Carat RVZ-500 User manual

OPERATION MANUAL
ASPHALT AND CONCRETE CUTTER
RVZ-500

RVZ-500 Operation manual
page 2 03/2021
Congratulations! You have purchased an asphalt and concrete cutter. You receive a high-quality
and powerful machine, intended for professional use under the heavy duty conditions.
Read this operation manual carefully before starting the machine and always keep this manual - in
this way you will secure safe operation, high working output and long durability of the machine.
The manufacturer bears no responsibility for damages arising from not keeping the operation
manual.

RVZ-500 Operation manual
page 3 03/2021
CONTENT:
1. SAFETY INSTRUCTIONS ....................................................................................................................................3
1.1. GENERAL INSTRUCTIONS ........................................................................................................................................3
1.1.1 Requirements for qualification of the operator................................................................................................3
1.1.2 Contractor´s obligations ..................................................................................................................................3
1.1.3 Operator´s obligations.....................................................................................................................................3
1.1.4 Operation of the machine.................................................................................................................................4
1.1.5 Maintenance and Service .................................................................................................................................4
1.1.6 Transport and Storage .....................................................................................................................................4
1.1.7 Testing..............................................................................................................................................................4
1.2. PROHIBITED ACTIVITIES ..........................................................................................................................................5
1.3. HYGIENIC PRINCIPLES .............................................................................................................................................5
1.4. ENVIRONMENTAL PRINCIPLES .................................................................................................................................5
1.5. LIQUIDATION OF THE MACHINE ..............................................................................................................................5
1.6. SAFETY INSTRUCTIONS ............................................................................................................................................6
1.7. HYGIENIC DATA ......................................................................................................................................................6
2. TECHNICAL DESCRIPTION ..............................................................................................................................7
2.1. BASIC TECHNICAL DATA .........................................................................................................................................7
2.2. LUBRICANTS ...........................................................................................................................................................8
2.3. IDENTIFICATION ......................................................................................................................................................8
2.4. ENGINE IDENTIFICATION .........................................................................................................................................8
3. PRIOR TO STARTING..........................................................................................................................................9
3.1. CHECK-OIL LEVEL ..................................................................................................................................................9
3.2. VISUAL INSPECTION OF THE MACHINE .....................................................................................................................9
3.3. ADDING FUEL .........................................................................................................................................................9
3.4. CHECK-AIR FILTER ..................................................................................................................................................9
4. OPERATION......................................................................................................................................................... 10
4.1. STARTING .............................................................................................................................................................10
4.1.1 Gasoline engines HONDA
4.2. OPERATION ...........................................................................................................................................................10
4.2.1 Selection of the cutting disc............................................................................................................................10
4.2.2 Fastening of the cutting disc ..........................................................................................................................11
4.2.3 Cutting............................................................................................................................................................11
4.2.4 Cutting depth scale.........................................................................................................................................11
4.3. ENGINE TURNING-OFF ...........................................................................................................................................11
4.4. HANDLING,TRANSPORT,STORING ........................................................................................................................12
4.4.1 Manual handling ............................................................................................................................................ 12
4.4.2 Handling by crane..........................................................................................................................................12
4.4.3 Handling by forklift........................................................................................................................................12
4.4.4 Transport........................................................................................................................................................12
4.4.5 Storing............................................................................................................................................................12
4.5. SPECIAL CONDITIONS OF OPERATION .....................................................................................................................13
4.5.1 Work at low temperatures ..............................................................................................................................13
4.5.2 Work at high altitudes ....................................................................................................................................13
4.5.3 Work in dusty environment.............................................................................................................................13
5. MAINTENANCE ..................................................................................................................................................14
5.1. MAINTENANCE OF THE ENGINE..............................................................................................................................14
5.2. TENSIONING OF THE DRIVE BELTS ........................................................................................................................14
5.3. INSPECTION OF BOLTED CONNECTIONS .................................................................................................................14
5.4 ADJUSTMENT OF ENGINE SPEED .............................................................................................................................14
6. MAINTENANCE SCHEDULE............................................................................................................................ 15

