REV. 00


Assembly sequences and start-up instructions for the evacuation area
VRI-6-27-04-30-30-06 + VRC-1-27-04-19-19-27 + CCS-L-3-6-15-23-028 + CCP-1-6-15-10-24-029 +
DBR-029-24-3-15-L-E + VRL-6-27-04-42-42-11 + TEC-094-310-06-2-R + PRC-093-094-06-2-B +
VRE-03-04-26-26-34 + PWI-168-094-00-C-181 + PRC-090-094-06-2-B + PRC-090-094-06-2-B

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

1.0 - ASSEMBLY SEQUENCES FOR


THE EVACUATION AREA

P. 5
Of 22

1.3 - CROPS END COLLECTING CAR


MACHINE ASSEMBLY SEQUENCE
Machine: Crops end collecting car

Pos.

1.3 - crops
end collecting
car

Type: CCS-L-3-6-15-23-028

Component/Unit

01

Sliding rails

02

Capstan unit and driving tightener

03

Crop end collecting car

04

Crop end collecting boxes

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

1.0 - ASSEMBLY SEQUENCES FOR


THE EVACUATION AREA

P. 6
Of 22

SEC. 1.0

DOC. No. DPXXXX-HC11-M1001-KB0X1 REV. 00


Assembly sequences and start-up instructions for the evacuation area
VRI-6-27-04-30-30-06 + VRC-1-27-04-19-19-27 + CCS-L-3-6-15-23-028 + CCP-1-6-15-10-24-029 +
DBR-029-24-3-15-L-E + VRL-6-27-04-42-42-11 + TEC-094-310-06-2-R + PRC-093-094-06-2-B +
VRE-03-04-26-26-34 + PWI-168-094-00-C-181 + PRC-090-094-06-2-B + PRC-090-094-06-2-B

1.4 - samples
collecting car

1.4 - SAMPLES COLLECTING CAR


MACHINE ASSEMBLY SEQUENCE
Machine: Samples collecting car

Pos.

Type: CCP-1-6-15-10-24-029

Component/Unit

01

Sliding rails

02

Capstan unit and driving tightener

03

Samples collecting car

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

1.0 - ASSEMBLY SEQUENCES FOR


THE EVACUATION AREA

P. 7
Of 22

SEC. 1.0

DOC. No. DPXXXX-HC11-M1001-KB0X1 REV. 00


Assembly sequences and start-up instructions for the evacuation area
VRI-6-27-04-30-30-06 + VRC-1-27-04-19-19-27 + CCS-L-3-6-15-23-028 + CCP-1-6-15-10-24-029 +
DBR-029-24-3-15-L-E + VRL-6-27-04-42-42-11 + TEC-094-310-06-2-R + PRC-093-094-06-2-B +
VRE-03-04-26-26-34 + PWI-168-094-00-C-181 + PRC-090-094-06-2-B + PRC-090-094-06-2-B

1.5 - NOSE AND TAIL DEBURRING SYSTEM


MACHINE ASSEMBLY SEQUENCE
Machine: Nose and tail deburring system

Pos.

1.5 - nose and


tail deburring
system

Type: DBR-029-24-3-15-L-E

Component/Unit

01

Steel structure support for roller

02

Roller with head blade

03

Tail blade

04

Systems on the machine

1) Steel structure support for roller


Sling the beam 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.
2) Roller with head blades
Sling the roller with support in the correct way and put it into the relevant seat with
a proper lifting device.
Check the correct tightening of the bolts of the bladeholders.
3) Tail blade
Sling properly the blade unit and put it on the relevant seat by means of a suitable
lifting device. Check its verticality.
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.
4) Systems on the machine
Connect the following systems to the nose deburring system:
 motor electrical feeding;
 cooling system;
 pneumatic system;
 lubrication system.
For all systems, see the instructions in the Manufacturers documentation.

April, 2006

1.0 - ASSEMBLY SEQUENCES FOR


THE EVACUATION AREA

P. 8
Of 22

SEC. 1.0

DOC. No. DPXXXX-HC11-M1001-KB0X1 REV. 00


Assembly sequences and start-up instructions for the evacuation area
VRI-6-27-04-30-30-06 + VRC-1-27-04-19-19-27 + CCS-L-3-6-15-23-028 + CCP-1-6-15-10-24-029 +
DBR-029-24-3-15-L-E + VRL-6-27-04-42-42-11 + TEC-094-310-06-2-R + PRC-093-094-06-2-B +
VRE-03-04-26-26-34 + PWI-168-094-00-C-181 + PRC-090-094-06-2-B + PRC-090-094-06-2-B

1.6 - DISCHARGE ROLLER TABLE


MACHINE ASSEMBLY SEQUENCE
Machine: Discharge roller table

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

Guards and safety devices

06

Systems on the machine

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

1.0 - ASSEMBLY SEQUENCES FOR


THE EVACUATION AREA

P. 9
Of 22

SEC. 1.0

DOC. No. DPXXXX-HC11-M1001-KB0X1 REV. 00


Assembly sequences and start-up instructions for the evacuation area
VRI-6-27-04-30-30-06 + VRC-1-27-04-19-19-27 + CCS-L-3-6-15-23-028 + CCP-1-6-15-10-24-029 +
DBR-029-24-3-15-L-E + VRL-6-27-04-42-42-11 + TEC-094-310-06-2-R + PRC-093-094-06-2-B +
VRE-03-04-26-26-34 + PWI-168-094-00-C-181 + PRC-090-094-06-2-B + PRC-090-094-06-2-B

DOC. No. DPXXXX-HC11-M1001-KB0X1 REV. 00


Assembly sequences and start-up instructions for the evacuation area
VRI-6-27-04-30-30-06 + VRC-1-27-04-19-19-27 + CCS-L-3-6-15-23-028 + CCP-1-6-15-10-24-029 +
DBR-029-24-3-15-L-E + VRL-6-27-04-42-42-11 + TEC-094-310-06-2-R + PRC-093-094-06-2-B +
VRE-03-04-26-26-34 + PWI-168-094-00-C-181 + PRC-090-094-06-2-B + PRC-090-094-06-2-B

SEC. 1.0

5) Guards and safety devices


Install the required guards and safety devices on each discharge roller table as
shown in the relevant assembly drawings.
6) Systems on the machine
Connect the following systems to the discharge roller table:
 motor electrical feeding;
 cooling system;
 hydraulic system;
 lubrication system.
For all systems, see the instructions in the Manufacturers documentation.

