TYROLIT Hydrostress HRG500 User manual

Operating Instructions
Ring saw HRG500 
Index 000
10992852 en /17.04.2012

Page 2 Ring saw HRG500 
TYROLIT Hydrostress AG
Witzbergstrasse 18
CH-8330 Pfäkon
Switzerland
Tel. [phone]
Fax [phone]
Congratulations!
You have decided to purchase a tried and tested TYROLIT Hydrostress unit and have thus ac-
quired a highly sophisticated and reliable state-of-the-art unit. Only genuine TYROLIT Hydro-
stress replacement parts can guarantee quality and interchangeability. If maintenance work is
neglected or carried out inexpertly we will be unable to honour our warranty obligations. Any
repair work must be carried out by trained personnel only.
Should you need more details concerning your TYROLIT Hydrostress unit in order to keep it in
perfect condition, please contact our after-sales service for further information.
We hope that working with your TYROLIT unit will be a satisfying and fault-free experience.
TYROLIT Hydrostress
Copyright © TYROLIT Hydrostress

TYROLIT Hydrostress AG
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Ring saw HRG500 
Concerning these instructions
These instructions are a constituent of the unit. They describe how to use the equipment safely
and properly in all phases of operation.
• Read the instructions carefully before use, particularly the safety instructions.
• Keep the instructions for the entire service life of the equipment.
• Ensure that the instructions are available to the operator and the service engineers at all
times.
• Pass the instructions on to all subsequent owners or users of the equipment.
• Update instructions with all supplements received from the manufacturer.
Danger symbols in these instructions
DANGER
Warning of danger, where failure to comply could lead to death or serious injury.
WARNING
Warning of danger, where failure to comply could lead to injuries or damage to property.
Information for optimum use of equipment. Failure to take note of this information may mean
that the performance information shown in the technical data can no longer be guaranteed.
1
1.1

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Safety instructions
Please pay attention to the safety instructions
Do not work with the unit unless you have read and understood the safety instructions.
The unit has been inspected before being shipped and is delivered in perfect condition.
TYROLIT Hydrostress does not accept liability for damage caused by failing to follow these
instructions. This applies in particular to the following damage:
• Damage caused by improper use and operator error
• Damage caused by failure to observe the safety-related information in these instructions or
the warning signs on the unit.
• Damage caused by substandard maintenance work
Use for correct purpose
The ring saw is used by trained personnel for cutting concrete, masonry and stone.
Incorrect use:
• Working without protective equipment or inadequate protective equipment
• Cutting other materials
• Removal of protective devices
• Cutting in potentially explosive areas
• Cutting loose parts
• Incorrect or absence of waste water disposal (sawing sludge)
Target groups and responsibility
Authorised personnel
Work on or with machines or systems from TYROLIT Hydrostress may only be carried out by
authorised persons. Personnel are considered to be authorised if they meet the necessary
training and know-how requirements and they have been assigned an exact functional role.
Manufacturer
The following are considered to be manufacturers of products that are supplied by TYROLIT
Hydrostress:
• TYROLIT Hydrostress
• A company explicitly nominated by TYROLIT Hydrostress
Within the context of an integrated quality assurance and safety control system, the manufac-
turer is entitled to request from the operator information about the products.
Operator
The operator named by TYROLITHydrostress is the primary, legal entity responsible for the cor-
rect use of the product and for the training and assignment of the authorised personnel. The
operator sets out the skills and level of training of the authorised personnel.
Personnel qualications
• A technical trained person in a management position.
• Relevant experience in personnel management and risk assessment
• Has read and understood the safety instructions
2
2.1
2.2
2.3
2.3.1
2.3.2
2.3.3

