HYCON HRS400 User manual

Operating Manual
HYCON HRS400
Hydraulic Ring Saw
From serial no. 6539
Revised December 2014
www.hycon.dk

HYCON HRS400 Ring Saw
HYCON A/S • Juelstrupparken 11 • DK-9530 Støvring • Tel [phone]
2
 
Table of Content
Prior to Operation ............................................................................................................ 2
Technical Details ............................................................................................................. 3
Useful Information regarding the Use of HRS400 Ring Saw ............................................ 3
Safety Precautions .......................................................................................................... 4
HRS400 Hydraulic Ring Saw Overall Dimensions ........................................................... 6
Operation ........................................................................................................................ 7
General Working Instructions .......................................................................................... 7
Cold Weather Operation .................................................................................................. 7
Water Supply................................................................................................................... 7
Equipment Protection and Care ....................................................................................... 7
Starting Instructions ......................................................................................................... 8
Use of HRS400 Ring Saw Blades.................................................................................... 8
Service and Maintenance ................................................................................................ 8
Oil Types ......................................................................................................................... 8
Length of Hoses .............................................................................................................. 8
How does your HYCON Ring Saw work .......................................................................... 9
Mounting and Adjusting the Blade ................................................................................. 10
Cleaning Instructions ..................................................................................................... 11
Gear Oil Change ........................................................................................................... 12
Use of Hydraulic Power Sources ................................................................................... 13
Warranty Terms ............................................................................................................ 13
Replacement/Adjustment of Blade................................................................................. 14
Adjustment of Support Rollers ....................................................................................... 14
Dismounting of Front Cover and Water Blade ................................................................ 15
Replacement of Drive Wheel ......................................................................................... 15
Replacement of Blade ................................................................................................... 16
Replacement of Support and Guide Rollers ................................................................... 16
HYCON HRS400 Blade Information .............................................................................. 17
HYCON Ring Saw Variables ......................................................................................... 19
Trouble Shooting ........................................................................................................... 20
EC-Declaration of Conformity ........................................................................................ 21
Spare Parts List ............................................................................................................. 22
Prior to Operation

We thank you for choosing a
HYCON HRS400 ring saw.
To ensure smooth operation and
long-lasting performance of your
new ring saw, we recommend
you to study this operating
manual carefully and pay special
attention to the chapters about
Safety and Service
Precautions

We hope you will be satisfied with
your new HYCON ring saw.
Best regards
HYCON A/S

HYCON HRS400 Ring Saw
HYCON A/S • Juelstrupparken 11 • DK-9530 Støvring • Tel [phone]
3
Technical Details
HRS400 Ring Saw
Weight w/o hoses and blade 10.9 kg
Oil flow 30-40 l.p.m.
Recommended minimum water supply 4 l.p.m. / 2 bar
Working pressure nominal 160 bar
Pressure relief valve in power source Max. 172 bar
Max. return pressure 40 bar
Max. oil temperature 80°C
Blade diameter 400 mm
Max. cutting depth 300 mm
Circumferential speed 37–49 m/s
Vibration level <2.5m/s²
Sound pressure level 1 m L
PA
109 dB(A)
Sound power level L
WA
98 dB(A)
Necessary cooling capacity on power source 1 kW
Power 4.7 kW
Useful Information regarding the Use of HRS400 Ring Saw
The HRS400 ring saw is a compact tool with great
performance. There are no other ring saws on the market with
higher performance in relation to size.
It is the perfect tool for cutting in all types of concrete, brick
wall, asphalt etc.
The HRS400 ring saw cannot be mounted in a HYCON cart,
but only used for handheld cutting jobs.
The HRS400 ring saw has two handles for optimum operator
comfort.
The HRS400 ring saw is unaffected by water and can be
operated in all working environments, even for cutting under
water.
The HRS400 ring saw can also be connected to excavators
and other machines. We recommend the use of a HYCON
powerpack and/or an oil flow divider, which protects against
too high oil flow, too high pressure and backwards rotations.
See section about Use of Hydraulic Power Sources.
The saw is designed for wet cutting. If you use the HRS400
ring saw for dry cutting you will destroy the blade and have an
excessive wear on spare parts. ONLY do wet cutting, as this
cools the blade and removes the slurry. This results in as little
wear on the blade as possible.
Therefore always use sufficient water flow and pressure for
cleaning slurry from rollers and blade.
The utility values of your HYCON HRS400 ring saw are
numerous, and you will be pleased with your investment.