April, 2006

1.0 - ASSEMBLY SEQUENCES FOR


THE EVACUATION AREA

P. 10
Of 22

1.7 - blooms
elevator

1.7 - BLOOMS ELEVATOR


MACHINE ASSEMBLY SEQUENCE
Machine: Blooms elevator

Pos.

Type: TEC-094-310-06-2-R

Component/Unit

01

Metal structure

02

Supports for chain wheels

03

Chain wheels

04

Chain and chain adjuster

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

1.0 - ASSEMBLY SEQUENCES FOR


THE EVACUATION AREA

P. 11
Of 22

SEC. 1.0

DOC. No. DPXXXX-HC11-M1001-KB0X1 REV. 00


Assembly sequences and start-up instructions for the evacuation area
VRI-6-27-04-30-30-06 + VRC-1-27-04-19-19-27 + CCS-L-3-6-15-23-028 + CCP-1-6-15-10-24-029 +
DBR-029-24-3-15-L-E + VRL-6-27-04-42-42-11 + TEC-094-310-06-2-R + PRC-093-094-06-2-B +
VRE-03-04-26-26-34 + PWI-168-094-00-C-181 + PRC-090-094-06-2-B + PRC-090-094-06-2-B

DOC. No. DPXXXX-HC11-M1001-KB0X1 REV. 00


Assembly sequences and start-up instructions for the evacuation area
VRI-6-27-04-30-30-06 + VRC-1-27-04-19-19-27 + CCS-L-3-6-15-23-028 + CCP-1-6-15-10-24-029 +
DBR-029-24-3-15-L-E + VRL-6-27-04-42-42-11 + TEC-094-310-06-2-R + PRC-093-094-06-2-B +
VRE-03-04-26-26-34 + PWI-168-094-00-C-181 + PRC-090-094-06-2-B + PRC-090-094-06-2-B

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

1.0 - ASSEMBLY SEQUENCES FOR


THE EVACUATION AREA

P. 12
Of 22

1.8 - PAWL COLLECTING PLATE


MACHINE ASSEMBLY SEQUENCE
Machine: Pawl collecting plate

Pos.

1.8 - pawl
collecting
plate

Type: PRC-093-094-06-2-B

Component/Unit

01

Supporting frame

02

Pawl moving cylinder

03

Support for shaft with levers

04

Pawl supporting frame

05

Guards and safety devices

06

Systems on the machine

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

1.0 - ASSEMBLY SEQUENCES FOR


THE EVACUATION AREA

P. 13
Of 22

SEC. 1.0

DOC. No. DPXXXX-HC11-M1001-KB0X1 REV. 00


Assembly sequences and start-up instructions for the evacuation area
VRI-6-27-04-30-30-06 + VRC-1-27-04-19-19-27 + CCS-L-3-6-15-23-028 + CCP-1-6-15-10-24-029 +
DBR-029-24-3-15-L-E + VRL-6-27-04-42-42-11 + TEC-094-310-06-2-R + PRC-093-094-06-2-B +
VRE-03-04-26-26-34 + PWI-168-094-00-C-181 + PRC-090-094-06-2-B + PRC-090-094-06-2-B

DOC. No. DPXXXX-HC11-M1001-KB0X1 REV. 00


Assembly sequences and start-up instructions for the evacuation area
VRI-6-27-04-30-30-06 + VRC-1-27-04-19-19-27 + CCS-L-3-6-15-23-028 + CCP-1-6-15-10-24-029 +
DBR-029-24-3-15-L-E + VRL-6-27-04-42-42-11 + TEC-094-310-06-2-R + PRC-093-094-06-2-B +
VRE-03-04-26-26-34 + PWI-168-094-00-C-181 + PRC-090-094-06-2-B + PRC-090-094-06-2-B

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

1.0 - ASSEMBLY SEQUENCES FOR


THE EVACUATION AREA

P. 14
Of 22

1.9 - TRANSPORT ROLLER TABLE (W.B. AREA)


MACHINE ASSEMBLY SEQUENCE

1.9 - transport
roller table
(w.b. area)

Machine: Transfer roller table (walking beam area) Type: VRE-03-04-26-26-34

Pos.

Component/Unit

01

Frame supports

02

Supporting frame

03

Rollers

04

Motor unit

05

Guards and safety devices

06

Systems on the machine

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

1.0 - ASSEMBLY SEQUENCES FOR


THE EVACUATION AREA

P. 15
Of 22

SEC. 1.0

DOC. No. DPXXXX-HC11-M1001-KB0X1 REV. 00


Assembly sequences and start-up instructions for the evacuation area
VRI-6-27-04-30-30-06 + VRC-1-27-04-19-19-27 + CCS-L-3-6-15-23-028 + CCP-1-6-15-10-24-029 +
DBR-029-24-3-15-L-E + VRL-6-27-04-42-42-11 + TEC-094-310-06-2-R + PRC-093-094-06-2-B +
VRE-03-04-26-26-34 + PWI-168-094-00-C-181 + PRC-090-094-06-2-B + PRC-090-094-06-2-B

DOC. No. DPXXXX-HC11-M1001-KB0X1 REV. 00


Assembly sequences and start-up instructions for the evacuation area
VRI-6-27-04-30-30-06 + VRC-1-27-04-19-19-27 + CCS-L-3-6-15-23-028 + CCP-1-6-15-10-24-029 +
DBR-029-24-3-15-L-E + VRL-6-27-04-42-42-11 + TEC-094-310-06-2-R + PRC-093-094-06-2-B +
VRE-03-04-26-26-34 + PWI-168-094-00-C-181 + PRC-090-094-06-2-B + PRC-090-094-06-2-B

SEC. 1.0

5) Guards and safety devices


Install the required guards and safety devices on each discharge roller table as
shown in the relevant assembly drawings.
6) Systems on the machine
Connect the following systems to the discharge roller table:
 motor electrical feeding;
 cooling system;
 hydraulic system;
 lubrication system.
For all systems, see the instructions in the Manufacturers documentation.

April, 2006

1.0 - ASSEMBLY SEQUENCES FOR


THE EVACUATION AREA

P. 16
Of 22

1.10 - walking
beam

1.10 - WALKING BEAM


MACHINE ASSEMBLY SEQUENCE
Machine: Walking beam

Pos.

