TYROLIT Hydrostress HBH534 series User manual

Safety & Operator Manual Hydraulic Hand Saw HBH534***
1 10984829 EN / 28.08.2007
Safety & Operator Manual
System Description
Hydraulic hand saw HBH534***
Index / Indice 000

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Overview Page
0 Introduction
0.1 Scope of the Safety Manual 3
0.2 Document structure 3
0.3 Terms 3
1 Technical data
1.1 Recommended ambient temperature 4
1.2 Water connection 4
1.3 Cutting speed 4
1.4 Vibration level 4
1.5 Sound level 4
1.6 Specification for oils 4
1.7 Dimensions 4
1.8 Weight 4
2 Safety instructions
2.1 General 5
2.2 Safety principles 7
2.4 General safety rules 8
2.5 Responsibility 9
3 Start-up
3.1 Putting into operation 11
4 Operation
4.1 General 11
4.2 Safety-related operator’s controls 11
4.3 Operation 11
5 Maintenance
5.1 General 17
5.2 Inspection 17
5.3 Maintenance 17
5.4 Servicing 17
5.5 Maintenance record sheet 18

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0 Introduction
0.1 Scope of the Safety Manual
The Safety Manual contains a description of how to safely operate this hydraulic hand
saw machine. It contains all the safety instructions that must be followed when working
with and on the system and must be strictly adhered to.
0.2 Document structure
The hydraulic hand saw documentation is structured as follows:
General system: Safety Manual with the following contents:
(Technical Data, Safety Instructions, Start-up, Operation,
Maintenance)
Components: Instruction leaflet with the following contents: (Exploded view
with part numbers, important instructions on use)
0.3 Terms
0.3.1 General Terms
Operating Instructions
The Operating Instructions are an essential document accompanying the product. They
contain all the information that is necessary to operate the product safely and to be able
to maintain it.
0.3.2 Terms related to hydraulic hand sawing
Term Definition
Saw: The saw contains the hydraulic motor, blade guard, handles and
machine components.
Cutting tool: The saw blade (diamond blade) is referred to as the cutting tool.
Drive: The drive (power pack) provides the power (hydraulic oil pressure and
flow for the hydraulic motor.
Motors: The hydraulic motor drives the pulley for the belt
Blade guard: The blade guard is a safety device that prevents accidental contact with
the tool, intercepts flying parts and at the same time acts as a spray
guard.

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1 Technical data
1.1 Recommended ambient temperature
Storage: between 5 °C and 35 °C
Usage: from 0 °C to 50 °C
1.2 Water connection
Pressure: min. 2 bar to max. 6 bar at max. 25 °C
Quantity: min. 6 l/min.
1.3 Cutting speed
This must be selected according to the nature of the material. The recommended values
in m/sec. are:
•Max. permitted blade diameter 534 mm
•Max. rotation speed 2862 rpm
•Max. peripheral speed 80 m/s
1.4 Vibration level
front handle 1,4 m/s2
rear handle 3,7 m/s2
1.5 Sound level
Sound pressur level L PA 95 dB
Sound power level L WA 104 dB
1.6 Specification for oils
1.4.1 Oils
Hydraulic oil: HLP / ISO VG46
1.4.2 Pressure
Hydraulic performance to be set at 35-40 l/min @ 140 bar
1.7 Dimensions
1.8 Weight
Weight 13.5 kg

