TYROLIT Hydrostress HRH500 Series User manual

Operating Instructions
Ring saw HRH500 
Index 000
10991784 en /25.07.11

Page 2 Ring saw HRH500 
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 appliance and have thus
acquired a highly sophisticated and reliable state-of-the-art device. Only genuine TYROLIT
Hydrostress 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 only be carried out by trained personnel.
In order to keep your TYROLIT Hydrostress appliance in perfect condition our after-sales service
are always at your disposal and pleased to help.
We hope that working with your TYROLIT appliance will be a satisfying and trouble free expe-
rience.
TYROLIT Hydrostress
Copyright © TYROLIT Hydrostress

TYROLIT Hydrostress AG
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Ring saw HRH500 
About these instructions
These instructions are part of the appliance. They describe the safe and proper use in all phases
of operation.
• Before use read the instructions carefully, especially the information on safety.
• Keep the instructions somewhere safe during the life of the appliance.
• Make these instructions available to the operator and service engineer at all times.
• Pass on these instructions to future owners or users of the appliance.
• Always keep these instructions up-to-date by including the received manufacture's up-dates.
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 injury or damage to property.
Information for the optimum use of appliance. Failure to take note of this information may
mean that the performances shown in the technical data can not be guaranteed.
1
1.1

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Safety information
Pay attention to the safety information
One is only permitted to work with the appliance when the safety information has been read
and understood.
The appliance has been inspected before being shipped and is delivered in perfect condition.
TYROLIT Hydrostresss accepts no liability for any damage arising due to disregarding these in-
structions. This applies in particular to the following damage:
• Damage caused by improper use and operator error
•Damage resulting from disregard of the safety relevant information in these instructions or
the warning labels on the appliance
• Damage resulting from unsatisfactory maintenance work
Correct application
The ring saw is to be used by trained personnel for cutting concrete, brickwork and masonry.
The appliance is intended to be connected to a drive unit and must be connected and the drive
engaged in accordance with the drive unit operating instructions.
Adhering to these instructions constitutes proper use of the appliance.
Misuse:
• Working without protective equipment or with inadequate protective equipment
• Cutting other materials
• Removal of protective devices
• Cutting in areas with danger of explosion
• Cutting loose parts
• Incorrect or absence of waste water disposal (saw sludge)
Target groups and responsibility
Authorised personnel
Working on or with machines or systems from TYROLITHydrostress may only be undertaken
by authorised personnel. 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.
Manufacturer
As manufacturer of the product, which is supplied by TYROLITHydrostress accept:
• TYROLIT Hydrostress
• a TYROLITHydrostress specically named company
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
operating company sets out the mandatory skills and level of training of the authorised person-
nel for the company.
Personnel qualications
• A technically trained person in a management position
• Has relevant experience in personnel management and danger assessment
• Has read and understood the safety instructions
2
2.1
2.2
2.3
2.3.1
2.3.2
2.3.3

TYROLIT Hydrostress AG
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Operator (user)
As a user TYROLITHydrostress designates a person who independently performs the following
work:
• Setting up of machines and systems from TYROLITHydrostress within the scope of intended
application
• Independent execution and supervision of work
• Location of faults and instigation of fault rectication or independent fault rectication
• Maintenance
• Verify the correct functioning of the safety devices
Personnel qualications
• Completed training as a concrete cutting specialist or relevant occupational experience
• Introduction (basic training) in the operation of the appliance by a service technician
Service technician
As a service technician TYROLITHydrostress designates a person who independently performs
the following work:
• Installation of machines and systems from TYROLITHydrostress
• Makes adjustments to machines and systems for which special access rights are required
• Complex service and maintenance work
Personnel qualications
• Specialist professional training (mechanical / electro technical)
• Product specic training from TYROLITHydrostress
Organisational measures
Product monitoring obligation
The appliance must only be operated in a defect free and undamaged condition. Operating
personnel must notify immediately changes in operational behaviour or safety-related compo-
nents to a responsible person or the manufacturer.
The maintenance intervals must be adhered to. Faults aecting safety must be rectied imme-
diately.
Location of these instructions
A copy of the instructions must be available to sta at all times at the location where the appa-
ratus is used.
Workplace
XCreate sucient free space to enable safe working.
XProvide sucient workplace illumination.
XCordon o danger area visibly so that during sawing operations no person can enter the
danger area.
2.3.4
2.3.5
2.4
2.4.1
2.4.2
2.4.3