RVZ-500 Operation manual
page 4 03/2021
1. SAFETY INSTRUCTIONS
1.1. General instructions for operation of light construction equipment
1.1.1. Requirements for qualification of the operator
1. The machine must be operated by
trained reliable operators of age above
18. The operator must read and
understand the safety instructions, the
regulations valid for the respective
jobsite and valid technological
procedure. This should be proved by
getting the operator’s signature.
2. The operator is obliged to use suitable
working dress, safety gloves and firm boots
with hard tip. Do not wear loose or torn
clothes, chains or jewelry that could be
caught by moving parts of the machine. The
operator is obliged to use safety goggles and
ear protection.
3. The machine may be used for intended
purpose only, in accordance with this
operation manual.
1.1.2. Contractor's obligations
The contractor is understood to be a physical or
legal person that carries out construction works
and for such purpose uses construction
equipment. The contractor is responsible for
operational safety.
The contractor is obliged to:
•designate the operator and arrange his
training
•ensure safe working conditions
•inspect attendance of the safety
regulations
•inspect that the operator works with the
machine in accordance with the Operation
Manual
•ensure regular inspections, maintenance
and repairs of the machine
•store the Operation Manual so that it is
readily available
•arrange suitable, safe and adequate storing
of the machine when not in use
The contractor is also responsible for proper
attendance of lawful regulations of work safety
and regulations valid for each respective jobsite.
1.1.3. Operator's obligations
The operator is to be designated by the
contractor, while keeping conditions of the
article 1.1.1.
The operator is namely obliged to:
•prior to starting, he should read and
understand the Operation Manual
including the safety instructions
•attend all instructions of the Operation
Manual
•learn about the jobsite and the locally
valid safety regulations; these must be
kept during the work
•pay full attention to operation of the
machine
•arrange that regular inspections,
maintenance and repairs of the machine
are carried our as according to the
Operation Manual
•require from the contractor proper
conditions for keeping safety instructions,
regular inspections, maintenance and
repairs
•avoid damage, misuse or unauthorized use
to the machine, namely by proper storing
the machine to a secured place

RVZ-500 Operation manual
page 5 03/2021
1.1.4. Operation of the machine
Before starting:
1. Check the machine thoroughly, repair all
failures before starting the engine. If the
failures cannot be repaired at the jobsite, do
not operate the machine.
2. Check the fuel system for leaking. Dripping
fuel poses fire hazard.
Starting and operation:
3. When starting the engine, take stable
position and held the grip firmly.
4. The controls must be in good order.
5. The operator must not leave from his
position when the engine is running.
6. Stop the engine before interrupting the work.
When parking the machine, secure it from
falling.
7. Stop the engine before refueling. Avoid
contact between fuel and hot parts of the
engine. Let the engine to cool down first.
8. Keep the fuel tank tightly closed. Close the
fuel tap when not in operation. Drain the fuel
before transporting the machine for longer
distances.
DANGER! Leaking fuel tank and distribution
may cause explosion. Replace these parts
immediately if damaged.
Jobsite:
9. No bystanders are allowed within the
operational range of the machine. Especially
children should be kept in safe distance.
10. Do not operate the machine in areas with
explosion danger.
11. If operated in closed spaces (halls, tunnels),
there should be ensured sufficient
ventilation.
12. Held and guide the machine with high care
in order to avoid hands injury caused with
contact with an obstacle.
14. Do not smoke, do not use naked flame. Do
not work close to flammables or in explosion
danger areas.
15. Avoid touching hot parts. The exhaust
silencer and other parts of the engine are
very hot during operation and touching them
can cause serious burns.
1.1.5. Maintenance and Service
1. Do not remove any covers or other safety
devices. In case this must be done because of
service, install all the parts back before
starting.
2. Use genuine spare parts only. Do not carry
out any modifications without prior written
approval of the manufacturer.
3. Stop the engine before servicing the
machine.
1.1.6. Transport and Storage
1. When loading and transporting the machine
fasten the machine properly on the carrier.
2. The machine is to be transported in upright
position (with engine upwards). This
position is also suitable for storing.
3. Prior to long-term storage: Conserve the
machine, cover it and store it at safe, dry and
ventilated place.
1.1.7. Testing
It is recommended to test the machine by
authorized service at least once a year or more
often if used under heavy conditions.
If necessary, carry out repairs of all possible
failures.