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2 Safety instructions
2.1 General
2.1.1 Target audience
This chapter describes the safety instructions that are essential to follow when using the
hydraulic hand saw. All persons who work on and with the hydraulic hand saw have a
duty to read and understand the chapters of the Safety Manual relevant to their particular
activities. This applies in particular to the “Safety instructions” chapter which is mandatory
for all persons and activities.
2.1.2 Design Purpose
This saw was designed to be operated with:
•Hydraulic power packs, with hose length 10metres
•Hydraulic power output 40 l/min / 140bar
•Max blade rpm not to exceed 2862 rpm. When using power packs fitted with flow
control valves, it is the operator’s responsibility to ensure the correct flow has
been selected and the max blade rpm are not exceeded!
This saw was designed to perform:
•Straight cuts in concrete or fixed solid structures.
•Cuts on flat surfaces, not curved (pipes)
This saw needs to be operated:
•With both hands on both handles at all times
•With consideration of kick back when saw blade is jammed, therefore head must
not be in line with saw blade/guard.
•Never for overhead cutting or cutting above shoulder height.
•Never kneeling or on ladders
•Never forced.
•Never without a blade guard.
2.1.3 Saw blade
•A witness cut or precut must be made with a standard saw to a depth of 125mm.
Only then use the hydraulic hand saw with the 534mm saw blade.
•Always ensure the saw blade has enough clearance from the diamond
segments. The minimum side clearance should be 0.5 – 0.8mm both side and a
segment width of no less than 3.2mm.
•Only use diamond saw blades designed for this machine from TYROLIT.
•Only use laser welded saw blades.
2.1.4 Observance of the safety instructions
No work must be performed on or with the hydraulic hand saw before the safety
Instructions contained in the Safety Manual and in the Operating Instructions (Chapter 2)
have been read and understood. The Safety Manual and the Operating Instructions are

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the mandatory references for all work – Instruction leaflets are of an informative nature
and contain certain instructions only concerning correct use.
The hydraulic hand saw has been inspected before being shipped and are delivered in
perfect condition. TYROLIT Hydrostress AG does not accept any liability for damage
caused by the failure to observe the instructions and information provided in the Safety
Manual and in the Operating Instructions.
This applies in particular to:
•Damage caused by improper use and operator error.
•Damage caused by improperly installed third-party components.
•Damage caused by failure to observe safety-related information in the Safety Manual
or shown on the warning signs fitted to the machine.
•Damage caused by defective or absence of maintenance work.
•Damage caused by cutting unauthorized material.
•Independently performed conversions and alterations may affect safety and are not
permitted.
Warning
Danger of allergic reactions if skin comes into contact with hydraulic 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 adhere to this regulation may result in allergic reactions or injuries to the eyes.

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2.2 Safety principles
2.2.1 Safety measures (organisational)
2.2.1.1 Product monitoring obligation
Operating personnel must notify changes in operational behaviour or of safety-related
parts to a responsible person or the manufacturer immediately.
2.2.1.2 Location of the Safety Manual
A copy of the Safety Manual must be available at all times to staff at the place of use of
the apparatus.
2.3.1 Safety measures (personnel)
2.3.1.1 Individual protective equipment
Anyone working with and on the hydraulic hand saw is required to wear individual
protective equipment.
The individual protective equipment comprises the following:
Fig. 1 Individual protective equipment
1. Helmet with ear protectors
2. Visor or goggles
3. Breathing mask
4. Safety gloves
5. Close-fitting, sturdy, comfortable clothing
6. Work boots with steel toecaps and non-slip soles