HYCON HRS400 Ring Saw
HYCON A/S • Juelstrupparken 11 • DK-9530 Støvring • Tel [phone]
4
Safety Precautions
• Read the HRS400 ring saw and power source operating
manuals prior to use.
• Only use the HRS400 ring saw in accordance with the
local working regulations on allowed working time
• Check the oil flow to the HRS400 ring saw. The oil flow
may not exceed 40 l.p.m. A too high oil supply can result
in the speed of the diamond blade being too high, causing
the blade to break.
• Make sure that the diamond blade is mounted correctly
and firmly fastened.
• Always use diamond blades approved for handheld
cutting and for the material to be cut.
• Always use blades that are in good condition.
• From the factory, the HRS400 ring saw is mounted with a
safety trigger, which may never be disturbed or
dismounted.
• The HRS400 ring saw has an automatic integrated safety
function that makes the saw stop if the diamond blade
jams. However, in case of jamming, always loosen the
blade from the material, before you start cutting again.
• Start the HRS400 ring saw just before you start cutting,
and stop it again once the cutting is done. Do not let the
HRS400 ring saw run freely in the air without water
supply.
• In case of horizontal cutting or cutting above the head,
always be aware of material falling down.
• A fine jet of oil at pressure can penetrate the skin. It is
therefore important never to use your fingers to check for
oil leaks and never to hold your face close to suspected
leaks – use a piece of cardboard instead. If oil has
penetrated the skin, you should get medical treatment
immediately.
• Never leave the HRS400 ring saw when connected to the
powerpack.
• Always use approved hoses. Contact your dealer, if
necessary. Mount the hoses correctly so that the HRS400
ring saw rotates in the right direction. The hydraulic motor
will be destroyed if pressure is set to the wrong
connection. (T)
• The operator must pay extra attention and show caution
when working in difficult working areas, such as slopes
and other dangerous nature of the ground. Do not reach
too far with the HRS400 ring saw, but always maintain a
good footing and keep your balance.
• The operator must be properly trained in using the
HRS400 ring saw or under supervision of a qualified
instructor.
• The operator must always use protective goggles,
earplugs, hard hat and shoes when operating the
HRS400 ring saw.
• Never use the HRS400 ring saw close to electric cables.
Prior to operation, check whether there are hidden or
buried cables.
• Never wear loose clothing as it may get entangled in the
moving parts of the saw.
• Always connect hoses to the HRS400 ring saw before
starting the powerpack. Be sure that all couplings are
tight.
• The HRS400 ring saw may not be operated if the oil
temperature is above 80 C°. Operation at higher
temperatures may result in the HRS400 ring saw getting
warmer than normal and the operator risks getting burnt
on it.
• To avoid all personal injury and damage to material, all
repair, maintenance and service work must be carried out
by authorized or properly trained persons only.
• An HRS400 ring saw not in use should always be kept in
a safe and dry place.
• Always make sure that the HRS400 ring saw labels and
warning signs are legible.
• Always use hoses, couplings and spares as such
recommend by HYCON A/S.
• Repairs may only be carried out by experienced
personnel.
• Make sure that all couplings are cleaned before
connection.
• Do not throw or drop the ring saw! It is a highly
specialized tool and it needs to be handled with care, or
failure to the ring saw may occur.
• Do not block or damage the safety trigger for any reason.
If the safety trigger is non functional, replace it
immediately.
• Always disconnect the hydraulic circuit before connecting
or disconnecting the HRS400 ring saw. If this is not done,
there is a risk of damage to the quick release couplings or
the hydraulic system getting superheated
• Never let the saw run dry – always cut only with water.