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Protective devices and labels on the appliance
Protective devices
Protective devices must only be removed when the appliance is turned o, disconnected from
the mains and at a standstill. Safety components, in particular, may only be removed and ret-
ted by authorised personnel.
Before switching the appliance back on again, the safety elements must be checked to ensure
correct operation.
Labels on the appliance
1 Wear safety shoes 5 Wear protective clothing
2 Wear protective gloves 6 Read the instructions
3 Wear a breathing mask 7 Disconnect from the mains supply before working on the appliance
4 Wear hard hat, eye protection and
hearing protection
Replacement parts and modications
Only original spare parts from TYROLITHydrostress must be used. Otherwise damage may be
caused to the appliance or to other property and persons.
No additions or modications may be carried out to the appliance without the written agree-
ment of TYROLITHydrostress.
2.5
2.5.1
2.5.2
1 5432 6 7
2.6

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Personal protective clothing
Personal protective clothing
Residual risks
On the basis of residual risks, which are described in the following chapters, there is danger of
serious injuries.
Sharp edges
On coming in to contact with the tool there is a danger of serious cut injuries.
XDo not touch tool when in operation.
XOnly touch a stationary tool when wearing gloves.
Flying diamond segments
XEach time before use ensure that the blade guard is correctly tted and undamaged.
XOnly begin sawing when no other person is in the danger area.
XEnsure that the safe distance to the ring saw of 15m is maintained.
XChange the cutting ring when diamond segments break o.
Recoil
Due to incorrectly tting the cutting ring or cutting unspecied materials the ring saw can sud-
denly recoil seriously injuring the operator.
XOnly cut materials that are permitted within the scope of intended application.
XDo not place the cutting ring above the centre at a work piece corner.
Unintentional start up
XBefore operating ensure:
–The switch handle with safety lock functions correctly.
–There is no other person in the danger area.
Uncontrolled movements and vibrations
XNever connect or disconnect hoses while the drive unit is running.
XWhen the ring saw is switched on always hold the handle rmly with both hands. Thumbs
and ngers must be closed around the handles.
XKeep the handle clean.
A loose cutting ring can cause uncontrolled vibration of the ring saw.
XEnsure that the smooth drive rolls are tted correctly.
2.7
2.8
2.8.1
2.8.2
2.8.3
2.8.4
2.8.5

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Vibrations
Vibrations can cause circulatory problems or nerve damage.
XOn signs of symptoms seek medical help.
Catching and entanglement
Items of clothing or long hair can get caught up in rotating cutting rings.
XOnly operate when wearing appropriate protective clothing.
XDo not operate when wearing loose hanging items of clothing.
XIf hair is long wear a hairnet.
Pressure connections
Hydraulic oil can be released at high pressure.
If the hoses cannot be connected or only connected with diculty, they are under pressure.
XCheck hydraulic connections regularly for damage and if required have changed by an au-
thorised person.
XNever connect or disconnect hoses while the drive unit is running.
XNever apply force to connect couplings.
XDepressurise the hoses by means of the pressure relief device.
Flying particles
Flying particles can cause injury to eyes.
XWear protective glasses or visor.
XSecure danger area professionally.
Falling parts
Falling parts can cause serious head and foot injuries.
XWear safety helmet and protective shoes with steel toecaps.
XSecure removed pieces of concrete against falling.
XSecure against parts or saw slurry falling to the front, below and to the rear of the sawing
area: Persons must not be injured and equipment not damaged.
Noise
Noise can cause hearing damage.
XWear hearing protection.
Harmful vapours and aerosols
Inhaling harmful vapours and aerosols can cause breathing problems.
Breathing in the water fog that is created is a health hazard.
XWear a breathing mask.
XIn enclosed spaces ensure that there is adequate ventilation.
Hydraulic oil
Contact with hydraulic oil can cause allergic reactions.
XWear protective gloves.
XOn contact with hydraulic oil the aected skin areas must be washed immediately with plen-
ty of water.
On connecting and disconnecting the hoses there is the danger of an uncontrolled hydraulic oil
leak.
XNever connect or disconnect hoses while the drive unit is running.
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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Electrical energy
A defective electric device (e.g. drive unit) can result in an electric shock.
XBefore operating and regularly during long operating periods check the electric device for
damage.
XDefective parts, as for example cable and plug, should be replaced by electrically trained
personnel.
XDisconnect the mains plug before working on electrical devices.
Danger of slipping
XDo not operate on uneven surfaces.
XWear safety shoes with non-slip soles.
The sludge resulting from cutting is very slippery.
XRemove the sludge or ensure that people can not slip on it.
Unt to work
XDo not operate when under the inuence of alcohol, drugs or medication.
XDo not operate when overtired.
Danger of the ring saw restarting in the event of an accident
XEnsure that the ring saw (e.g. by means of the drive unit emergency STOP) can be brought
rapidly to a halt.
Reduced blade quality
XDo not use damaged cutting rings.
XCheck cutting ring for damage before tting.
XDo not t new diamond segments to saw blades.
Danger of damage to property
Sideways cutting
Cutting with the side of the blade can damage the cutting ring.
XDo not cut sideways.
Decient water cooling
The cutting ring can be damaged when cutting with insucient water cooling.
XDo not operate ring saw without water cooling.
Excessive pressure
The drive can be damaged by excessive pressure.
XDo not operate ring saw at a pressure higher than specied.
XIf necessary install pressure reducing valve or a ow divider.
Frost damage
XOn termination of work or before long shut downs drain the water system and blow out.
2.8.14
2.8.15
2.8.16
2.8.17
2.8.18
2.9
2.9.1
2.9.2
2.9.2
2.9.3