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2.4 General safety rules
2.4.1 Statutory provisions
The generally applicable national and local safety and accident prevention provisions and
the supplementary operator regulations must be followed and complied with.
2.4.2 Warranty
TYROLIT warrants that the hydraulic hand saw will operate correctly and safely on
condition that all the directions, working instructions and maintenance instructions
contained in this Safety Manual and in the Operating Instructions are strictly followed and
observed.
TYROLIT will not entertain claims for liabilities, any damages or warranty Claims for
damage that has arisen as a result of improper or inappropriate handling.
2.4.3 Inspection and maintenance obligation
The operator is under an obligation to only use the hydraulic hand saw when in perfect
and undamaged condition. The maintenance intervals shown in the Safety Manual must
be strictly observed and documented in this hand book. Malfunctions and mechanical
damage must be rectified without delay. Prior every use inspect the following:
•Shaft arm for fatigue or damage
•Shaft / spindle for fatigue or damage
•Inner and outer flange for fatigue or damage (replace flanges when worn)
•Diamond saw blade for any faulty or damaged segment weld, mounting screws
and bolt for any damage.
2.4.4 Spare parts
Only original spare parts should be used. Otherwise damage may be caused to the
machine or damage to other property and personal injury may result.
2.4.5 Modifications
No technical alterations should be made independently to the equipment and installation
components in the form of additions or conversions without the written consent of
TYROLIT. This concerns all additions and conversions that are not provided for by the
system design.
2.4.6 Safety instructions in the individual chapters
The chapters of this Safety Manual and of the Operating Instructions contain additional
safety instructions. These make reference to specific potential dangers (residual
dangers). The instructions must be followed closely and require that the actions or
sequences of actions described are taken.
2.4.7 Correct application
The hydraulic hand saw is designed and built for the following application:
•Cutting of concrete (including reinforced) and natural stone.
•Cutting of parting cuts, flush cuts, cross-cuts and joints.

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•Only tools with the original hole pattern must be used.
•If the hydraulic hand saw is operated in an enclosed area, the exhaust gases from
combustion motor of the power pack must be discharged into the open air.
2.4.8 Abuse or misuse
Any use other than for the intended purpose (see Chapter 2.4.8,  2-5.5.2), constitutes
improper use or misuse. Since improper use or misuse can sometimes results in
considerable danger, details are given here of what we believe constitutes improper use
or misuse.
The following applications are prohibited:
•Cutting wood, glass and plastics.
•Cutting of loose material or loose-detached steel reinforcing (including in concrete)
•Operation in explosion-protected areas
•Cutting without system and tool cooling
•Cutting without the safety devices provided
•Incorrect or absence of waste water disposal (saw sludge)
2.4.9 Making the workplace safe
Before starting work enough space should be created to ensure working without danger.
The workplace must be adequately lit.
Danger areas must be visibly cordoned off so that no-one can enter the danger areas
during sawing.
The front, underneath and rear of the sawing area must be protected so that persons or
equipment cannot be harmed by falling parts or sawing sludge. Lumps of concrete that
have been loosened must be secured against falling.
Breathing in the water fog/mist that is created is a health hazard. Ensure adequate
ventilation in sealed-off areas.
The sludge resulting from cutting is very greasy. Suitable steps must be taken (removal
or cordoning off) so that persons do not slip and injure themselves.
2.5 Responsibility
2.5.1 Authorised personnel
Work on or with hydraulic hand saw should only be performed by authorized persons.
Personnel are considered to be authorised if they meet the necessary training and know-
how requirements and they have been assigned a precise functional role.
The personnel qualifications for the corresponding work are defined in the introduction
under “General” of the respective chapters.
2.5.2 Delimitation of authority (functional roles)
2.5.2.1 Manufacturer
TYROLIT or its local agents are deemed to be the manufacturer of equipment
components supplied by TYROLIT. The manufacturer is entitled to request from the
operator information on its hydraulic hand saw machine.

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2.5.2.2 Operator
As the primary legal entity, the operator is responsible for the correct use of the product
and for the training and use of the authorised personnel. He sets out the mandatory skills
and level of training of the authorised personnel for his company.
2.5.3 User (operative)
•Sets up the hydraulic hand saw for the material to be cut or the material thickness.
•Performs sawing 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.
•Makes the site safe.
2.5.4 Service engineers
The service engineer is an employee of TYROLIT Hydrostress AG or a person
authorised by TYROLIT Hydrostress AG .
•Makes adjustments to the system.
•Performs repairs, complex service work and maintenance work.
2.5.5 Qualification and training Operator
•Trained building expert in a specialist role
•Has extensive experience in personnel training and danger assessment.
•Has read and understood the “Safety instructions” chapter.
2.5.5.1 User
•Has attended user training at TYROLIT Hydrostress AG or corresponding technical
courses at regional professional associations and federations.
•Has received an introduction (basic training) to the operation of the hydraulic hand
saw machine from the manufacturer.
2.5.5.2 Service engineers
•Specialist professional training (mechanical / hydraulically).
•Has attended specialist courses at TYROLIT Hydrostress AG.