HYCON HRS400 Ring Saw
HYCON A/S • Juelstrupparken 11 • DK-9530 Støvring • Tel [phone]
5
You must use approved personal protective
equipment whenever you use the machine.
Personal protective equipment cannot
eliminate the risk of injury but it will reduce
the degree of injury if an accident does
happen. Ask your dealer for help in choosing
the right equipment.
WARNING

HYCON HRS400 Ring Saw
HYCON A/S • Juelstrupparken 11 • DK-9530 Støvring • Tel [phone]
6
HRS400 Hydraulic Ring Saw Overall Dimensions
   
    

HYCON HRS400 Ring Saw
HYCON A/S • Juelstrupparken 11 • DK-9530 Støvring • Tel [phone]
7
Operation
CONNECTION TO HYDRAULIC POWER SOURCES -
CHECK HYDRAULIC POWER SOURCE
Using a calibrated flow meter and pressure gauge,
make sure the hydraulic power source develops flow
and pressure that is appropriate for the ring saw.
Make certain that the power source is equipped with
a relief valve set to open at 250 bar maximum.
Make sure the ring saw is connected correctly to the
powerpack and that hoses are not leaking from
rubber or couplings.
CONNECTING HYDRAULIC HOSES
Wipe all hose couplers with a clean lint free cloth
before making connections. Do not connect pressure
to the return port.
Connect the hoses from the hydraulic power source
to the couplers on the ring saw hoses. It is a good
practice to connect return hose first and disconnect it
last to minimize or avoid trapped pressure within the
hydraulic motor.
Make sure the hydraulic hoses are connected
properly and fully seated to ensure that the flow is in
the proper direction.
Note: If uncoupled hoses are left in the sun, pressure
increase inside the hoses might make them difficult to
connect. Whenever possible, connect the free ends of the
hoses together when not in use.
General working Instructions
WARNING
Observe all safety precautions.
Never use the machine if you are tired, if you have
drunk alcohol, or if you are taking medication that
could affect your vision, your judgment or your co-
ordination.
Look around to ensure that no obstacles can affect
your control of the ring saw.
Do not use the machine in bad weather, such as
dense fog, rain, strong wind, intense cold, etc.
Working in bad weather is tiring and can lead to
dangerous conditions, e.g. slippery surfaces.
Never start to work before the working area is clear
and you have a firm foothold. Look out for any
obstacles with unexpected movement. Ensure when
cutting that no material can become loose and fall,
causing operating injury. Take great care when
working on sloping ground.
Be aware that your clothes or limbs may not have
contact to the moving parts on the ring saw or
power.
Always keep a safe distance to the moving parts.
The guard protection of the spinning blade must
ALWAYS be in good condition and ALWAYS
mounted correctly.
Always have enough illumination for a secure
working environment.
Always ensure you are in balance and having a
good foothold when operating the ring saw.
ALWAYS check for hidden gas pipes or electrical
cables in the material you cut!
Cold Weather Operation
If the ring saw is to be used during cold weather, preheat the
hydraulic fluid at low power source speed. When using the
normally recommended fluids, fluid should be at or above
freezing level 32°F/0° C before use. Damage to the hydraulic
system or hydraulic motor seals can result from use with fluids
that is too viscous or thick. See page 8.
Note: Remember to empty the saw from water after cutting
in freezing conditions to avoid damage.
Water Supply
Only use with water. Make sure water supply is sufficient.
Abrasive material and too little water when cutting increases
wear on the drive wheel and the inner edge of the blade and
may cause the blade to slip.
Note: The recommended minimum water supply is 4
l.p.m./2 bar.
Equipment Protection and Care
Make sure all couplers are wiped clean before
connection.
The hydraulic circuit control valve must be in the
“OFF” position when coupling or uncoupling the ring
saw. Failure to do so may result in damage to the
quick couplers and cause overheating of the
hydraulic system.
Make sure the circuit PRESSURE hose (with male
quick disconnect) is connected to the “P” port. The
circuit RETURN hose (with female quick disconnect)
is connected to the opposite port. Do not reverse
circuit flow. This can cause damage to internal seals.
Always replace hoses, couplings and other parts
with replacement parts recommended by HYCON.
Hoses must have a minimum working pressure
rating of 250 bar.
Do not exceed the rated flow or pressure (refer to
Technical Details in this manual for correct flow rate
and pressure). If specifications are exceeded, rapid
failure of the internal seals may result.
Always keep critical labels and markings, such as
warning stickers and tags legible.
Ring saw repair should be performed by
experienced personnel only.
Make certain that the recommended relief valves are
installed in the pressure side of the system
This section describes basic instructions on
how to use the HRS400 ring saw. If you feel
unsafe while operating the HRS400 ring saw,
STOP and seek expert advice. Do not attempt
to use the HRS400 ring saw any further until
instructions on how to proceed is given. Ask
a specialist or your local HRS400 ring saw
dealer.