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Ring saw HRG500 
Operator (user)
User is the term employed by TYROLIT Hydrostress to designate a person who independently
performs the following work:
• Setting up the machines and systems of TYROLIT Hydrostress within the scope of correct
purpose of use
• Independent performance and monitoring of work
• Localisation of faults and organisation of troubleshooting and independent fault remedying
• Maintenance
• Testing the correct operation of safety equipment
Personnel qualications
• Completed training as a concrete expert or relevant professional experience
• Introduction (basic training) to the operation of the unit by a service engineer
Service engineer
A service engineer is the term employed by TYROLIT Hydrostress to designate a person who in-
dependently performs the following work:
• Installs TYROLIT Hydrostress machines and systems
• Makes adjustments to machines and systems for which certain access rights are required.
• Complex service and repair work
Personnel qualications
• Specialist professional training (mechanical / electrotechnical)
• Product-specic training at TYROLIT Hydrostress
Organisational measures
Product monitoring obligation
The unit may only be operated in perfect and undamaged condition. Operating personnel must
notify changes in operational behaviour or safety-related components to a responsible person
or the manufacturer, immediately.
The maintenance intervals must be adhered to. Faults that aect safety must be remedied im-
mediately
Location of these instructions
A copy of these instructions must be available to personnel at the place of use of the unit at all
times.
Workplace
XProvide sucient space to carry out work safely.
XEnsure that the workplace is suciently illuminated.
XCordon o the danger area in a clearly noticeable way so that no person can enter the dan-
ger area during sawing.
2.3.4
2.3.5
2.4
2.4.1
2.4.2
2.4.3

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Protective devices and signs on the equipment
Protective devices
Protective devices may only be removed if the equipment has been switched o and is at a
standstill. Safety components in particular should only be removed and retted by authorised
personnel.
Before switching the equipment back on again, check that the safety elements are operating
correctly.
Signs on the equipment
1 Wear safety shoes 4 Wear a helmet, goggles and hearing protection
2 Wear gloves 5 Wear safety clothing
3 Wear a breathing mask 6 Read the instructions
Spare parts and modications
Only original spare parts from TYROLIT Hydrostress must be used. Otherwise damage may be
caused to the unit or to other property and persons.
No additions or modications must be made to the unit without written permission from
TYROLIT Hydrostress.
2.5
2.5.1
2.5.2
1 5432 6
2.6

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Safety clothing
Safety clothing
Residual risks
Risk of serious injuries from the residual risks described in the chapters that follow.
Sharp edges
Risk of serious lacerations if the tool is touched.
XDo not touch the tool during operation
XAlways wear gloves when handling the stationary tool.
Diamond segments ying o
XBefore use, always ensure that the ring guard is correctly tted and undamaged.
XDo not start sawing if any other persons are in the danger zone.
XEnsure that a safety distance of 15 m is maintained from the ring saw.
XReplace the disk grinding ring if diamond segments start to break o.
Recoil
Erroneous positioning of the disk grinding ring or cutting the wrong materials can make the
ring saw recoil and seriously injure the operator.
XOnly cut materials that are permitted within the scope of the correct purpose of use.
XDo not apply disk grinding ring above the middle of a workpiece edge.
Unintentional start-up
XBefore starting up, please ensure that:
–The control handle with lock is working correctly.
–There are no other persons in the danger zone.
Vibration
Vibration can cause circulation problems and/or nerve damage.
Consult a doctor in the event of symptoms.
2.7
2.8
2.8.1
2.8.2
2.8.3
2.8.4
2.8.5

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Uncontrolled movements and vibration
XAlways hold ring saw by the handles with both hands during operation. Thumbs and ngers
must be closed around the handles.
XKeep the handles clean.
XNever saw above shoulder height.
XNever stand on ladder when sawing.
XGuide the motor saw in such a way that no part of your body is inside the extension of the
disk grinding ring of the saw.
A loose disk grinding ring can cause uncontrolled ring saw vibration.
XEnsure that the drive rolls are correctly mounted.
Catching and winding in
Items of clothing or long hair can be caught by the rotating disk grinding ring.
XAlways work with the protective covers tted.
XDo not wear loose items of clothing at work.
XWear a hair net if you have long hair.
Particles ying o
Flying particles can cause eye injuries.
XWear safety goggles or a visor.
XEnsure that danger area is properly cordoned o.
Falling parts
Falling parts can cause serious head and foot injuries.
XWear helmet and safety shoes with steel toecaps.
XLumps of concrete that have been cut loose must be secured against falling.
XSafeguard front, underneath and rear of sawing area from falling parts or sawing sludge.
People must not be injured or equipment damaged.
Noise
Noise can damage the hearing.
XWear hearing protection.
Damaging vapours and aerosols
Inhaling damaging vapours and/or aerosols can cause breathing problems.
Breathing in the water fog and exhaust that is emitted is a health hazard.
XWear a breathing mask.
XProvide adequate ventilation in conned spaces.
Risk of slipping
XDo not work on uneven surfaces.
XWear safety shoes with non-slip soles.
The sludge resulting from cutting is very greasy.
XRemove sludge or ensure that people cannot slip in it.
Risk of ring saw restart in the event of an accident
XEnsure that the ring saw can be stopped quickly.
2.8.6
2.8.7
2.8.8
2.8.9
2.8.10
2.8.11
2.8.12
2.8.13