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3 Start-up
3.1 Putting into operation
Each time that the hydraulic hand saw is put into operation it must be checked to ensure
that it is free of defects. Putting into operation of the individual system parts (machines
and components) is described in the corresponding Operating Instructions or instruction
leaflets.
4 Operation
4.1 General
Before proceeding read Chapter 2 “Safety instructions”,  2-1 in this Safety Manual. Be
sure also to take note of all the danger information given here and follow the instructions
on how to avoid physical injury and damage to property.
4.1.1 Safety instructions
It is essential to observe the following safety instructions, in particular in relation to the
operation of the hydraulic hand saw.
4.1.2 Personnel qualifications
The hydraulic hand saw should not be operated by unauthorised persons.
Personnel are only authorised where they meet the following requirements:
•Have successfully completed user training at TYROLIT Hydrostress AG or
corresponding technical courses at regional professional associations and
federations.
•The Safety instructions in Chapter 2 must have been read and understood.
•Are familiar with all the general rules of architecture
4.2 Safety-related operator’s controls
4.2.1 Blade guard
The blade guard is a safety device. It provides protection from accidental contact with the
cutting tool and from flying parts and at the same time acts as a spray guard. Working
without the blade guard is prohibited.
4.3 Operation
In order to guarantee that all work is carried out in complete safety, it is essential to
perform the activities described in this Safety Manual.

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Sawing Information:
This checklist is intended solely to provide a better overview of the sequence in which the stages
of the work should be carried out. It is merely information for general cutting. It is the operator’s
responsibility to be familiar with the proper action to saw concrete and solid structures in general.
4.3.1 Process checklist
1. Approval from the supervision of works
Before any work commences the approval of the supervision of works must be
obtained. The following points must be clarified:
•Are their static concerns about the building structure?
•Are electrical lines laid in the wall or ceiling (floor)?
•Are sanitation lines laid in the wall or ceiling (floor)?
•Have loose parts been left in the wall or ceiling (floor)?
•At what depth are any longitudinally running reinforcements?
2. Mark out cut
The cut to be made must be marked out. In doing so the size and/or the weight
of the structural blocks must be taken into account.
3. Determine cutting sequence
In principle, for a wall cutting for example, first the bottom, then the side and
only at the end the top, cuts must be performed.
4. Secure danger area
Before starting work the danger areas must be secured
5. Secure structural blocks
Before sawing work commences the structural blocks must be correctly
secured from the structural engineering point of view. It must be ensured that
the structural blocks neither overturn nor fall out or down and that they cannot
displace.
6. Carry out a pre-cut / guide cut
Before the cut itself a pre-cut / guide cut should be made. This will ensure that
the cutting tool (saw blade) does not drift.
7. Sawing, etc.
Now the cuts must be performed in the order envisaged. For each new cut
steps 4 to 9 must be repeated. If necessary, steel wedges are used to secure
the cut concrete.
8. Removal of the structural blocks
Removal of the structural blocks is dangerous and therefore particular care is
called for. It must in particular be ensured that no persons remain in the danger
areas and the securing and suspension or crane apparatus are adequately
designed for the load to be held or lifted.
9. Disposal of sawing sludge
If necessary the sawing sludge must be disposed of according to the normal
local environmental regulations. The sawing sludge contains all the materials
that have been sawn through.

