TYROLIT Hydrostress PPH40RR Series User manual

Operating Instructions
Spare Parts List
10983813 en / 18.7.07
Drive Unit PPH40RR***
Index 000

Operating Instructions
10983813 en / 18.7.07
Manufacturer's address:
TYROLIT Hydrostress AG
Witzbergstrasse 18
CH-8330 Pfäffikon
Switzerland
Phone +41 (0) 44 / 952 18 18
Fax +41 (0) 44 / 952 18 00
TYROLIT Hydrostress AG reserves the right to make technical changes
without prior notice.
Copyright © 2007 TYROLIT Hydrostress AG, CH-8330 Pfäffikon ZH
All rights reserved, in particular the copying and translation rights.
The reprinting of these Operating Instructions, includingextracts, is prohib-
ited. No part of these Operating Instructions may be reproduced in any
form whatsoever or be processed, copied or distributed using electronic
systems without the written permission of TYROLIT Hydrostress AG.

Operating Instructions Overview
PPH40RR*** / 000 I (II)
Overview
Page
0 Introduction 1
0.1 Congratulations!- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1
0.2 Validity of these Operating Instructions - - - - - - - - - - - - - - 2
0.3 Standards - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2
0.4 Delimitation of the system- - - - - - - - - - - - - - - - - - - - - - - - 2
1 Product description 1
1.1 Application - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1
1.2 Safety measures - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1
1.3 Operating instructions for connectable equipment- - - - - - - 1
1.4 Name plate - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1
1.5 Information sign- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2
1.6 EC Declaration of Conformity - - - - - - - - - - - - - - - - - - - - - 3
1.7 Technical data - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4
1.8 Hydraulics - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5
1.9 Electrical equipment- - - - - - - - - - - - - - - - - - - - - - - - - - - - 6
1.10 Water - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7
1.11 Noise exposure (noise level)- - - - - - - - - - - - - - - - - - - - - - 7
1.12 Scope of supply- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7
1.13 Country list for radio transmission frequency- - - - - - - - - - - 8
2 Safety instructions 1
2.1 General- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1
2.2 General safety rules- - - - - - - - - - - - - - - - - - - - - - - - - - - - 1
2.3 Safety principles - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2
2.4 Responsibility - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3
2.5 Generally applicable warnings of residual dangers - - - - - - 5
3 Design and function 1
3.1 Design - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1
3.2 Function - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2
3.3 Radio remote control - - - - - - - - - - - - - - - - - - - - - - - - - - - 4
4 Controls and displays 1
4.1 Controls - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1
4.2 Electric controls - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2
4.3 Displays - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4
5Operation 1
5.1 Personnel qualifications - - - - - - - - - - - - - - - - - - - - - - - - - 1
5.2 System requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - 1
5.3 Preparatory operations- - - - - - - - - - - - - - - - - - - - - - - - - - 2
5.4 Working - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6
5.5 After the work - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10
6 Servicing 1
6.1 Servicing and maintenance table- - - - - - - - - - - - - - - - - - - 1

Overview Operating Instructions
II (II) PPH40RR*** / 000
7 Corrective maintenance 1
7.1 Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1
7.2 Storage - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4
8 Transport 1
8.1 Transport- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1
8.2 Safety instructions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1
8.3 Crane shackles and transport handles - - - - - - - - - - - - - - - 2
9 Disposal 1
9.1 General - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1
9.2 Disposal regulations - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2
9.3 Disposal of the Drive Unit PPH40RR*** - - - - - - - - - - - - - - 2