Type: PWI-168-094-00-C-181

Component/Unit

01

Lifting cylinder support

02

Fixed frame supports

03

Fixed frame

04

Movable frame

05

Translation cylinder

06

Fixed frame blades

07

Movable frame blades

08

Guards and safety devices

09

Systems on the machine

1) Lifting cylinder supports


Sling the support, place it on the foundation plates with a proper lifting device and
carry out the final fastening to the foundations after checking carefully the
elevation values according to the drawing.
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 the other supports.
2) Fixed frame supports
Sling the support, place it on the foundation plates with a proper lifting device,
check the alignment and flatness 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.
Carry out the operations described above for the other supports.
3) Fixed frame
Sling the fixed frame 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.
Check the beam geometry and, in particular, their diagonals; carry out the frame
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.

April, 2006

1.0 - ASSEMBLY SEQUENCES FOR


THE EVACUATION AREA

P. 17
Of 22

SEC. 1.0

DOC. No. DPXXXX-HC11-M1001-KB0X1 REV. 00


Assembly sequences and start-up instructions for the evacuation area
VRI-6-27-04-30-30-06 + VRC-1-27-04-19-19-27 + CCS-L-3-6-15-23-028 + CCP-1-6-15-10-24-029 +
DBR-029-24-3-15-L-E + VRL-6-27-04-42-42-11 + TEC-094-310-06-2-R + PRC-093-094-06-2-B +
VRE-03-04-26-26-34 + PWI-168-094-00-C-181 + PRC-090-094-06-2-B + PRC-090-094-06-2-B

DOC. No. DPXXXX-HC11-M1001-KB0X1 REV. 00


Assembly sequences and start-up instructions for the evacuation area
VRI-6-27-04-30-30-06 + VRC-1-27-04-19-19-27 + CCS-L-3-6-15-23-028 + CCP-1-6-15-10-24-029 +
DBR-029-24-3-15-L-E + VRL-6-27-04-42-42-11 + TEC-094-310-06-2-R + PRC-093-094-06-2-B +
VRE-03-04-26-26-34 + PWI-168-094-00-C-181 + PRC-090-094-06-2-B + PRC-090-094-06-2-B

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)

Fixed frame blades

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

1.0 - ASSEMBLY SEQUENCES FOR


THE EVACUATION AREA

P. 18
Of 22

1.11 - PAWL COLLECTING PLATE (W.B.)


MACHINE ASSEMBLY SEQUENCE
Machine: Pawl collecting plate

Pos.

1.11 - pawl
collecting
plate (w.b.)

Type: PRC-090-094-06-2-B

Component/Unit

01

Supporting frame

02

Pawl moving cylinder

03

Support for shaft with levers

04

Pawl supporting frame

05

Guards and safety devices

06

Systems on the machine

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

1.0 - ASSEMBLY SEQUENCES FOR


THE EVACUATION AREA

P. 19
Of 22

SEC. 1.0

DOC. No. DPXXXX-HC11-M1001-KB0X1 REV. 00


Assembly sequences and start-up instructions for the evacuation area
VRI-6-27-04-30-30-06 + VRC-1-27-04-19-19-27 + CCS-L-3-6-15-23-028 + CCP-1-6-15-10-24-029 +
DBR-029-24-3-15-L-E + VRL-6-27-04-42-42-11 + TEC-094-310-06-2-R + PRC-093-094-06-2-B +
VRE-03-04-26-26-34 + PWI-168-094-00-C-181 + PRC-090-094-06-2-B + PRC-090-094-06-2-B

DOC. No. DPXXXX-HC11-M1001-KB0X1 REV. 00


Assembly sequences and start-up instructions for the evacuation area
VRI-6-27-04-30-30-06 + VRC-1-27-04-19-19-27 + CCS-L-3-6-15-23-028 + CCP-1-6-15-10-24-029 +
DBR-029-24-3-15-L-E + VRL-6-27-04-42-42-11 + TEC-094-310-06-2-R + PRC-093-094-06-2-B +
VRE-03-04-26-26-34 + PWI-168-094-00-C-181 + PRC-090-094-06-2-B + PRC-090-094-06-2-B

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

1.0 - ASSEMBLY SEQUENCES FOR


THE EVACUATION AREA

P. 20
Of 22

1.12 - PAWL COLLECTING PLATE (SLOW COOL)


MACHINE ASSEMBLY SEQUENCE
Machine: Pawl collecting plate

Pos.

Type: PRC-090-094-06-2-B

1.12 - pawl
collecting
plate (slow
cool)

Component/Unit

01

Supporting frame

02

Pawl moving cylinder

03

Support for shaft with levers

04

Pawl supporting frame

05

Guards and safety devices

06

Systems on the machine

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

1.0 - ASSEMBLY SEQUENCES FOR


THE EVACUATION AREA

P. 21
Of 22

SEC. 1.0

DOC. No. DPXXXX-HC11-M1001-KB0X1 REV. 00


Assembly sequences and start-up instructions for the evacuation area
VRI-6-27-04-30-30-06 + VRC-1-27-04-19-19-27 + CCS-L-3-6-15-23-028 + CCP-1-6-15-10-24-029 +
DBR-029-24-3-15-L-E + VRL-6-27-04-42-42-11 + TEC-094-310-06-2-R + PRC-093-094-06-2-B +
VRE-03-04-26-26-34 + PWI-168-094-00-C-181 + PRC-090-094-06-2-B + PRC-090-094-06-2-B

DOC. No. DPXXXX-HC11-M1001-KB0X1 REV. 00


Assembly sequences and start-up instructions for the evacuation area
VRI-6-27-04-30-30-06 + VRC-1-27-04-19-19-27 + CCS-L-3-6-15-23-028 + CCP-1-6-15-10-24-029 +
DBR-029-24-3-15-L-E + VRL-6-27-04-42-42-11 + TEC-094-310-06-2-R + PRC-093-094-06-2-B +
VRE-03-04-26-26-34 + PWI-168-094-00-C-181 + PRC-090-094-06-2-B + PRC-090-094-06-2-B

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

1.0 - ASSEMBLY SEQUENCES FOR


THE EVACUATION AREA

P. 22
Of 22

DOC. No. DPXXXX-HC11-M1001-KB0X1 REV. 00


Assembly sequences and start-up instructions for the evacuation area
VRI-6-27-04-30-30-06 + VRC-1-27-04-19-19-27 + CCS-L-3-6-15-23-028 + CCP-1-6-15-10-24-029 +
DBR-029-24-3-15-L-E + VRL-6-27-04-42-42-11 + TEC-094-310-06-2-R + PRC-093-094-06-2-B +
VRE-03-04-26-26-34 + PWI-168-094-00-C-181 + PRC-090-094-06-2-B + PRC-090-094-06-2-B

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)

Connect the lubrication system to the relevant power mains.