RVZ-500 Operation manual
page 6 03/2021
1.2. Prohibited activities
Never:
•use the machine for other than intended
purposes
•use the machine in other way than as
described in the Operation Manual
•operate the machine drunk or intoxicated
•operated the machine if its operation
could cause harm to other people
•start and operate the machine if there are
other people within the dangerous area
•operate the machine if some safety device
(i.e. cover) is damaged or missing
•operate the machine in areas with external
risks (risk of soil flow, dangerous fumes,
risk of explosion, risk of electrical shock,
etc.)
•operate the machine in areas where its
operation may cause damage to buildings,
structures or utility lines
•operate the machine within the protective
range of power lines or transformer
stations
•operate the machine under poor visibility
or at night, unless the jobsite is
sufficiently illuminated
•leave unprotected machine
•disable or modify safety devices,
protective and safety systems
•operate the machine with leaking oil, fuel
or other liquids
•start the engine in other way than
described in the Operation Manual
•clean a running machine
•smoke or use naked flame when refueling
1.3. Hygienic principles
Oil derivates (fuel, lubricants) as well as paints
and thinners are harmful agents. Anyone who
gets into contact with such agents is obliged to
protect himself and follow general principles
health protection as well as to follow
instructions valid for each specific agent.
Pay special care to:
•skin care
•wash hands properly after finishing the
work and apply suitable cream
Store the fuels, lubricants, paints, thinners,
cleansing and conservation agents, as well as
other dangerous agents in original containers,
properly sealed. Never allow storing in
unmarked bottles or containers or even in
beverage bottles. Store such agents in safe place,
out of reach of children.
In case that the agent gets into touch with skin or
eyes, or when it is eaten or inhaled, apply the
first aid and get immediately medical aid.
1.4. Environmental principles
Fuel, lubricants and other operational fluids are
harmful to environment. This category also
includes part of the machine that get into contact
with operational fluids, such as filter and
hydraulic hoses.
After use these belong to dangerous waste.
Pay high attention to avoid leakage of the fluids
and their escape into soil or water (including the
sewage).
Store the fluids in such manner, that the fluids
gets caught in case of accidental leakage.
If these agents still escape, arrange their safe
collection and liquidation.
1.5. Liquidation of the machine
After the machine exceeds its lifetime period,
the contractor is obliged to arrange its proper
liquidation in accordance with the respective
lawful regulations and with regards to
environmental protection.
It is highly recommended to commit this task to
a specialized company.

RVZ-500 Operation manual
page 7 03/2021
1.6. Safety instructions
Besides of general safety instruction, the
following special instruction must be followed:
1. Prior to starting the work, find out where are
underground spaces, utility lines, etc.
2. Never remove the blade cover when the
engine is running.
3. After stopping the engine, wait till the blade
gets fully halted.
4. After fitting the cutting blade, pace on the
cover and secure it.
5. Be sure to remove the wrenches from the
blade shaft!
6. Do no allow other people close to running
machine.
7. DANGER!
The cutting blade is always turning as soon
as the engine is started. The revolving blade
presents a risk of injury!
1.7. Hygienic data
RVZ-500
Noise level
104,5 dB(A)
Acoustic power
115,6 dB(A)
Acceleration transferred to hands
14,5 m/s2
RVZ-500
1. Because of the noise level, the
operator is obliged to use ear
protection effective for the noise level:
105 dB(A)
2. Work with the machine must be
interrupted regularly, the breaks
should last at least:
10 min.
3. Technological procedures should be adapted
to suit the safety breaks.
4. The operator shouldn't be exposed to
excessive noise and/or vibrations during the
safety breaks.
5. Should the limits of maximal exposition be
exceeded, the working position should be
pronounced as “risky” and the respective
authorities should be informed.
6. Operation in or close to residential areas is
restricted from 6.00 a.m. to 6.00 p.m.