Operating Instructions Introduction
PPH40RR*** / 000 0-1
0 Introduction
0.1 Congratulations!
You have decided to purchase a tried and tested TYROLIT
Hydrostress AG system and have thus acquired a highly sophisticated and
reliable state-of-the-art unit.
Thanks to the emphasis we place on quality assurance, your TYROLIT
Hydrostress AG system is another top-of-the-range Swiss product:
• High performance
• Reliable operation
• High portability
• Easy handling
• Low maintenance costs
Only original TYROLIT Hydrostress AG spare parts can guarantee quality
and interchangeability.
In the case of neglected or inappropriate maintenance, we will be unable
to accept the warranty commitment as specified in our terms of delivery.
Any repair work must be carried out by trained personnel only.
If you need more details about how to keep your TYROLIT Hydrostress AG
system in perfect condition, please contact our after-sales service for fur-
ther information.
We hope that working with your TYROLIT Hydrostress AG system will be
a problem-free and fault-free experience.
TYROLIT Hydrostress AG
Management
Copyright © TYROLIT Hydrostress AG, May 2007
TYROLIT Hydrostress AG
Witzbergstrasse 18
CH-8330 Pfäffikon
Switzerland
Phone +41 (0) 44 / 952 18 18
Fax +41 (0) 44 / 952 18 00

Introduction Operating Instructions
0-2 PPH40RR*** / 000
0.2 Validity of these Operating Instructions
This manual is only valid for the following system:
Drive Unit PPH40RR***
0.3 Standards
These Operating Instructions have been prepared in accordance with the
CE Machinery Directive Appendix I and with the relevant standards in force
at the time of printing.
0.4 Delimitation of the system
These Operating Instructions describe the use of the Drive Unit
PPH40RR***.

Operating Instructions Product description
PPH40RR*** / 000 1-1
1 Product description
1.1 Application
The Drive Unit PPH40RR*** has been designed as a component for the fol-
lowing concrete processing systems:
• Hydraulic wall saw systems
• Hydraulic diamond wire saw systems
• Hydraulic core drilling systems
• Hydraulic chainsaws
The applicable mandatory limitations on use and other parameters are con-
tained in Chapter 1 "Technical data" 1.7, 1-4
1.2 Safety measures
Any use other than for the intended purpose (see Chapter 1.1, 1-1) con-
stitutes abuse or misuse.
1.3 Operating instructions for connectable
equipment
In order to ensure safety in the workplace and in danger areas, as well as
the safe operation of connectable equipment, the relevant Operating In-
structions must in all cases be followed.
1.4 Name plate
Fig. 1-1 Name plate

Product description Operating Instructions
1-2 PPH40RR*** / 000
1.5 Information sign
Attached to the plastic hood is an information sign containing the following
information:
• Hose connections
(For a description see "Chapter 5" 5.3.2.1, 5-2)
• Pressure stages
(For a description see "Chapter 5" 5.4.3, 5-8)
• Risk of frost
(For a description see "Chapter 6" 6.1.1, 6-2)
• Hydraulic oil
(For a description see "Chapter 6" 6.1.2.1, 6-2)
Fig. 1-2 Information sign

Operating Instructions Product description
PPH40RR*** / 000 1-3
1.6 EC Declaration of Conformity
We declare under our own liability that this product complies with the fol-
lowing directives and standards:
1.6.0.1 Directive applied:
Machinery Directive 2006/42/EC
EC EMC Directive 89/336/EC
EC Low Voltage Directive 73/23/EC
1.6.0.2 Standards applied:
Description Hydraulic drive unit
Type designation Drive Unit PPH40RR***
Year of construction 2007
EN12100-1
EN 12100-2Safety of machinery – Basic concepts, general design principles
EN 294 Safety of machinery – Safety distances to prevent upper limbs
reaching danger areas
EN 349 Safety of machinery – Safety distances to avoid crushing of
body parts
EN 982 Safety of machinery
Safety requirements of safety systems and their components -
Hydraulics
EN 60204-1Safety of machinery - Electrical equipment of machines

Product description Operating Instructions
1-4 PPH40RR*** / 000
1.7 Technical data
1.7.1 Dimensions
Fig. 1-3 Dimensions
1.7.2 Weight
Operating weight 255 kg
1.7.3 Tyres
Wheel Ø 30 cm
Operating pressure 3 bar
82 cm
110 - 126 cm
83 cm
56 cm