Connect the cooling system to the relevant power mains.
Connect the hydraulic system to the relevant power mains.
Connect the pneumatic system to the relevant power mains.

2.2 - electrical
connections

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.

DOC. No. DPXXXX-HC11-M1001-KB0X1 REV. 00


Assembly sequences and start-up instructions for the evacuation area
VRI-6-27-04-30-30-06 + VRC-1-27-04-19-19-27 + CCS-L-3-6-15-23-028 + CCP-1-6-15-10-24-029 +
DBR-029-24-3-15-L-E + VRL-6-27-04-42-42-11 + TEC-094-310-06-2-R + PRC-093-094-06-2-B +
VRE-03-04-26-26-34 + PWI-168-094-00-C-181 + PRC-090-094-06-2-B + PRC-090-094-06-2-B

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

b) Systems on the machine


Connect the electric systems to the relevant networks and auxiliary systems by
means of the Junction Boxes (J.B.), according to the relevant diagrams indicated
at the end of this manual and to DANIELI Automation documentation supplied
separately.

April, 2006

2.0 - CONNECTIONS

P. 2
Of 2

DOC. No. DPXXXX-HC11-M1001-KB0X1 REV. 00


Assembly sequences and start-up instructions for the evacuation area
VRI-6-27-04-30-30-06 + VRC-1-27-04-19-19-27 + CCS-L-3-6-15-23-028 + CCP-1-6-15-10-24-029 +
DBR-029-24-3-15-L-E + VRL-6-27-04-42-42-11 + TEC-094-310-06-2-R + PRC-093-094-06-2-B +
VRE-03-04-26-26-34 + PWI-168-094-00-C-181 + PRC-090-094-06-2-B + PRC-090-094-06-2-B

3.0 - NO-LOAD TESTS AND SET-UP


3.1 - first lubrication

3.1 - FIRST LUBRICATION


For the correct lubricant type and quantity (oil, grease), please see the
"Lubrication tables collection" manual.

a) Lubrication system of the reduction gear


The reduction gear with splash lubrication requires the following operations:
 if necessary, clean thoroughly the inner part of the reduction gear body with
a suitable detergent, dry it with compressed air and make sure that there are
no foreign bodies or detergent residues inside it;
 place the draining plug in the proper way and fill the reduction gear. *During
this operation, make sure that oil is not contaminated with foreign materials
from the surrounding environment;
 check the oil level by means of the relevant indicator;
 check for any leak from the gaskets;
 make sure that the air bleeding filter is installed in the proper way.

3.2 - no-load tests


and set-up of the
components and
systems

* 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.

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

3.0 - NO-LOAD TESTS AND


SET-UP

P. 1
Of 11

SEC. 3.0

3.2 - NO-LOAD TESTS AND SET-UP OF THE COMPONENTS


AND SYSTEMS

DOC. No. DPXXXX-HC11-M1001-KB0X1 REV. 00


Assembly sequences and start-up instructions for the evacuation area
VRI-6-27-04-30-30-06 + VRC-1-27-04-19-19-27 + CCS-L-3-6-15-23-028 + CCP-1-6-15-10-24-029 +
DBR-029-24-3-15-L-E + VRL-6-27-04-42-42-11 + TEC-094-310-06-2-R + PRC-093-094-06-2-B +
VRE-03-04-26-26-34 + PWI-168-094-00-C-181 + PRC-090-094-06-2-B + PRC-090-094-06-2-B

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

3.0 - NO-LOAD TESTS AND


SET-UP

P. 2
Of 11

DOC. No. DPXXXX-HC11-M1001-KB0X1 REV. 00


Assembly sequences and start-up instructions for the evacuation area
VRI-6-27-04-30-30-06 + VRC-1-27-04-19-19-27 + CCS-L-3-6-15-23-028 + CCP-1-6-15-10-24-029 +
DBR-029-24-3-15-L-E + VRL-6-27-04-42-42-11 + TEC-094-310-06-2-R + PRC-093-094-06-2-B +
VRE-03-04-26-26-34 + PWI-168-094-00-C-181 + PRC-090-094-06-2-B + PRC-090-094-06-2-B

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

Carry out the following operations:


 clean thoroughly the area near the greaser;
 insert the pump quick coupling into the greaser;
 pump the correct quantity of grease;
 remove the quick coupling and any outcoming grease.
d) Hydraulic system
Before carrying out the following checks, make sure that the hydraulic central unit
has been properly started according to the operations described in the relevant
manual of instructions, including the washing of the pipings:
 drain the air from the circuit through the proper air bleeds;
 check the pressure of the hydraulic fluid that feeds the various devices;
 set the working pressure and speed on each adjusting valve;
 check carefully the whole system and make sure that there are no leaks of
hydraulic fluid, in particular on the connections between flexible and rigid pipes.
The pipings shall be washed VERY CAREFULLY: some welding slags or foreign
materials inside them can damage them or alter their good operation.
e) Water cooling system
Note: If not otherwise indicated on the reference drawings, use cooling water
according to DANIELI standard n. 2.4.305.
Before carrying out the operation described below, make sure that the pumping
station of the water treatment system has been properly started.
At the end of all the required connections (feeding pipings for the various users),
open the valves and carry out the following operations:
 set the required working pressure by means of the proper adjusting instruments;
 check the circuits carefully with particular attention to the gaskets and the
connectors between the flexible/rigid ducts and eliminate any water leak;
connect a flowmeter and measure the water flow rate to each circuit;
connect a pressure switch and measure the water pressure to each circuit.
Furthermore, check the following alarm conditions:
 simulation of minimum flow rate of direct cooling water;
 simulation of maximum temperature of indirect cooling water (if required).