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4.3.2 The procedure in detail
4.3.2.1 Obtaining the approval of the supervision of works
Before any work commences the approval of the supervision of works must be obtained.
The following points must be clarified:
• are their static concerns about the building structure?
Action:
If structurally important bearing or support structures are cut through, this may have fatal
consequences (static weakening or subsidence)
• are electrical lines laid in the wall or ceiling (floor)?
Action:
If one or more electricity lines are located in the wall, the ceiling or the floor, it must be
ensured that these have been disconnected and secured against reconnection.
• are sanitation line laid in the wall or ceiling (floor)?
Action:
If sanitary lines (supply or waste pipes for water or waste water) exist, these must first be
drained.
• have loose parts been left in the wall or ceiling (floor)?
Action:
Loose or soft materials cannot be cut. They must therefore be removed first. Otherwise
the result would be that the tool would jam or that individual segment would come away
and be propelled.
• how deeply are any longitudinally running reinforcements?
Action:
If along the cuts to be performed there are reinforcements in the concrete, it is important
to know how deep below the surface these may be located. If instead of the
reinforcements being sawn through, the reinforcements are sawn along, the resultant
heat could make the segments come loose with the result that the cutting tool is
destroyed.
4.3.2.2 Mark out cuts and anchoring holes
The parts to be sawn out are normally already marked out by the customer. It is now a
matter of determining the maximum concrete block weight and adapting to the conditions.
In doing so the following points must be taken into account:
•it must be possible to adapt the handling to the task
•the crane or the lifting device must be designed for the loads to be lifted
•the weight of the structural block cut out should not exceed the maximum permitted
floor loading
4.3.2.3 Define the sequence of cuts
The sequence of cuts is important in order that the cutting tool does not jam later and that
the structural blocks can be removed without problems. When defining the sequence of
cuts express account must also be taken of personal safety issues. In principle, for a wall
cut for example, first the bottom, then the side and only at the end the top cuts must be
performed.

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Fig. 2 Define the sequence of cuts
For floor cutouts the cutout blocks must be supported with suitable building material or
suspended and secured on a crane or other suitable lifting apparatus with sufficient load-
bearing capacity.
4.3.2.4 Secure danger area
Danger areas with wall cuts
The danger areas must be marked out and secured. During sawing operations no
persons should remain in these danger areas. It is just as important to secure the rear of
the danger area. Individual concrete splinters or cutting tool segments may come loose
and be projected.
4.3.2.5 Securing cutouts
Before commencing the sawing activities the structural blocks to be cut out must be
secured against falling out in the case of a wall cutout, or against falling down in the case
of a floor or ceiling cutout.
Example: Securing by supporting from below
Another way of securing the structural blocks to be removed during floor cutouts is to
support them from below with the help of timber and structural supports.
Removal of the structural blocks can take place later as follows:
•lifting down with the help of a fork-lift truck
•lowering down with the help of a block and tackle
4.3.2.6 Carry out a guide cut / pre-cut
Definition Guide cut: Cut for blade guide
(Cut depth max. 10 % of the blade diameter no
reinforcement)
Pre-cut: The pre-cut is performed with a small blade diameter
and possibly with a wider segment width (never less
than the width of the segments on the 534mm blade!)