HYCON HRS400 Ring Saw
HYCON A/S • Juelstrupparken 11 • DK-9530 Støvring • Tel [phone]
8
Starting Instructions
• Mount a diamond blade. See settings and
adjustment page 10.
• Connect hoses – clean couplings before connection.
Connect water supply.
• Set the power source on ”ON”.
• Open for water supply.
• Find a good footing for the cutting. See safety
instructions!
• Activate the safety trigger, press the trigger lever
towards the handle and start the saw.
• Start by holding the blade towards the material.
When gradually a groove is cut, press the blade
towards the material and cut in lines of 5-7 cm until
you have cut through the material. This is the
quickest way of cutting instead of cutting through in
one attempt.
• It is important to keep the water supply steady and
sufficient as it cools the blade, removes the slurry
and guarantees you the best result with as little wear
on the blade and rollers as possible.
Stop
• Remove the blade from the material and let go of the
trigger lever
• Set the power source on “OFF”
• Disconnect water supply
Note: For easier cleaning let the blade spin in the air with full
water running for 30 seconds. It will help removing slurry from
blade and rollers. HYCON recommends cleaning each roller for
slurry after usage for longer lifetime and better adjustment of
blade. See separate instruction .
Use of HRS400 Ring Saw Blades
Sharpening diamond blades
Diamond blades can become dull if you use the wrong feeding
pressure on the blade, wrong blade or cut the wrong material.
If the diamond blade becomes dull it will only produce heat and
can cause overheating to the material or the blade can be out
of round. Sharpen the blade by butting in soft material i.e.
sandstone or bricks.
Vibrations on diamond blades
The blade can become out of round if a too high pressure is
used. A lower feed pressure can stop the vibration. Otherwise
replace the blade. The blade shall be intended for the material
to be cut.
Note: USE only HYCON blades, rollers and drive
wheel or no warranty will be granted in case of failure
to ring saw.
HYCON provides 2 different kinds of blades:
• Standard blade, diamonds are not positioned
• Premium blade, diamonds are positioned
• Both types of blade come in a soft (20), medium (45)
and hard (70) version.
See page 16 for more info regarding HRS ring saw blades.
Note: Drive wheel must be replaced with every new
blade. Guide rollers should be replaced after 10
blades
Service and Maintenance
Note: the chart is based on daily use
Oil Types
The HYCON HRS400 Ring Saw uses standard hydraulic oil,
i.e. all types of mineral oil and biodegradable oil, which comply
with the following values:
Under normal working conditions in a temperature range of
-10° to +40°, a viscosity 46 oil is usually suitable. At
temperatures beyond this range use oil with another viscosity.
Note: If using biodegradable oil, we recommend the use of oil
based on rape. Other types of oil can be aggressive towards
parts of the pump
Length of Hydraulic Hoses
Hose extension Inside diameter of hydraulic hose (inch)
Up to 30 m 1/2
30 – 45 m 5/8
45 – 100 m 3/4
Note:
Hoses over 30 m will create a very high loss of pressure
resulting in poor performance.
Service/Maintenance Daily Weekly Yearly
Check couplings and clean
carefully X
Check hydraulic hoses X
Clean rollers X
Lubricate rollers
(grease nipples) X
Adjust drive wheel X
Adjust rollers and check for
wear X
Check drive wheel X
Check blade guard condition X
Check the water disc X
Clean with water and spray X
Gear oil change
Change gear oil after first 5 hours
of operation. After that, change it
every 200 hours of operation, but
at least once a year. Use gear oil
GL-5 75W90. See page 12.
Recommended viscosity 20-40 cSt
Permitted viscosity 15-1000 cSt
Viscosity index Min. 100
Temperature area -20° to +70° C

How does your HYCON ring saw work?
Service Accessories
Over the blade are the guide rollers.
Their function is to guide (press) the blade
against the drive wheel (by the grooves
in the blade)
Under the blade are the support rollers.
Their function is to support the blade.
Looking from the other
side - the guide rollers
have the black handle
The drive wheel
ä
ãã
ä
æ
From left to right :
Two pin wrench, open
spanner, hex key and
feeler gauge supplied
with every saw (except
for the feeler gauge
that comes with every
blade). WD40 lubricant
can be purchased at
HYCON distributor or
your local dealer.