April, 2006

3.0 - NO-LOAD TESTS AND


SET-UP

P. 3
Of 11

DOC. No. DPXXXX-HC11-M1001-KB0X1 REV. 00


Assembly sequences and start-up instructions for the evacuation area
VRI-6-27-04-30-30-06 + VRC-1-27-04-19-19-27 + CCS-L-3-6-15-23-028 + CCP-1-6-15-10-24-029 +
DBR-029-24-3-15-L-E + VRL-6-27-04-42-42-11 + TEC-094-310-06-2-R + PRC-093-094-06-2-B +
VRE-03-04-26-26-34 + PWI-168-094-00-C-181 + PRC-090-094-06-2-B + PRC-090-094-06-2-B

3.3 - NO-LOAD TESTS AND CHECKS


When all the adjustments and checks described in the previous chapter have
been completed and all the moving components have been lubricated, start up
the machine loadless (see also the "Electrical sequences" manual supplied
separately).
With this operation, which should last several hours, all the moving parts can
further settle and all the auxiliary devices and equipment can be set up, in order
to ensure the proper performance of the machine at the best safety conditions.
Even when the system is used irregularly or in case of long stops, it is always
advisable to start the system idle several times before the operating cycle in order
to check the proper performance of all its components.
Idle tests must be carried out manually and automatically, simulating a real
operating sequence.

3.3 - no.load tests


and checks

Start the machine, operating in the manual mode from the local control desk.

3.3.1 - INTERMEDIATE ROLLER TABLE



















Proper installation check


Preconditions:
Mechanical, electrical erection completed, oil filled in the gear box and
grease the chain
MCC-PLC and MMI started-up.
Motor rotation check.
Verify the correct function of all devices installed on the roller tables (control
flaps, movable rollers, disappearing stops, fixed stops).
Verify correspondence between field sensors and PLC/MMI.
Check that the nuts and bolts are correctly tightened, in according at the
Danieli Standard 2.4.603.
Check that all parts are properly fixed.
Verify that the welding parts must be in according at the Danieli standard
No.2.8.006
Check the general lubrication, verify that the grease reach all the bearings
supports.
Verify before to install the flexible hoses that they are complete free without
any restriction or clogged internal hoses.
Set the hydraulic cylinders speed at the design value.
Verify the brake at the end of cylinder stroke.
Verify if there is any oil leakage.
Set the pneumatic cylinders speed at the design value.
Verify the brake at the end of cylinder stroke.
Verify if there is any air leakage.
Check the water flow cooling and set the flow switches indicator.
Verify the correct alarm indication on alarm page.
Sequence checks from MMI.

April, 2006

3.0 - NO-LOAD TESTS AND


SET-UP

3.3.1 intermediate
roller table

P. 4
Of 11

SEC. 3.0

Make the no load tests complying strictly with the safety rules.

DOC. No. DPXXXX-HC11-M1001-KB0X1 REV. 00


Assembly sequences and start-up instructions for the evacuation area
VRI-6-27-04-30-30-06 + VRC-1-27-04-19-19-27 + CCS-L-3-6-15-23-028 + CCP-1-6-15-10-24-029 +
DBR-029-24-3-15-L-E + VRL-6-27-04-42-42-11 + TEC-094-310-06-2-R + PRC-093-094-06-2-B +
VRE-03-04-26-26-34 + PWI-168-094-00-C-181 + PRC-090-094-06-2-B + PRC-090-094-06-2-B

3.3.2 - crops end


collecting car

3.3.2 - CROPS END COLLECTING CAR








Proper installation check


Preconditions:
Mechanical and electrical erection completed.
Oil gear filled and grease in all manual points.
MCC-PLC and MMI started-up.
Verify the limit switches position.
Electrical motor driver setting
Set spring force for correct rope tension
Car movement. Electrical motor absorbtion.
Verify the interlocks, the electrical signal and the sequence.
Verify the work time for the crop car.

3.3.3 - samples
collecting car

3.3.3 - SAMPLES COLLECTING CAR








Proper installation check


Preconditions:
Mechanical and electrical erection completed.
Oil gear filled and grease in all manual points.
MCC-PLC and MMI started-up.
Verify the limit switches position.
Electrical motor driver setting
Set spring force for correct rope tension
Car movement. Electrical motor absorbtion.
Verify the interlocks, the electrical signal and the sequence.
Verify the work time for the crop car.

3.3.4 - CUTTING AND TRANSPORT ROLLER TABLE











SEC. 3.0

3.3.4 - cutting and


transport roller table

Proper installation check.


Preconditions:
Mechanical and electrical erection completed.
Oil gear filled and grease in all manual points.
MCC-PLC and MMI started-up.
Motor rotation check.
Verify the correct function of all devices installed on the roller tables (control
flaps, movable rollers, disappearing stops, fixed stops).
Set the hydraulic pressure at the design values.
Set the cylinders speed at the appropriate value.
Verify if there is any oil leakage.
Check the water flow cooling and set the flow switches indicator.
Verify the correct alarm indication on alarm page.
Check the limith or proximity switches function and position.
Sequence checks from main pulpit and MMI.

April, 2006

3.0 - NO-LOAD TESTS AND


SET-UP

P. 5
Of 11

DOC. No. DPXXXX-HC11-M1001-KB0X1 REV. 00


Assembly sequences and start-up instructions for the evacuation area
VRI-6-27-04-30-30-06 + VRC-1-27-04-19-19-27 + CCS-L-3-6-15-23-028 + CCP-1-6-15-10-24-029 +
DBR-029-24-3-15-L-E + VRL-6-27-04-42-42-11 + TEC-094-310-06-2-R + PRC-093-094-06-2-B +
VRE-03-04-26-26-34 + PWI-168-094-00-C-181 + PRC-090-094-06-2-B + PRC-090-094-06-2-B

3.3.5 - NOSE AND TAIL DEBURRING SYSTEM








Proper installation check.


Preconditions:
Mechanical and electrical erection completed.
Oil gear filled and grease in all manual points.
MCC-PLC and MMI started-up.
Set the air pressure at the design values.
Set the cylinders speed at the appropriate value.
Verify if there is any air leakage.
Verify the correct alarm indication on alarm page.
Check the limith or proximity switches function and position.
Sequence checks from main pulpit and MMI.

3.3.6 - discharge
roller table

3.3.6 - DISCHARGE ROLLER TABLE















Proper installation check.