Operating Instructions Product description
PPH40RR*** / 000 1-5
1.8 Hydraulics
1.8.1 Main circuit
Main circuit 3 pumps
Flow rates can be set to 65 / 75 / 80 / 90 l/min., depending on the cutting
tool speed required
Flow rates and pressures
EU USA
Stage I 65 l/min 250 bar 11,6 gpm 2130 psi
Stage II 75 l/min 220 bar 15,2 gpm 3479 psi
Stage III 80 l/min 200 bar 18,2 gpm 2840 psi
Stage IV 90 l/min 180 bar 21,8 gpm 2627 psi
Same power in all stages
1.8.2 Feed circuits
Feed circuits: 1 pump
Two hydraulic feed outputs which can be regulated independently of each
other, controlled using radio remote control.
1.8.3 Oil tank
Oil tank volume: 10 litres
Filter quality: 20 µm
1.8.4 Return oil filter
Type: Tank-mounted filter
1.8.5 Oil cooling
Oil cooler: Water/oil heat exchanger
1.8.6 Couplings and hoses
Plug-in couplings Type FD and FF, non-drip
Hoses Length 8m (filled with hydraulic oil)
1.8.7 Oil quality
TYROLIT Hydrostress AG recommends:
Hydraulic oil: HLP/ISO VG 46

Product description Operating Instructions
1-6 PPH40RR*** / 000
1.9 Electrical equipment
1.9.1 Different voltages
For countries where different mains networks operate the following types
are available:
Drive Unit PPH40RR*** 380-420 V 50 Hz
Drive Unit PPH40RR*** 420-480 V 60 Hz
Drive Unit PPH40RR*** 575 V 60 Hz
1.9.2 Motor
Electric motor water-cooled
Power supply 3 P / LNPE 380 - 420 V / 50 Hz
420 - 480 V / 60 Hz
Current consumption 380 - 420 V / 50 Hz 63 A
420 - 480 V / 60 Hz 57 A
575 V 60 Hz 56 A
Output P1 40 kW / P2 34 kW
Speed at 50 Hz 2910 rpm
at 60 Hz 3480 rpm
1.9.2.1 Motor protection
Thermal protection Winding thermostat
Electrical protection Thermal relay
1.9.2.2 Electric motor cooling
Water cooling Cooling channels in the aluminium
Throughput of cooling water min. 6 l/min at max. 25° C
Water connection min. 2 bar, max. 6 bar
Information
Electrical data are only valid for the installed loads
3 P / LNPE 400 VAC / 50 Hz
Warning
A danger will arise if the Drive Unit PPH40RR*** is operated with a
different mains network voltage.
The details on the name plate must correspond to the mains net-
work values (voltage and frequency).
Damage may be caused to the unit if it is connected to a different
voltage; there is also a risk of fire and personal injury.

Operating Instructions Product description
PPH40RR*** / 000 1-7
1.9.2.3 Protection class
IP 65
1.9.2.4 Internal control voltage (valve control)
24V / DC
1.9.2.5 Secondary socket
Connections 2 sockets 230V / 10A
with fault current tripping at 10 mA
1.10 Water
Pressure min. 2 bar to max. 6 bar
Quantity min. 6 l/min at max 25°C
1.11 Noise exposure (noise level)
Depending on the working environment and the connected device, the
Drive Unit PPH40RR*** can produce high noise levels during operation.
1.11.0.1 Noise level measurement
Noise level measured at the ear of the operator 0.5 m from the Drive Unit
PPH40RR***; noise power level according to ISO 3744; drive unit only;
highest value taken from all operating states at full load; mean values from
three series of measurements.
Noise level 83 dB (A) noise power level 92 dB (A)
1.12 Scope of supply
• Drive Unit PPH40RR***
• Radio remote control
• Water purge pump
• Operating Instructions / Spare parts list
Danger
Noise danger
When operating the PPH40RR*** drive unit, the wearing of hearing
protection is mandatory at all times.
If this instruction is not followed irreparable hearing damage may
result.