Place the saw on firm ground.
Mount the drive wheel.
Adjust the guide roller against the drive wheel -
turn the black knob clockwise until it stops.
Both guide rollers should be equally tightened!
NB: It cannot be overtightened
Tighten the nut at the end of the support roller. You must be able to turn the blade by the hand. Check that the distance between water blade
and blade is the same full circle.
Re-adjust the support rollers > loosen the screw
counterclockwise with the hex key, use the feeler
gauge to adjust the gap between the support
roller and the blade > turn the screw clockwise
until the gap matches the feeler gauge.
If the support roller is correctly adjusted you
can turn the roller by the finger. If it cannot turn
it is too tight.
Tighten the drive wheel. Mount the water blade and the cover.
Place the blade between the rollers.
Make sure the guide roller is placed correctly
into the grooves of the blade.
Gently (NOT tightly) adjust the support roller
against the blade using the hex key.
NB: The roller adjustment is eccentric -
if you tighten too far to the right it will become
loose again.
1 2 3
4 5 6
7 8 9
10 11
➚
12
Mounting and adjusting the blade
NB: Re-tighten after 10 min. operation

During operation water and slurry can
get into the housing where the rollers are.
Therefore - to ensure that your HYCON
HRS will perform perfectly - it is VITAL
that you follow our 4 very simple
instructions for daily cleaning:
Let the ring blade spin free for minimum 30 seconds
after EACH JOB. Clean water will flush the rollers.
- ON BOTH SIDES..!
Clean the rollers and housing very carefully with the
water hose EVERY DAY after use...
Finally spray all parts with WD-40 or equivalent
water-displacing spray
1
3
2
4
Daily cleaning makes
your HYCON ring saw
work perfectly..!
CLEAN
AFTER USE
Letthe saw blade with water
minimum30 seconds after use
Flushthe rollers with water at
theend of every day
CLEAN
AFTERUSE
Our advice:
The guide roller adjustment should
every day after use be turned
COUNTERCLOCKWISE to protect
the function.
➚

HYCON HRS400 Ring Saw
HYCON A/S • Juelstrupparken 11 • DK-9530 Støvring • Tel [phone]
12
Gearolieskift/Gear Oil Change/Getriebeöl wechseln
Skift gearolie efter de første 5 timers drift. Derefter udskiftes gearolien for hver 200 timer, dog mindst én
gang årligt. Brug 50 ml gearolie GL-5 (varenummer 9992760).
Change gear oil after first 5 hours of operation. After that, change it every 200 hours of operation, but at
least once a year. Use 50 ml gear oil GL-5 (item No. 9992760).
Nach den ersten 5 Betriebsstunden Getriebeöl wechseln. Danach alle 200 Betriebsstunden, jedoch
wenigstens einmal im Jahr. 50 ml Getriebeöl GL-5 verwenden (Bestell-Nr. 9992760)

HYCON HRS400 Ring Saw
HYCON A/S • Juelstrupparken 11 • DK-9530 Støvring • Tel [phone]
13
Use of Hydraulic Power Sources
The HRS400 ring saw can be connected to various hydraulic
power sources, such as excavators, trucks, loaders, tractors
etc., and of course HYCON powerpacks, the design of which
ensures your new HRS400 ring saw a perfect match and the
absolute best working conditions.
It is important that the HRS400 ring saw is not subjected to an
oil flow and a working pressure beyond its design capability. In
case of doubt, please refer to the ID-tag on the saw and the
technical details on page 3.
Check the oil supply and the working pressure by means of
test equipment. The test equipment should comprise a
pressure gauge, a flow meter and a valve for adjustment of
pressure.
Make sure that:
• the oil supply is not too high
• the working pressure is not too high
• the return pressure is not too high
• the pressure relief valve is not set higher than 172 bar
• the internal diameter of the hoses is sufficient (min. ½”)
• all couplings are in order
• the power source is equipped with an oil filter of min.
25 Micron
Hoses with too small internal diameter and/or defect couplings
cause the HRS400 ring saw to work with incorrect working
pressure.
Your dealer can help you check this.
If the output of the power source is too high:
• the power source must be adjusted to correct output
• or you can choose to mount a HYCON oil flow divider
to protect the HRS400 ring saw against overload
• or you can choose one of our HYCON powerpacks.
Your dealer can guide you in choosing the right
powerpack.
In case of doubt, please contact your dealer or HYCON A/S.
Warranty Terms
We grant 12 months warranty from the first date of operation.
The warranty applies to faults that can be related to design and
production errors.
Faults caused by incorrect operation, incorrect handling, lack
of maintenance or the like, will not be accepted as warranty.
The warranty covers the parts necessary for repair and the
suggested average time needed for repair.
Normal wear and tear is excluded.
Special terms apply for use under water.
For further warranty details, please contact your local dealer.