Preconditions:
Mechanical erection and electrical erection completed.
MCC-PLC and MMI started-up.
Verify correspondence between field sensors and PLC/MMI.
Check that the nuts and bolts are correctly tightened, in according at the
Danieli Standard 2.4.603.
Check that all parts are properly fixed.
Verify that the welding parts must be in according at the Danieli standard
No.2.8.006.
Electrical motor driver setting.
Check the general lubrication, oil levels in the reduction gears, verify that the
grease reach all the bearings supports, pins and guide.
Verify the movement for each device installed on the discharge roller table.
Verify the limit switches.
Check the properly function of hydraulic system.
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 pressure water.
Check the hydraulic cylinders moviment without unusually noise and friction.
Verify the properly stroke.
Sequence checks from main pulpit and MMI.

April, 2006

3.0 - NO-LOAD TESTS AND


SET-UP

SEC. 3.0

3.3.5 - nose and tail


deburring system

P. 6
Of 11

DOC. No. DPXXXX-HC11-M1001-KB0X1 REV. 00


Assembly sequences and start-up instructions for the evacuation area
VRI-6-27-04-30-30-06 + VRC-1-27-04-19-19-27 + CCS-L-3-6-15-23-028 + CCP-1-6-15-10-24-029 +
DBR-029-24-3-15-L-E + VRL-6-27-04-42-42-11 + TEC-094-310-06-2-R + PRC-093-094-06-2-B +
VRE-03-04-26-26-34 + PWI-168-094-00-C-181 + PRC-090-094-06-2-B + PRC-090-094-06-2-B

3.3.7 - blooms
elevator

3.3.7 - BLOOMS ELEVATOR










Proper installation check.


Preconditions:
Mechanical erection and electrical erection completed.
MCC-PLC and MMI started-up.
Verify correspondence between field sensors and PLC/MMI.
Check that the nuts and bolts are correctly tightened, in according at the
Danieli Standard No. 2.4.603.
Check that all parts are properly fixed.
Verify that the welding parts must be in according at the Danieli standard
No.2.8.006.
Check the general lubrication, verify that the grease reach all the bearings
supports, pins and guide.
Sequence checks from main pulpit and MMI.
Verify the complete cycle time without load.
Verify the complet cycle time with load.

3.3.8 - PAWL COLLECTING PLATE
















Proper installation check.


Preconditions: Mechanical erection and electrical erection completed.
MCC-PLC and MMI started-up.
Verify correspondence between field sensors and PLC/MMI.
Check that the nuts and bolts are correctly tightened, in according at the
Danieli Standard 2.4.603.
Check that all parts are properly fixed.
Verify that the welding parts must be in according at the Danieli standard
No.2.8.006.
Check the general lubrication:
verify that the grease reach all the bearings cylinder supports, pins and
guide.
Check the properly function of hydraulic system.
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

3.0 - NO-LOAD TESTS AND


SET-UP

3.3.8 - pawl
collecting
plate

P. 7
Of 11

SEC. 3.0

DOC. No. DPXXXX-HC11-M1001-KB0X1 REV. 00


Assembly sequences and start-up instructions for the evacuation area
VRI-6-27-04-30-30-06 + VRC-1-27-04-19-19-27 + CCS-L-3-6-15-23-028 + CCP-1-6-15-10-24-029 +
DBR-029-24-3-15-L-E + VRL-6-27-04-42-42-11 + TEC-094-310-06-2-R + PRC-093-094-06-2-B +
VRE-03-04-26-26-34 + PWI-168-094-00-C-181 + PRC-090-094-06-2-B + PRC-090-094-06-2-B

3.3.9 - TRANSPORT ROLLER TABLE (W.B. AREA)
















Proper installation check.


Preconditions: Mechanical erection and electrical erection completed.
MCC-PLC and MMI started-up.
Verify correspondence between field sensors and PLC/MMI.
Check that the nuts and bolts are correctly tightened, in according at the
Danieli Standard No. 2.4.603.
Check that all parts are properly fixed.
Verify that the welding parts must be in according at the Danieli standard
No.2.8.006.
Electrical motor driver setting.
Check the general lubrication, oil levels in the reduction gears, verify that the
grease reach all the bearings supports, pins and guide.
Verify the movement for each device installed on the discharge roller table.
Verify the limit switches.
Check the properly function of hydraulic system.
Check the properly function of water system.
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.

3.3.10 - walking
beam

3.3.10 - WALKING BEAM













SEC. 3.0

3.3.9 - transport roller


table (w.b. area)

Proper installation check.


Preconditions:
Mechanical erection and electrical erection completed.
MCC-PLC and MMI started-up.
Verify correspondence between field sensors and PLC/MMI.
Check that the nuts and bolts are correctly tightened, in according at the
Danieli Standard 2.4.603.
Check that all parts are properly fixed.
Verify that the welding parts must be in according at the Danieli standard
No.2.8.006.
Encoder proper assembly
Check the general lubrication:
verify that the grease reach all the bearings cylinder supports, pins and
guide.
Verify the movement for each device installed on the walking beam
Verify the limit switches of flap unit.
Check the properly function of hydraulic system.
Check the properly function of water system.
Verify before to install the flexible hoses that they are complete free without
any restriction or clogged internal hoses.

April, 2006

3.0 - NO-LOAD TESTS AND


SET-UP

P. 8
Of 11

DOC. No. DPXXXX-HC11-M1001-KB0X1 REV. 00


Assembly sequences and start-up instructions for the evacuation area
VRI-6-27-04-30-30-06 + VRC-1-27-04-19-19-27 + CCS-L-3-6-15-23-028 + CCP-1-6-15-10-24-029 +
DBR-029-24-3-15-L-E + VRL-6-27-04-42-42-11 + TEC-094-310-06-2-R + PRC-093-094-06-2-B +
VRE-03-04-26-26-34 + PWI-168-094-00-C-181 + PRC-090-094-06-2-B + PRC-090-094-06-2-B








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 lifting/lowering hydraulic cylinders.
Set the time for forward/backword hydraulic cylinders.
Verify the complete cycle time without load.
Verify the complet cycle time with load.

3.3.11 - pawl
collecting plate (w.b.)

3.3.11 - PAWL COLLECTING PLATE (W.B.)
















Proper installation check.


Preconditions: Mechanical erection and electrical erection completed.
MCC-PLC and MMI started-up.
Verify correspondence between field sensors and PLC/MMI.
Check that the nuts and bolts are correctly tightened, in according at the
Danieli Standard 2.4.603.
Check that all parts are properly fixed.
Verify that the welding parts must be in according at the Danieli standard
No.2.8.006.
Check the general lubrication:
verify that the grease reach all the bearings cylinder supports, pins and
guide.
Check the properly function of hydraulic system.
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.