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Description
Ring saw
1 Roller pre-tension device 5 Frame
2 Hydraulic motor 6 Blade guard
3 Operating handle 7 Cutting ring
4 Hydraulic coupling 8 Splash protection aps
9 Water connection
Accessories
1 Allen key WAF 5/32”
2 Allen key WAF 1/4”
3 Combination spanner WAF 9/16”
3
3.1
3.2
1 2 3
1 2 3 4 5 6
7
9
8

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Preparatory operations
The work is prepared in the following manner:
1. Clarify the fundamental conditions:
–Position of pipes and cables in walls, oors and ceilings
–Cooling water drainage (danger of electric shock and water damage)
2. Securing the site.
3. Secure out-cuts from wall, ceilings or oors (e.g. crane or supports). Consider the weight of
concrete (1m3weighs 2400 to 2700kg). Decide on the position and sequence of cuts.
4. Visually inspect the ring saw.
Position and sequence of cuts
Decide on position
XObtain information on sawing concrete or sawing brickwork:
–Where does the reinforcement run?
–Is the concrete heavily or lightly reinforced?
XCuts in concrete to be as near as possible at right angles
Dene the sequence of cuts
An incorrect sequence of cuts can lead to the cutting ring jamming.
XDene the sequence of cuts (e.g., for a window cut-out 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
Cutting ring assembly
1. Undo upper bolts.
2. Undo lower bolts.
3. Remove cover.
5
5.1

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4. Undo securing bolts of smooth drive roller.
5. Remove smooth drive roller.
6. Thoroughly clean cutting ring.
7. Withdraw and lock roller pre-tension device.

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Page 14 Ring saw HRH500 
8. Replace slide plate (1).
9. Place cutting ring on proled drive roller. Ensure that the cutting ring groove lies on the pro-
led drive roller recess.
10. Tighten smooth drive roller bolts.
1

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11. Slacken roller pre-tension device.
12. Check the cutting ring for free movement.
13. Replace cover but do not yet tighten bolts.

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Fit safety devices
1. Place casing on table edge.
2. Bolt on splash protection aps loosely.
3. Press the casing down on to the base plate and keep pressed.
4. Tighten bolts of blade guard and splash protection aps.
5.2

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Page 17 Ring saw HRH500 
5. Rotate blade guard over the cutting ring.
Attaching hose connectors
Attachment preparations
XEnsure cleanliness of connections, ring saw and service connections.
XCheck hoses and couplings for damage and oil leaks.
Connect hydraulic hoses
XConnect hydraulic hoses.
Connect water hose
XConnect water hoses.
5.3
5.3.1
5.3.2
5.3.3

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Operation
Operating procedure
1. Start the drive unit.
2. Open drive unit water valve and check water delivery to ring saw.
3. Set operating pressure.
4. Hold ring saw rmly with both hands.
5. Press on safety handle (A) and operate hand start lever (B).
6. Check direction of cutting saw rotation.
WARNING
Danger of injury due to sudden recoil of ring saw.
XDo not place the cutting ring above the centre at a work piece corner.
7. Position the cutting ring below the centre position.
6
6.1
✓

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Page 19 Ring saw HRH500 
It is more economical to achieve the total required depth of cut in a number of steps.
8. Cutting:
–For optimum guidance rst of all make a cut from 50 to 70mm deep.
–Divide the total depth of cut into a number of steps.
Terminating the work
1. Close o and disconnect the water feed.
2. Blow out water from all lines.
3. Withdraw drive unit mains plug.
4. Disconnect hydraulic hoses.
5. Clean ring saw with water.
6.2

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Page 20 Ring saw HRH500 
Maintenance
Change rollers
XChange drive roller (proled) (1) and drive roller (smooth) (2).
7
Maintenance and servicing table
Before starting work each time At end of work Weekly Annually When faults occur After damage
Hydraulic system XCheck hydraulic hoses and connectors
(damage, leaks, cleanliness). X X X X
Water supply XCheck water supply (damage, leaks,
cleanliness). X X X X
XBlow out water (frost hazard). X
Rollers XCheck rollers for wear. X X
Motor XClean and thoroughly grease motor
valves. X
Blade guard XCheck blade guard. X
Cutting ring XCheck the cutting ring for wear. X X
Guide plate XCheck guide plate alignment. X
Major service XTo be performed by TYROLIT Hydros-
tress AG or an authorised workshop. X
7.1
2
1