RVZ-500 Operation manual
page 8 03/2021
2. TECHNICAL DESCRIPTION
The RVZ-500 is intended for cutting of asphalt
and concrete floors or road layers when
repairing roads, industrial areas, etc.
The machine is based on a rigid frame with fixed
spindle; the cutting disc is lowered to the cut
together with the whole frame. Lowering and
rising of the cutting disc is controlled by means
of a arrested handle that enables fine regulation
of cutting depth.
The machine is intended for wet cutting and
therefore it is equipped with a sprinkling system.
Water for sprinkling can be brought either from
machines-mounted water tank of from external
source.
The machines can be used also for dry cutting,
assuming a suitable cutting disc is used. This
method however causes high generation of dust
and thus breathing protection would be required.
The machine is driven by a single-cylinder, four-
stroke gasoline engine HONDA.
Travel is manual; the operator pushes the
machines by height-adjustable handle.
2.1. Basic Technical Data:
RVZ-500
Cutting depth
(mm)
170
Cutting disc fastening
at right
Max. disc dia
(mm)
500
Travel
manual
Cutting depth adjustment
manual
Arbor hole dia
(mm)
25,4 + PH
Spindle speed
(RPM)
2800
Water tank capacity
(ltr)
20
Weight
(kg)
106
Dimensions L x W x H
(mm)
1050x530x1040
Engine
HONDA
Type
GX 390 Cyclon
Power
(kW)
9,6
Speed
(RPM)
3600
Oil sensor
yes
Fuel consumption
(ltr/hr)
1,5

RVZ-500 Operation manual
page 9 03/2021
2.2. Lubricants
Use brand lubricants according to the specification below only:
- engine oil 15W-40 API SG/CF 4, API SG/CE
content - depending on engine HONDA approx. 1,1 ltr
2.3. Identification
For communication with the manufacturer (i.e.
for warranty claims, service requests, spare parts
ordering) always report exact model and serial
number of your machine.
These data are stamped on the machine decal.
2.4. Engine Identification
In case of problems related to the engine report
also engine type and serial number. This number
is stamped on the engine block of the HONDA
engine.

RVZ-500 Operation manual
page 10 03/2021
3. Prior to Starting
3.1. Check - Oil Level
It is highly recommended to check regularly the
engine oil level even on machines equipped with
the oil sensor.
Clean the filling hole before checking or adding
oil. Wipe dry the dipstick and immerse it in the
oil without screwing it in.
If necessary, add specified sort of oil up to the
upper mark.
NOTE :
Operation with insufficient oil level may cause
serious damage to the engine.
Check the engine oil level daily!
3.2. Visual Inspection of the Machine
Check regularly the machine for:
•missing parts
•released bolts and screws
•oil or fuel leakage
•free motion of the cutting disc spindle
Pay special attention to safety devices (covers)
and controls.
3.3. Adding Fuel
1. Gasoline engines:
Use unleaded or leaded gasoline for motor
vehicles, with octane number 91 or more.
Top up fuel as necessary.
Never use dirty fuel or mixture with oil.
Avoid water and dust from entering the fuel
tank.
3.4. Check - Air Filter
Check the air filter for cleanness on a daily
basis. Clean or replace the filter if dirty.
Never run the machine with air filter missing or
damaged. Dust and dirt which get into the
engine would cause rapid wear.
Fig. Air filter - HONDA

RVZ-500 Operation manual
page 11 03/2021
4. Operation
4.1. Starting
4.1.1. Gasoline Engine HONDA
1. Turn the fuel tap into the ON position.
2. Turn on the electric switch of ignition .
3. Engage the choke („CHOKE“). Do not use it
at warm engine or at high ambient
temperature.
4. Adjust the throttle control lever to idle.
5. Pull out the starter grip slowly till some
resistance is felt, then pull vehemently. Do
not release the grip, but return it slowly into
the original position.
6. Let the engine warm up, then disengage the
choke.
7. Let the engine run at idle for a while before
applying full load.
8. For cutting, shift the throttle control lever to
fully open position.
DANGER!
The spindle and the cutting disc start to
rotate immediately. Be sure that the revolving
disc can not cause any danger for the
bystanders. Have the disc cover installed
before starting.
4.2. Operation
4.2.1. Selection of the Cutting Disc
For safe and efficient operation, right selection
of the cutting disc is highly important. Choose a
high-quality diamond cutting disc and
appropriate type depending on the material to be
cut (asphalt, concrete).
Cutting discs of most suppliers are divided in
quality categories (standard/profi etc.),
sometimes also according to length and height of
the diamond segments, spacing, etc.
Cutting disc diameter is to be selected according
to the type of the machine; if possible, choose
always the maximal allowed diameter. The
spindle speed is adjusted for this size to keep
optimal circumferential cutting speed of the disc.