HYCON HRS400 Ring Saw
HYCON A/S • Juelstrupparken 11 • DK-9530 Støvring • Tel [phone]
14
Replacement/Adjustment of Blade
Loosening:
Loosen the tightening knob completely by turning it counter
clockwise, thereby loosening the blade from the drive wheel.
Tightening:
To adjust the blade firmly against the drive wheel, turn both
tightening knobs clockwise alternately so that the built-in
compression springs are pressed together. Make sure that the
distance between blade and water blade is the same both at
the left and the right side.
Adjustment of Support Rollers
Loosening:
Use a ring spanner size 13 mm to loosen the hexagon nuts
and then retighten them slightly. Turn the adjustment screw
approx. 8-9 turns counter clockwise. This will lift the support
roller approx. 2 mm from the blade.
Tightening:
Adjust the support roller down against the blade by loosening
the hexagon nuts just slightly and then turning the adjustment
screw clockwise. Do under no circumstances press the support
roller too hard against the blade. You must be able to turn the
blade by hand. Now tighten the hexagon nuts completely.
If the guide rollers cannot be turned
completely back into bottom position, the
cause could be deposit of concrete
dust/slurry on the back side. Dismount the
rollers and clean thoroughly.
If the
support
rollers cannot be turned
completely back into bottom position, the
cause could be deposit of concrete
dust/slurry on the back side. Dismount the
rollers and clean thoroughly.

HYCON HRS400 Ring Saw
HYCON A/S • Juelstrupparken 11 • DK-9530 Støvring • Tel [phone]
15
Dismounting of Front Cover and
Water Blade
Use a hex key size 4 mm to loosen the 3 screws. Remove the
front cover.
Remove the entire water blade.
Replacement of Drive Wheel
Use a hex key size 4 mm to loosen the 2 hexagon screws. You
can use a two pin wrench to prevent the drive wheel from
turning round.
If the
drive wheel is worn out replace
immediately. Use only original spare parts.
Contact your local dealer for further
support and information.

HYCON HRS400 Ring Saw
HYCON A/S • Juelstrupparken 11 • DK-9530 Støvring • Tel [phone]
16
Replacement of Blade
Replacement of Support and Guide
Rollers
Use a ring spanner size 17 mm to hold on to the hexagon
washer, and use a hex key size 4 mm to loosen the screws.
The support rollers and the guide rollers can now be removed.
Lock the screws with Loctite 275 when
mounting them again
The roller edge interlocking with the
blade
must be sharp. Replace the roller if the
edge is not sharp.
Do not retip the diamond
blade
. Use only
original blades. Contact your local dealer for
further information.
When mounting the
blade
make sure that the
three raised edges on the guide roller and the
three grooves on the blade interlock.

HYCON HRS400 Ring Saw
HYCON A/S • Juelstrupparken 11 • DK-9530 Støvring • Tel [phone]
17
HYCON HRS400 Blade Information
The following chart can be used to determine what kind of blade is needed for different kinds of material to cut.
Blades Type of Bond Granite
Heavy
Reinforced
concrete
Reinforced
concrete
Semi-hard
concrete
Soft
concrete Soft bricks
Abrasive
building
blocks
Premium 20
YELLOW soft (X) X X (X)
Premium 45
BLUE medium (X) X X (X) (X)
Premium 70
RED hard (X) X X X (X)
Standard 20
YELLOW soft (X) X X (X)
Standard 45
BLUE medium (X) X X (X) (X)
Standard 70
RED hard (X) X X X (X)