3.3.12 - PAWL COLLECTING PLATE (SLOW COOL)









Proper installation check.


Preconditions: Mechanical erection and electrical erection completed.
MCC-PLC and MMI started-up.
Verify correspondence between field sensors and PLC/MMI.
Check that the nuts and bolts are correctly tightened, in according at the
Danieli Standard 2.4.603.
Check that all parts are properly fixed.
Verify that the welding parts must be in according at the Danieli standard
No.2.8.006.
Check the general lubrication:
verify that the grease reach all the bearings cylinder supports, pins and
guide.
Check the properly function of hydraulic system.

April, 2006

3.0 - NO-LOAD TESTS AND


SET-UP

SEC. 3.0

3.3.12 - pawl
collecting plate (slow
cool)

P. 9
Of 11

DOC. No. DPXXXX-HC11-M1001-KB0X1 REV. 00


Assembly sequences and start-up instructions for the evacuation area
VRI-6-27-04-30-30-06 + VRC-1-27-04-19-19-27 + CCS-L-3-6-15-23-028 + CCP-1-6-15-10-24-029 +
DBR-029-24-3-15-L-E + VRL-6-27-04-42-42-11 + TEC-094-310-06-2-R + PRC-093-094-06-2-B +
VRE-03-04-26-26-34 + PWI-168-094-00-C-181 + PRC-090-094-06-2-B + PRC-090-094-06-2-B





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

3.0 - NO-LOAD TESTS AND


SET-UP

P. 10
Of 11

DOC. No. DPXXXX-HC11-M1001-KB0X1 REV. 00


Assembly sequences and start-up instructions for the evacuation area
VRI-6-27-04-30-30-06 + VRC-1-27-04-19-19-27 + CCS-L-3-6-15-23-028 + CCP-1-6-15-10-24-029 +
DBR-029-24-3-15-L-E + VRL-6-27-04-42-42-11 + TEC-094-310-06-2-R + PRC-093-094-06-2-B +
VRE-03-04-26-26-34 + PWI-168-094-00-C-181 + PRC-090-094-06-2-B + PRC-090-094-06-2-B

2.4 - INSTRUMENTS AND TOOLS FOR CHECKS AND TESTS


During the setting-up phases and tests, a set of readily available measure
instruments is required to guarantee that the operations described in the previous
chapters are carried out properly.

2.4 - instruments and


tools for checks and
tests

The following is a list of the most important:


Idle tests and setting up of the lubrication and pneumatic systems
 Pressure gauges complete hoses with minimeck connection
 P.p.m. meter to measure the pollution of the fluid
 Contact thermometer
 Tester
Machine idle test and setting up
Megger
Tester (digital type)
Revolution counter
Stethoscope
Vibration control device (doppler effect)
Contact thermometer

April, 2006

SEC. 3.0








3.0 - NO-LOAD TESTS AND


SET-UP

P. 11
Of 11

DOC. No. DPXXXX-HC11-M1001-KB0X1 REV. 00


Assembly sequences and start-up instructions for the evacuation area
VRI-6-27-04-30-30-06 + VRC-1-27-04-19-19-27 + CCS-L-3-6-15-23-028 + CCP-1-6-15-10-24-029 +
DBR-029-24-3-15-L-E + VRL-6-27-04-42-42-11 + TEC-094-310-06-2-R + PRC-093-094-06-2-B +
VRE-03-04-26-26-34 + PWI-168-094-00-C-181 + PRC-090-094-06-2-B + PRC-090-094-06-2-B

4.0 - TECHNICAL DOCUMENTATION


4.1 - list of drawings

4.1 - LIST OF DRAWINGS

Intermediate roller table


8.322142.C

Cooling system for photocell

8.322138.G

Cooling system

8.322134.V

Guards

8.322133.R

Intermediate roller table

8.322132.T/A03

Mobile roller group

8.322131.S

Left roller table

8.322129.F/A07

Drive unit

8.322129.F/A06

Drive unit

8.322128.E

Cooling system for left roller table

8.322127.W

Grease lubrication system

8.322126.V/A01

Photocells installation

8.322125.R/A01

Roller group

8.322123.S/A03

Mobile roller group

8.322118.C/A01

Dummy bar disconnection system

8.322112.W

Right intermediate roller table

8.322111.V/A01

Roller group

8.317430.D

Hydraulic system for mobile roller

8.317400.P/A02

Arm support group

8.317398.Q/A02

Left measuring roller

8.317392.B/A02

Basement group

8.317389.P/A02

Right measuring roller

8.277861.Q

Wheel assembly

8.277719.S

Pneumatic system for measuring roller

8.120067.F

Hydraulic system

8.120050.H/A02

Lever group

April, 2006

4.0 - TECHNICAL DOCUMENTATION

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

Arm support group

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

Grease lubrication system

Crop ends collecting car


8.342616.K

Turnbuckle transmission wheel

8.342610.Z

Crop ends collecting car

8.120816.T/A06

Capstain group

6.146984.Q

Devices location

6.062873.X

Grease lubrication system

Samples collecting car


8.342611.M

Samples collecting car

8.120163.C/A06

Capstain group

6.146985.H

Devices location

SEC. 4.0

DOC. No. DPXXXX-HC11-M1001-KB0X1 REV. 00


Assembly sequences and start-up instructions for the evacuation area
VRI-6-27-04-30-30-06 + VRC-1-27-04-19-19-27 + CCS-L-3-6-15-23-028 + CCP-1-6-15-10-24-029 +
DBR-029-24-3-15-L-E + VRL-6-27-04-42-42-11 + TEC-094-310-06-2-R + PRC-093-094-06-2-B +
VRE-03-04-26-26-34 + PWI-168-094-00-C-181 + PRC-090-094-06-2-B + PRC-090-094-06-2-B