RVZ-500 Operation manual
page 12 03/2021
4.2.2. Fastening of the Cutting Disc
1. Turn off the engine and open the disc cover.
2. Use the enclosed wrenches to hold the
spindle and unscrew the fastening nut.
NOTE: Left thread!
3. Fit the cutting disc on the spindle and secure
it. Pay attention to the right sense of
direction – see arrow on disc.
4. Close the disc cover and secure it.
Fig. Location of wrenches
4.2.3. Cutting
1. Have the disc raised above floor.
2. Disengage the emergency button (counter
clockwise)
3. On/off switch on motor in on-position
4. Start the motor with the recoil and set to full
throttle.
5. Open the water tap to engage sprinkling.
6. Move the machine to the beginning of the
cut.
7. Lower slowly the disc into the cut, till
required cutting depth is reached.
8. Sensitively push the machine forward and
follow the marked path (use the guide).
9. The machine can only cut in straight
direction. In case the direction must be
changed, raise the disc from the cut, take
new direction and lower the disc again.
7. At the end of the cut, raise the disc, set the
throttle to idle.
NOTE! Check the water level in the tank and
timely add water if necessary.
For optimal service life of the cutting disc, the
operator should work carefully and sensitively.
Do not force the machine!
Nevertheless, lifetime of the disc may vary
depending on the material to be cut and other
factors.
4.2.4. Cutting Depth Scale
Cutter RVZ-500 has a cutting depth scale. Use
the scale as follows:
1. Lower the disc just to touch the ground. In
this position, adjust the "zero" using the
wing nuts below the scale.
2. Alternatively you can just remember the value
on the scale and then add or subtract required
cutting depth as necessary.
4.3. Engine Turning-Off
1. Shift the throttle control lever to idle
position.
2. Let the engine run idle for a while to cool
down.
3. Push emergency stop button
4. Turn the on/off switch to "OFF" position.
5. Close the fuel tap
4.4. Handling, Transport, Storing

RVZ-500 Operation manual
page 13 03/2021
When handling the machine keep safety
regulation shown in this manual and well as
general safety rules valid for operation of lifting
or hoisting equipment.
4.4.1. Manual Handling
For manual lifting, cooperation of more than one
person is required. Hold the machine by frame
or the base plate. Never lift the machine by the
engine.
4.4.2. Handling by Crane
Use a crane of sufficient payload (see Technical
Data). Observe the regulations valid for
operation of cranes. Only qualified personnel
may carry out this work.
Fasten the lifting cable to the marked hooking
point at the machine.
Fig. Hooking point
4.4.3. Handling by Forklift
Should the machine be extensively handled by a
forklift (as when sending it by a transport
service), it is recommended to palletize it. For
one machine use "small" palette (0,8x0,6m), for
two machines standard EUR pallet (1,2x0,8m).
4.4.4. Transport
Secure the machine against rolling over, falling
down or sliding on the carrier. Fasten straps to
suitable points at the frame.
NOTE:
The machine must always be kept in upright
position to prevent oil / fuel leakage.
4.4.5. Storing
Store the machine in a safe place, secured from
theft and misuse. We recommend an indoor dry
place, without excessive concentration of
chemical agents and dust.
Prior to long-term storing clean the machine,
repair the paint and apply suitable preservation
agents. Mark visibly that the machine has been
conservated.
4.5. Special Conditions of Operation

RVZ-500 Operation manual
page 14 03/2021
4.5.1. Work at Low Temperatures
The RVZ-500 cutter is able to work even at low
temperatures. Let the engine to warm up
sufficiently before commencing the work.
In case that the machine is difficult to start, let it
warm up at room temperature first.
4.5.2. Work at High Altitudes
With rising altitude the engine power decreases
due to changed air/fuel ratio. The engine power
can be partially improved by changing of the
main nozzle and different adjustment of the
carburetor (gasoline engines).
In case that the engine should work long-term
above 1500 m above seal level, we recommend
to contact an authorized Honda service agent.
4.5.3. Work in Dusty Environment
In case of dusty environment shorten the
cleaning/replacement intervals of the air filter to
half.
Clean the machine from dust regularly.