HYCON HRS400 Ring Saw
HYCON A/S • Juelstrupparken 11 • DK-9530 Støvring • Tel [phone]
18
HYCON HRS400 Blade Information
If you do not use the right blade, you might see the
following problems occur:
Core or Segment Cracks
Cause Blade is too hard for material being cut
Solution Use a softer bonded blade
Cause Blade mounted improperly or saws needs repair
Solution Check rollers and drive wheel. Check all bearings,
shaft and flanges.
Undercutting
Cause Steel core wears faster than diamond segments
caused by highly abrasive fines grinding against
blade during cutting.
Solution Use a softer bonded blade and/or increase water
flow to flush out cut.
Uneven Segment Wear
Cause Insufficient water flow on one side of blade.
Solution Flush water system and check for adequate and
equal water flow/distribution.
Cause Blade mounted improperly or saw needs repair.
Solution Check rollers and drive wheel. Check all bearings,
shaft and flanges.
Short Blade Life
Cause Blade is too soft for material or water flow is too
low.
Solution Choose blade with a harder bond and/or increase
the water flow.
Slow Cutting Speed
Cause Material being cut is too hard for the blade. The
hard material wears the exposed diamonds but
not the metal portion of the segment. The
segment wears too slowly, no new diamonds are
exposed.
Solution Cut a soft abrasive material until diamonds are
well exposed. Try asphalt block, sandstone or
dried mortar. Choose a blade with softer bond.
Overheating
Cause Inadequate cooling.
Solution Follow guidelines for proper blade operation and
cooling procedures. Check water flow.
Segment Loss
Cause Blade is too hard for material being cut.
Solution Use a softer bonded blade.
Cause Steel core is worn due to undercutting.
Solution Use a softer bonded blade and/or increase water
flow to flush out cut.

HYCON HRS400 Ring Saw
HYCON A/S • Juelstrupparken 11 • DK-9530 Støvring • Tel [phone]
19
Variables
Change
Result
s
Cutting Speed
Blade Life
The Blade
Segment Bond
Hardness
Harder Slower Longer
Softer Faster Shorter
Diamond Quality Lower Slower Longer
Higher Faster Shorter
Diamond
Concentration
Lower Slower Longer
Higher Faster Shorter
Segment Width Thicker Slower Longer
Thinner Faster Shorter
The Saw
Horsepower Lower Slower Longer
Higher Faster Shorter
Blade Speed Higher Slower Longer
Lower Faster Shorter
The Job
Water Volume Higher Slower Longer
Lower Faster Shorter
Cutting Depth Deep Slower Longer
Shallow Faster Shorter
Cutting Pressure Lower Slower Longer
Higher Faster Shorter
The Material
Material Hardness Harder Slower Longer
Softer Faster Shorter
Material Abrasiveness Less Slower Longer
More Faster Shorter
Aggregate Size Larger Slower Longer
Smaller Faster Shorter
Steel Reinforcing More Slower Longer
Less Faster Shorter
HYCON Ring Saw Variables

HYCON HRS400 Ring Saw
HYCON A/S • Juelstrupparken 11 • DK-9530 Støvring • Tel [phone]
20
Trouble Shooting
Problem
Probable Cause
Blade does not rotate Incorrect roller adjustment
Blade not fitted correctly on guide rollers
Support rollers tensioned too much
Possible faulty hose connection to the hydraulic system
Possible faulty hose connection to the drive source or other hydraulic
problem
Blade rotates too slowly Incorrect roller adjustment
Worn drive wheel
Saw is pushed too hard
V-shaped inner diameter of the blade is worn
The springs on the guide rollers are weakened
Dirty pressure relief valve in the hydraulic system and in the saw
Dirty filter
Defective roller bearings
Too high back pressure
Inadequate oil flow, check the hydraulic oil flow
Blade jumps out of its position Roller setting too loose
Worn guide rollers
Blade not fitted correctly on guide rollers
Blade damaged
Blade wobbles Support rollers tensioned too much
Blade overheating
Segments break Bent, twisted or badly maintained blade
Blade cuts too slowly Wrong blade for the material
Saw pushed too hard
Check that the right amount of water reaches the blade
Blade slips Guide rollers do not move in and out freely. A seized roller cannot
press the blade hard enough against the drive wheel
Worn drive wheel. Abrasive material and too little water when cutting
increases the wear on the wheel.
Worn guide roller flange. When more than half of the width of the
flange is worn the blade slips.
The blade’s groove and inner edge are worn. Caused by inferior
flushing of abrasive material and/or a worn drive wheel causing the
blade to slip.