TYROLIT Hydrostress TBS510 User manual

ig
OPERATING INSTRUCTIONS
TBS510
Index 000
Translation of the original instructions
11000656 en / 20.05.2019

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Congratulations!
You have decided to purchase a tried-and-tested TYROLIT Hydrostress unit 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. All repairs must be carried out by trained personnel only.
Our after-sales service is available to help ensure that your TYROLIT Hydrostress units remain in
perfect working order.
We hope that working with your TYROLIT unit will be a satisfying and fault-free experience.
TYROLIT Hydrostress
Copyright © TYROLIT Hydrostress
TYROLIT Hydrostress AG
Witzbergstrasse 18
CH-8330 Pfäffikon
Switzerland
Telefon [phone]
Telefax 0041 (0) 44 952 18 00

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BASIC SAFETY INSTRUCTIONS
Warning notices and symbols in this operating manual
Danger Indicates that failure to comply could
lead to severe injury or even death.
Caution Indicates that failure to comply could
sometimes lead to injuries.
Note Indicates that failure to comply leads
to damage to the machine or other property.
The defined sequence of the handling steps makes proper and safe handling of the machine easier.
•Handling instructions for the operator
The following warning and safety symbols were attached on the machine:
Observe the operating manual
Wear safety glasses and hearing protection
Wear hand protection
Cut hazard from rotating saw belt
Attachment point for crane transport
No attachment point for crane transport
Noise power level (noise level) of the machine
Running direction of saw belt
Align saw band
Tightening and releasing the saw belt

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OPERATING MANUAL
Preface This operating manual should make it easier to get to know the machine and make use of
its intended applications.
The operating manual contains important information on how to operate the machine
safely, properly and economically. Your close attention helps avoid risk, repair costs and
downtime, and increase the reliability and lifetime of the machine.
The operating manual is to be supplemented by directives for accident prevention and
environmental protection, according to applicable national requirements.
The operating manual is to be kept permanently available at the machine location.
The operating manual must be read and used by each person assigned to work with the
machine, e.g.:
•Operating, including tooling, troubleshooting during operating, correction of
production rejects, service, disposal of operating and auxiliary materials
•Maintenance (service, inspection, repair) and/or
•Transport
Along with the operating manual and the valid legal regulations for accident prevention in
the country of use and the place of use, also recognised regulations for safety and proper
work are to be observed.
Required tool In order for the masonry band saw to be operated, a tool - in the form of a saw belt - is
required. These tools can be purchased from the manufacturer.
Changes and reservations
We attempt for this operating manual to be correct and up-to-date. To maintain our
technological lead, it can be necessary to change the product without advance notice and
to perform their operation. We accept no liability for malfunctions, breakdowns and
damage caused by this.

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Notes:

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Table of Contents
1. Description of performance....................................................... 7
1.1. Basics of intended use......................................................................................................8
1.2. Organisational measures ..................................................................................................8
1.3. Personnel choice and personnel qualification; basic responsibilities............................... 9
1.4. Safety instructions and residual risks for the operation phases of the machine ............ 10
1.4.1. Transport, assembly and installation ..................................................................... 10
1.4.2. Moving the masonry band saw.............................................................................. 10
1.4.3. Commissioning.......................................................................................................10
1.4.4. Operation ...............................................................................................................11
1.4.5. Blockage of the masonry band saw .......................................................................11
1.4.6. Special work while using the machine ..................................................................12
1.5. Safety instructions for special types of dangers.............................................................12
1.5.1. Danger for the operator by the machine ................................................................12
1.5.2. Electric power ........................................................................................................13
1.5.3. Dust........................................................................................................................13
1.5.4. Noise......................................................................................................................13
1.6. Transport.........................................................................................................................13
1.7. Packaging and Storage ...................................................................................................14
1.8. Environmental protection................................................................................................ 14
1.9. Disposal..........................................................................................................................14
2. Description of the device ............................................................ 15
2.1. Name of machine parts ..................................................................................................15
2.2. Safety guards..................................................................................................................15
2.3. Technical data ................................................................................................................16
2.4. Noise power level...........................................................................................................16
3. Commissioning ......................................................................................... 17
3.1. Connections and operating materials .............................................................................17
3.2. Setting up the masonry band saw ..................................................................................17
3.3. Check distance between saw belt and guide rollers ......................................................18
3.4. Preparing to Start and Setting Operating Range.............................................................19
4. Transport ........................................................................................................ 20
4.1. Transport position...........................................................................................................20
4.2. Move by crane ................................................................................................................21
4.3. Moving the masonry band saws.....................................................................................21
5. Operation ....................................................................................................... 22
5.1. Safety .............................................................................................................................22
5.2. Cutting with the masonry band saw ...............................................................................22
5.3. Replacing the saw belt ...................................................................................................23
5.4. Workpiece blockage .......................................................................................................24
5.5. Selection of the tools......................................................................................................24
6. Cleaning ............................................................................................................ 24
7. Dismantling................................................................................................... 25
8. Maintenance................................................................................................ 25
8.1. Service............................................................................................................................25
8.2. Lubrication points ...........................................................................................................26
8.3. Troubleshooting table..................................................................................................... 27
8.4. Torque of screw connections..........................................................................................28
8.5. Maintenance plan...........................................................................................................29