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Guide cut Guide cuts are used to guide the blade so that it does not drift and
should always be performed for safety reasons. Guide cuts should only
be performed with blades with a maximum blade diameter of 400mm.
It is important that this guide cut is very straight!
Pre-cut Large depths cannot be cut in a single pass. Therefore, for blade
diameters of 534mm, pre-cuts must be made. The pre-cuts must be
performed with a blade of small diameter and with wide segments.
4.3.2.7 Sawing
If the cutouts are performed with overcuts, please note: the length of the overcut is
directly related to the cutting tool diameter selected, the plunging depth of the cutting tool
and the thickness of the concrete. If the cutouts are performed without overcut, the tool is
used to cut as far as the corners and then the remaining cut is performed with the
diamond bar saw (ICS). Sawing can now commence.
Feed after the pre-cut or guide cut
Following the pre-cut or guide cut more than 50-80 mm can be fed. The possible cutting
depth depends on the level of reinforcement, the aggregates in the concrete, the size of
the cutting tool, the blade specification and the drive assembly power.
Reinforcements in the longitudinal direction
When cutting it must be ensured that when plunged the tool is not in contact with any
reinforcement that runs alongside the cut. Ensure the operator cuts through the steel
completely and also has contact with concrete for sharpening effect.
Fig. 3 Longitudinal bars in the precut
Information
The depth of the precut must be selected to guarantee that any reinforcements running
alongside the cut are completely cut through. If the cutting tool runs along in the
reinforcement, there is a danger of the cut drifting with heavy wear of the tool rendering it
defective.
If the saw blade jams
•Carefully withdraw from the cut with travelling or swivelling motions.
•If this is not possible: Disassemble cutting tool from saw head and remove cutting
tool alone from the cut.

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At the end of each cut
•Withdraw from the cut with the cutting tool running
Wall cutout cutting example
Before the cut (left, vertical) steel wedges must be fitted (see diagram).
This prevents the cutout sections both from toppling over and from falling out. At the same
time it makes removal easier.
Fig. 4 Use of wedges
1 Cut
2 Steel wedge

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5 Maintenance
5.1 General
5.1.1 Safety instructions
Before proceeding read Chapter 2 “Safety instructions”, in this Safety Manual. Be sure
also to take note of all the danger information given here and follow the instructions on
how to avoid physical injury and damage to property.
5.1.2 Personnel qualifications
The hydraulic hand saw systems should not be operated by unauthorised persons.
Personnel are only authorised where they meet the following requirements:
•have successfully completed, and hold a certificate from, user training at
TYROLIT Hydrostress AG or corresponding technical courses at regional
professional associations and federations.
•the safety instructions in Chapter 2 must have been read and understood.
•are familiar with all the general rules of architecture
5.2 Inspection
Inspection activities are understood to be the work involved in checking wear parts, in
order to exchange these where they show unacceptable levels of wear before they are
able to cause a defect and a costly system failure.
Inspection activities are described in the Operating Instructions of the individual
machines.
Dailey
•Inspect shaft and blade shaft arm for fatigue or damage
•Saw blade must be inspected for wear and tear, steel core cracks, flange and
countersunk hole pattern for any cracks.
•Blade guard for any damage or fatigue
Any parts that appear defect need to be replaced immediately and documented.
5.3 Maintenance
Maintenance activities are understood to be the maintenance work that must be
performed in order to be able to guarantee trouble-free operation of the system. These
activities usually consist of: cleaning, oiling, greasing, etc.
Maintenance activities are described in the Operating Instructions of the individual
machines.
5.4 Servicing
Servicing activities are understood to be independently performed repair work. These
may be a result of inspection if unacceptable levels of wear are detected in wear parts, or
if defects arise. Servicing activities are described in the Operating Instructions of the
individual machines.

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Maintenance record sheet
Date Defect Remedy Service Person

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TYROLIT Hydrostress AG
Witzbergstrasse 18
CH-8330 Pfäffikon
Switzerland
Tel. +41 (0) 44 / 952 18 18
Fax +41 (0) 44 / 952 18 00
e-mail: [email protected]
www.tyrolit.com
TYROLIT Hydrostress AG reserves the right to make technical changes without prior notice.
Copyright © 2006 TYROLIT Hydrostress AG, CH-8330 Pfäffikon ZH, Switzerland
All rights reserved, in particular copyrighting and translating rights.
Printing of this operating manual, including extracts from it, is prohibited. No parts
of it may be reproduced in any form or processed using electronic systems,
duplicated or disseminated without the written permission of TYROLIT
Hydrostress AG.

Ersatzteilliste
Spare Parts List / Liste des pièces détachées / Lista di parti di ricambio
10984829 EN / 23.1.08
HBH534***
Index / Indice 000