Product description Operating Instructions
1-8 PPH40RR*** / 000
1.13 Country list for radio transmission frequency
Fig. 1-4 Country list for radio transmission frequency
*** On request
Country Frequency
MHz Country Frequency MHz
Australia 434 Mexico 458
Belgium 434 New Zealand 434
Bolivia 434 Netherlands 434
Brazil 434 Norway 434
Brunei 434 Austria 434
Bulgaria 434 Poland 434
China 419 Portugal 434
Denmark 434 Puerto Rico 458
Germany 434 Romania 434
Finland 434 Russia 434
France 434 Sweden 434
Greece 434 Switzerland 434
Great Britain 434 Singapore 434
Hong Kong 458 Slovenia 434
India, Mumbai 434 Spain 434
India, New Delhi 434 South Korea 447
Indonesia 434 South Africa 434
Ireland 434 Taiwan 480
Iceland 434 Thailand 434
Italy 434 Turkey 434
Japan 429 Ukraine 434
Canada 458 USA 458
Croatia 434 USA (South America) 434
Liechtenstein 434 Venezuela 434
Lithuania 434 United Arab Emirates 434
Luxembourg 434 Philippine 434
Malaysia 434

Operating Instructions Safety instructions
PPH40RR*** / 000 2-1
2 Safety instructions
2.1 General
All persons who work on and with the Drive Unit PPH40RR*** have a duty
to read and understand the Operating Instructions.
2.1.1 Observance of the safety instructions
The Drive Unit PPH40RR*** has been inspected before being shipped and
is delivered in perfect condition. TYROLIT Hydrostress AG does not accept
any liability for damage which is caused by failure to observe the instruc-
tions and informationprovided in the Operating Instructions. This applies in
particular to:
• Damage caused by improper use and operator error.
• Damage caused by failure to observe safety-related information in the
Operating Instructions or shown on the warning signs attached to the
machine.
• Damage caused by defective or neglected maintenance work.
Independently performed conversions and alterations may affect safety
and are not permitted.
2.2 General safety rules
2.2.1 Statutory provisions
The generally applicable national and local safety and accident prevention
provisions and the supplementary operator regulations must be followed
and complied with.
2.2.2 Inspection and maintenance obligation
The operator is under an obligation to use the Drive Unit PPH40RR*** only
when it is in a perfect and undamaged condition. The maintenance inter-
vals shown in the Operating Instructions must be adhered to without fail.
Malfunctions and mechanical damage must be rectified without delay.
2.2.3 Spare parts
Only TYROLIT Hydrostress AG original spare parts may be used. Other-
wise, damage can be caused to the Drive Unit PPH40RR*** or other prop-
erty and may result in personal injury.
2.2.4 Power connections
The Drive Unit PPH40RR*** must be connected and coupled in accord-
ance with the Operating Instructions.

Safety instructions Operating Instructions
2-2 PPH40RR*** / 000
2.3 Safety principles
2.3.1 Delimitation of the safety concept
The Drive Unit PPH40RR*** does not affect the safety concept of the con-
nected systems, equipment and installations.
2.3.2 Safety elements
Protection from live electrical parts
All functional units containing parts which carry hazardous voltages are
shock-protected by suitable covers.
2.3.3 Removal of protective devices
Protective devices may only be removed if the unit has been switched off,
disconnected from the mains and is at standstill. Safety components, in
particular, may only be removed and refitted by authorised personnel, see
"Chapter 2" 2.4.1, 2-3.
Before switching the Drive Unit PPH40RR*** back on again, the safety el-
ements must be checked to ensure correct operation.
2.3.4 Safety measures (organisational)
2.3.4.1 Product monitoring obligation
Operating personnel must notify changes in operational behaviour or safe-
ty-related components to a responsible person or the manufacturer, imme-
diately.
2.3.4.2 Location of the Operating Instructions
A copy of the Operating Instructions must be available to staff at all times
at the place of use of the equipment.