Cutting and transport roller table


8.342604.X
Cooling system
8.342599.K

Cooling system

8.342598.H

Grease lubrication system

8.342594.E

Control flap

8.342589.Q

Guards

8.342588.P

Left cutting and transport roller table

8.342587.F

Right cutting and transport roller table

8.342586.E

Cutting and transport roller table

8.333017.W

Hydraulic system

8.333016.V

Movable stop

8.322132.T/A04

Mobile roller group

8.322129.F

Drive unit

8.322125.R/A02

Roller group

8.322125.R/A01

Roller group

April, 2006

4.0 - TECHNICAL DOCUMENTATION

P. 2
Of 7

DOC. No. DPXXXX-HC11-M1001-KB0X1 REV. 00


Assembly sequences and start-up instructions for the evacuation area
VRI-6-27-04-30-30-06 + VRC-1-27-04-19-19-27 + CCS-L-3-6-15-23-028 + CCP-1-6-15-10-24-029 +
DBR-029-24-3-15-L-E + VRL-6-27-04-42-42-11 + TEC-094-310-06-2-R + PRC-093-094-06-2-B +
VRE-03-04-26-26-34 + PWI-168-094-00-C-181 + PRC-090-094-06-2-B + PRC-090-094-06-2-B

8.322123.S/A04

Mobile roller group

8.322111.V/A02

Roller group

8.317430.D

Hydraulic system for mobile roller

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

Grease lubrication system

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

Dismantling and transportation diagram

6.146981.M

Devices location

Discharge roller table


8.342632.K

Guards

8.342631.H

Cooling system

8.342630.V

Grease lubrication system

8.342629.X

Left roller table

8.342628.W

Discharge roller table

8.342626.M

Hydraulic system

8.342625.L

Right roller table

8.342594.E

Control flap group

8.333017.W

Hydraulic system

April, 2006

4.0 - TECHNICAL DOCUMENTATION

SEC. 4.0

Nose and tail deburring system


8.342622.Q
Pneumatic system

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

Photocell group and sensor

8.325900.M

Guards

8.325893.S

Drive unit assembly

8.325892.Z

ASSIEME MAGLIA CATENA

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

Tie rod assembly

6.155234.Z

Dismantling and transportation diagram

6.155233.X

Devices location

Pawls collecting plate


8.342645.X

Cooling system

8.342638.Z

Hydraulic system

8.342634.M

Grease lubrication system

8.342623.H

Shaft with levers

8.342619.V

Pawls collecting plate

8.122277.C

Support

6.146989.V

Dismantling and transportation diagram

6.146988.R

Devices location

April, 2006

4.0 - TECHNICAL DOCUMENTATION

SEC. 4.0

DOC. No. DPXXXX-HC11-M1001-KB0X1 REV. 00


Assembly sequences and start-up instructions for the evacuation area
VRI-6-27-04-30-30-06 + VRC-1-27-04-19-19-27 + CCS-L-3-6-15-23-028 + CCP-1-6-15-10-24-029 +
DBR-029-24-3-15-L-E + VRL-6-27-04-42-42-11 + TEC-094-310-06-2-R + PRC-093-094-06-2-B +
VRE-03-04-26-26-34 + PWI-168-094-00-C-181 + PRC-090-094-06-2-B + PRC-090-094-06-2-B

P. 4
Of 7

DOC. No. DPXXXX-HC11-M1001-KB0X1 REV. 00


Assembly sequences and start-up instructions for the evacuation area
VRI-6-27-04-30-30-06 + VRC-1-27-04-19-19-27 + CCS-L-3-6-15-23-028 + CCP-1-6-15-10-24-029 +
DBR-029-24-3-15-L-E + VRL-6-27-04-42-42-11 + TEC-094-310-06-2-R + PRC-093-094-06-2-B +
VRE-03-04-26-26-34 + PWI-168-094-00-C-181 + PRC-090-094-06-2-B + PRC-090-094-06-2-B

Transport roller table (W.B. area)


8.346823.F
Cooling system for photocell
Hydraulic system

8.342646.Z

Pusher for bars

8.342641.T

Cooling system

8.342640.E

Grease lubrication system

8.342639.S/A01

Roller group

8.342637.Q

Transport roller table for W.B.

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

Grease lubrication system

8.146980.A

Limit switches

8.146967.G

Limit switches

8.122201.F

Control flap group

8.097517.Q

Encoder group

6.147394.S

Motion diagram

6.147392.X

Devices location

April, 2006

SEC. 4.0

8.342653.X

4.0 - TECHNICAL DOCUMENTATION

P. 5
Of 7

DOC. No. DPXXXX-HC11-M1001-KB0X1 REV. 00


Assembly sequences and start-up instructions for the evacuation area
VRI-6-27-04-30-30-06 + VRC-1-27-04-19-19-27 + CCS-L-3-6-15-23-028 + CCP-1-6-15-10-24-029 +
DBR-029-24-3-15-L-E + VRL-6-27-04-42-42-11 + TEC-094-310-06-2-R + PRC-093-094-06-2-B +
VRE-03-04-26-26-34 + PWI-168-094-00-C-181 + PRC-090-094-06-2-B + PRC-090-094-06-2-B

Pawls collecting plate (W.B.)


8.342658.C
Cooling system for photocells
8.342657.R/A02

Photocells group

8.342657.R/A01

Photocells group

8.342655.S

Photocells installation

8.342649.B

Shaft with levers

8.342648.A

Collecting plate

8.342638.Z

Hydraulic system

8.342634.M

Grease lubrication system

8.122277.C

Support

6.146999.X

Dismantling and transportation diagram

6.146998.W

Devices location

Pawls collecting plate (slow cool)


Photocells installation

8.342658.C

Cooling system for photocells

8.342657.R/A03

Photocells group

8.342652.W

Cooling system

8.342649.B

Shaft with levers

8.342642.R

Collecting plate

8.342638.Z

Hydraulic system

8.342634.M

Grease lubrication system

8.122277.C

Support

6.170878.H

Devices location

6.170877.A

Dismantling and transportation diagram

April, 2006

SEC. 4.0

8.342659.D

4.0 - TECHNICAL DOCUMENTATION

P. 6
Of 7

DOC. No. DPXXXX-HC11-M1001-KB0X1 REV. 00


Assembly sequences and start-up instructions for the evacuation area
VRI-6-27-04-30-30-06 + VRC-1-27-04-19-19-27 + CCS-L-3-6-15-23-028 + CCP-1-6-15-10-24-029 +
DBR-029-24-3-15-L-E + VRL-6-27-04-42-42-11 + TEC-094-310-06-2-R + PRC-093-094-06-2-B +
VRE-03-04-26-26-34 + PWI-168-094-00-C-181 + PRC-090-094-06-2-B + PRC-090-094-06-2-B

4.2 - technical
components

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

4.0 - TECHNICAL DOCUMENTATION

P. 7
Of 7