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Physical condition
XDo not work whilst under the inuence of alcohol, drugs or medication.
XDo not work when you are overtired.
XDo not allow children or adolescents below the age of 18 to operate the motor saw.
Adolescents aged 16 and over are excepted from this ban is they are under the supervision
of an expert for training purposes.
Reduced cutting ring quality
XDo not use damaged disk grinding rings.
XCheck disk grinding ring for damage before installation.
XDo not equip disk grinding ring with new diamond segments.
Fuel / refuelling
Contact with petrol and oil can cause allergic reactions.
XWear protective gloves.
XIf petrol or oil come into contact with skin, wash aected areas immediately with plenty of
water.
Refuelling
XSwitch motor o when refuelling the motor saw.
XSmoking and naked ames are prohibited.
XAllow machine to cool before refuelling.
XFuel can contain substances similar to solvents. Avoid skin and eye contact with mineral oil
products. Wear gloves when refuelling. Change and clean protective clothing at frequent
intervals. Do not inhale fuel vapour. Breathing in fuel vapour can cause physical injury.
XDo not spill fuel or oil. If fuel or oil is spilled, clean motor saw immediately. Do not allow fuel
to come into contact with clothing. If clothing comes into contact with fuel, replace clothing
immediately!
XEnsure that no fuel or oil gets into the soil (environmental protection). Use a suitable surface.
XDo not refuel in conned spaces. Fuel vapour accumulates at oor level (risk of explosion).
XEnsure that screw plugs of fuel tank and oil tank are closed properly.
XChange location before starting the motor saw (at least 3 metres away from refuelling sta-
tion).
XFuel has a limited storage time. Only buy as much as you intend to use within a foreseeable
time.
XAlways transport and store fuel and oil in approved and marked canisters.
Keep children away from fuel and oil.
Explosion hazard
Starting of res and smoking in the immediate vicinity of the ring saw is strictly prohibited.
Transport
XNever transport the motor saw while it is running!
XAlways carry motor saw with the bow-type handle.
2.8.14
2.8.15
2.8.16
2.8.17
2.8.18

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Risk of property damage
Lateral cutting
Cutting with the sides of the blade can damage the disk grinding ring.
XDo not cut laterally.
Defective water cooling
The disk grinding ring can be damaged if the water cooling is defective.
XDo not operate the ring saw without water cooling.
Frost damage
XAt the end of work or before long stop periods, drain and blow out the water system.
Storage
XStore the motor saw securely in a dry room. The saw must not be kept outdoors.
Keep children away from the motor saw.
XThe fuel tank and the oil tank must be drained completely during longer storage periods
and when shipping the motor saw.
2.9
2.9.1
2.9.2
2.9.3
2.9.4

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Description
Ring saw
1 Roll pretensioner 8 Ring guard
2 Petrol motors 9 Disk grinding ring
3 Starting handle 10 Water connection
4 Operating handle 11 Fuel tank cap
5 Anti-vibration element 12 Choke lever and part throttle lock
6 Metal guard 13 Housing
7 Bow-type handle 14 Splash guards
Accessories
1 Allen key WAF 5/32"
2 Allen key WAF 1/4"
3 Open-ended spanner WAF 9/16"
3
3.1
3.2
1 2 3