Operating Instructions Safety instructions
PPH40RR*** / 000 2-3
2.4 Responsibility
2.4.1 Authorised personnel
Work on or with the TYROLIT Hydrostress AG machines or systems may
only be performed by authorised personnel. Personnel are considered by
TYROLIT Hydrostress AG to be authorised if they meet the necessary
training and know-how requirements and they have been assigned a pre-
cise functional role.
The personnel qualifications for the corresponding work are contained in
the introduction under "General" of the respective chapters.
2.4.2 Manufacturer
TYROLIT Hydrostress AG or a company expressly nominated by
TYROLIT Hydrostress AG is deemed to be the manufacturer of the
products supplied by TYROLIT Hydrostress AG. Within the context of an
integrated quality and safety control system, the manufacturer is entitled to
request from the operator information about the products.
2.4.3 Operator (owner)
The operator named by TYROLIT Hydrostress AG is the primary, legal en-
tity responsible for the correct use of the product and for the training and
assignment of the authorised personnel. The operator sets out the manda-
tory skills and level of training of the authorised personnel for his company.
2.4.4 Operator (user)
User is the term employed by TYROLIT Hydrostress AG to designate a
person who independently performs the following work:
• Sets up TYROLIT Hydrostress AG machines or systems for tasks ac-
cording to the intended purpose.
• Performs tasks independently and monitors these.
• Locates malfunctions and initiates or performs troubleshooting.
• Carries out servicing and simple maintenance.
• Monitors the correct functioning of the safety devices.
2.4.5 Service engineer
Service engineer is a term used by TYROLIT Hydrostress AG to designate
a person who independently performs the following work:
• Installs TYROLIT Hydrostress AG machines and systems and controls
their correct application.
• Makes adjustments to machines and systems for which special access
rights are required.
• Performs repairs, complex service work and maintenance work.

Safety instructions Operating Instructions
2-4 PPH40RR*** / 000
2.4.6 Qualification and training
2.4.6.1 Operator (owner)
• A technically trained person in a management position.
• Has relevant experience in personnel management and danger assess-
ment.
• Has read and understood the "Safety instructions" chapter.
2.4.6.2 Operator (user)
• Has trained as a concrete cutting expert or has professional experience.
• Has received an introduction (basic training) to the operation of the
TYROLIT Hydrostress AG machines and systems from a service engi-
neer.
• Has read and understood Chapter 2 "Safety instructions".
2.4.6.3 Service engineer
• Has specialist professional training (mechanical / electrotechnical).
• Has attended specialist courses at TYROLIT Hydrostress AG.
• Has read and understood the "Safety instructions" chapter.

Operating Instructions Safety instructions
PPH40RR*** / 000 2-5
2.5 Generally applicable warnings of residual
dangers
Danger
Electric shock due to defective electronic equipment.
The electrotechnical equipment must be checked prior to each use
and from time to time during prolonged use. Defective parts, such
as e.g. cables and plugs, must be replaced immediately in the de-
energized state by electrotechnically trained personnel.
Failure to comply with this regulation may lead to serious physical
injury or death. Secondary damage such as fires may also occur.
Warning
Danger of allergic reactions if skin comes into contact with hydrau-
lic oil.
Persons who have an allergic reaction to hydraulic oil must wear
protective gloves and goggles when carrying out work where they
come into contact with hydraulic oil. Any areas of the skin affected
must be rinsed immediately with copious amounts of water.
Failure to observe this regulation may result in allergic reactions or
injury to the eyes.

Safety instructions Operating Instructions
2-6 PPH40RR*** / 000