RVZ-500 Operation manual
page 15 03/2021
5. Maintenance
The basic activities of maintenance which are
described in this Manual can be carried out by
the designated operator.
Repairs and adjustments beyond the extent of
this Manual should be committed to an
authorized service agent.
NOTE:
During the warranty period, no interventions to
the engine are allowed, except for prescribed
maintenance.
5.1. Maintenance of the Engine
- see enclosed Engine Operation Manual
5.2. Tensioning of the Drive Belts
check regularly tensioning of the drive belts that
drive the cutting disc. Deflection of the belts
under finger pressure should be about 2 cm.
To tension the belts, proceed as follows:
•loosen 4 bolts which fasten the engine to
the base plate
•turn the tensioning screw to tension the
belts
•re-tighten the fastening bolts
When replacing the belts, use all belts of the
same type and dimension.
NOTE! Do not over-tension the belts!
5.3. Inspection of Bolted Connections
It is recommended to inspect the bolted
connections daily before work.
5.4. Adjustment of Engine Speed
If in case of engine replacement or repair, it is
necessary to adjust engine speed. Proceed as
follows:
Engine speed can be measured either by contact
or non-contact revolution meter. If the contact
one is used, remove the belt cover first.
The engine speed should be 3600 RPM.
The disc spindle speed should be: 2800 RPM
NEVER ADJUST HIGHER ENGINE
SPEED THAN SPECIFIED!
(The engine could be damaged due to
excessive vibrations.)
The manufacturer shall not honor any
warranty claims arising from excessive speed
of the engine!
SPEED ADJUSTMENT SHOULD BE DONE
BY AN AUTHORIZED SERVICE AGENT
DURING THE WARRANTY PERIOD!
Fig. Basic groups of the cutter (see exploded views for details)
1= frame
2= drive system
3= undercarriage
4= push bar
5= depth control
6= water cooling system
7= pointer guide
9= accessories

Asphalt and concrete cutter RVZ-500 Operation
manual
page 17 issued 10/2002
5. MAINTENANCE SCHEDULE
This maintenance schedule contains only the most important operations. Besides of these operations, carry out maintenance and repairs of the machine as necessary
depending on the respective conditions of operation. Check also the engine operation manual.
WARNING:
Turn off the engine before any maintenance or repair activity.
Use genuine spare parts only. Use of non-original spare parts may lead to damage to the machine. The manufacturer will not honor any warranty claim
arising from such reason.
Item Operation Initial inspection After 1st month or 20
hrs.
Every 3 months or 50
hrs.
Every 6 months or
100 hrs.
Engine oil
Inspection of oil level

DAILY (3)
Exchange


Air filter
Inspection

DAILY (1)
Cleaning
If necessary (1)
Spark plug (gasoline
engines)
Inspection - cleaning

Filter bowl
Cleaning

Fuel hose
Inspection - Exchange
Every two years
Valve clearance
Inspection - adjustment
Every 12 months or 300 hrs. (2)
Fuel tank and sieve
Cleaning
Every 12 months or 300 hrs. (2)
Drive belt
Tensioning

Handle assembly
Lubrication

1. To be carried more often when operating in dusty environment!
2. It is recommended to be carried out by authorized service agent.
3. Use the dipstick for oil level inspection (supplied with every machine as an accessory)

Asphalt and concrete cutter RVZ-500
page 18
1. FRAME

Asphalt and concrete cutter RVZ-500
page 19
1. FRAME
Position
Art. Nr.
Description
Qty.
Dimension
0
0000030057
Frame
1
1
0010030057
Frame
1
2
2219500306
Rivet
4
3x8
3
3010010001
Serial plate
1
0,5-50x70

Asphalt and concrete cutter RVZ-500
page 20
2. DRIVE SYSTEM