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Preparatory operations
The work is prepared in the following way:
1. Sort out fundamental conditions:
–Location of supply lines in walls, oors and ceilings.
–Cooling water drainage (risk of electric shock and water damage)
2. Securing the site.
3. Secure cut-outs in walls, ceilings and oors (e.g. crane or supports). Take weight of concrete
into consideration (1m3corresponds to 2400 to 2700kg). Decide on position and sequence
of cuts.
4. Perform a visual inspection of the ring saw.
Position and order of cuts
Dene position
XObtain information about the concrete or masonry that is being sawn.
–Where does the reinforcement run?
–Is it heavily or lightly reinforced?
XCut across the concrete if possible.
Dene the sequence of cuts
Using the wrong cut sequence can result in the disk grinding ring getting jammed.
XDene cutting sequence (for example, for a window cutout carry out the bottom cut rst,
then the side cuts and nally the top cut).
4
4.1
4.1.1
4.1.2
3
1
22

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Assembly / Disassembly
Mounting the disk grinding ring
1. Remove the housing.
2. Undo smooth mounting bolt at drive roll.
3. Remove smooth drive roll.
5
5.1

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4. Clean disk grinding ring thoroughly.
5. Pull out and lock roll pretensioner.
6. Replace sliding plate (1).

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7. Place disk grinding ring on proled driver roll. When doing this, ensure that groove of
disk grinding roll is on projection of proled drive roll.
8. Fit smooth drive roll and screw in place.
9. Undo roll pretensioner.

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10. Check freedom of movement of disk grinding ring.
11. Fit housing but do not screw in place yet.
Fit safety equipment
1. Position housing on edge of table.
5.2

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Page 17 Ring saw HRG500 
2. Screw splash guards loosely into position.
3. Push housing downwards onto subsurface and hold down.
4. Screw ring and splash guard into place.
5. Swivel ring guard over disk grinding ring.

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Making the hose connection
Preparations for connection
XEnsure that coupling, ring saw and supply line are clean.
XCheck hose and coupling for damage.
Connect water hose
XConnect water hose.
5.3
5.3.1
5.3.2

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Page 19 Ring saw HRG500 
Operation
Working
Starting the motor
Cold start:
9The motor saw must be kept at least 3 metres away from the refuelling location.
9The disk grinding ring has been checked and is correctly tted.
9The water supply is secured.
XOpen water supply and check ring saw water outlet.
XTake a secure stance and place motor saw on oor in a position whereby the sawing equip-
ment is unobstructed.
XHold bow-type handle rmly with one hand and push motor saw downwards.
XPull out choke lever (4) until it is felt to engage. The part throttle lock is engaged at the same
time.
XPush I/STOP switch (3) of ignition in direction of arrow. Slowly pull out starting cord (5) until
resistance can be felt (piston is at top dead centre).
XNow pull quickly and powerfully until rst audible ignition takes place.
Caution: Do not pull starting cord out by more than 50cm, and always lead back slowly by
hand.
XPush in starter valve (6).
XPush in choke lever (4) and pull starting cord again. As soon as motor is running, get hold
of handle (safety locking button (2) is operated using the palm of your hand) and press the
throttle (1). The part throttle lock is cancelled and the motor runs at idle speed.
Warning: The motor must be set to idle speed immediately after starting, otherwise the
clutch could be damaged.
Warm start:
As described under cold start, but before starting, pull out choke lever (4) and push in again to
activate the part throttle lock.
6
6.1
6.1.1

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Page 20 Ring saw HRG500 
Cutting
Position disk grinding ring below the centre. Always start cutting with the disk grinding ring ro-
tating.
WARNING
Risk of injury from sudden ring saw recoil.
XDo not apply disk grinding ring above the middle of a workpiece edge.
Cutting technique
It is more economical to divide the entire cutting depth into several cuts.
–For optimum guidance, rst make a 50 to 70 mm cut.
–Divide the entire cut depth into several cuts.
Terminating the work
1. Switch o motor using the stop switch
2. Close o water supply and disconnect.
3. Blow out water from all lines.
4. Clean ring saw with water.
6.1.2
6.2