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1.
DESCRIPTION OF PERFORMANCE
Masonry band saws from TYROLIT are designed especially for processing porous concrete and have
proven themselves on all types of construction sites worldwide. The different models in the TBS
product line allow TYROLIT to offer their customers the greatest possible labour saving and highly
precise cutting technology.
•Perfect for porous concrete and usable under some conditions for bricks
•Optimally dimensioned saw belt rolls guarantee a high service life of the saw belt
•Direct drive saw belt wheels reduce maintenance work on V-belts or other drive elements
•No risk of jamming – a generous opening in the lower saw roller box enables the debris to
pass easily
•Constant, optimum tensioning using an automatic saw belt tensioner for optimum cutting
accuracy and reduced risk of saw band breakage
•Short saw band changing times – with quick-coupling, the saw table can be opened with one
hand movement
•Automatic saw belt cut-off – no excessive saw belt loading, since the saw belt only runs if it
is actually sawing
•The wheel set allows the band saw to be moved easily by one person

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1.1. Basics of intended use
1.1.1 The warranty obligation of the manufacturer and supplier is voided for improper or non-intended
use. Any change to the machine which is not carried out by the manufacturer is prohibited.
Changes, removal or addition of parts only with the written approval of the manufacturer.
1.1.2 The machine is constructed according to the state of the art and recognised technical safety rules.
However, danger to life and limb of the user or third parties, and/or damage to the machine or other
property may still arise from its use.
1.1.3 Only use the machine in technically faultless condition and for intended use, aware of safety and
danger complying with the operating manual. You should particularly handle malfunctions which
can compromise safety immediately, or have them addressed by experts.
1.1.4 The TYROLIT masonry band saw belongs to the masonry machines and is designed exclusively for
cutting large-sized bricks and stones. Cutting includes bricks made of porous concrete and
perforated bricks in dry cut within the adjustable operating range. Use with perforated bricks is only
possible to a limited extent, as the composition is different depending on the manufacturer. For hard
perforated bricks, the wear on the saw belt is too great and thus not recommended. The brick/stone
must lie flat against the stop on the saw table and must not be additionally held manually.
Intended use also includes compliance with the operating manual and observance of inspection and
maintenance manual. The manufacturer/supplier assumes no liability for damages caused by failure
to comply with the intended use.
1.1.5 Foreseeable misuse / non-intended use:
•Cutting wood, plastic or metal
•Free hand-guided cutting
•Any constructional changes, which change the safety or the type of design
1.1.6 The safety of this masonry band saw is only guaranteed if TYROLIT- saw belts are used.
1.2. Organisational measures
1.2.1 This operating manual must be easily accessible for each person at the location of use.
1.2.2 All additions to the operating manual, all generally valid legal and otherwise binding regulations for
accident prevention and environmental protection are to be followed and instructed!
Such obligations may also apply, for example, to the handling of hazardous materials or the wearing
of personal protective gear or traffic regulations.
1.2.3 Personnel assigned to jobs must have read and understood the operating manual, particularly the
Safety Instructions chapter, before starting work. In the middle of work it is too late. This
particularly applies to personnel who only work occasionally, such as those involved in tooling and
maintenance.
1.2.4 At least occasionally, perform checks for safe and hazard awareness work by operators while
following the operating manual!
1.2.5 Use personal protection equipment if necessary or required by regulations!
1.2.6 Observe all safety instructions and danger warnings and keep them in legible condition! Replace
safety and danger instructions that are damaged or non-readable any more.

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1.2.7 For safety-related changes to the machine or the running behaviour, stop the machine immediately
and mark it accordingly. Report the problem to the responsible post/person!
1.2.8 No changes, removal or addition of parts without the written approval of the manufacturer! The
instructions of the tool maker must be followed.
1.2.9 Only use tested original replacement parts from the manufacturer!
1.2.10 Observe required or prescribed deadlines given in the operating manual for inspection.
A yearly inspection by an expert is required. Before the inspection, the machine must be cleaned
thoroughly. Also, the power plug must be disconnected before any maintenance or repair work.
1.2.11 Follow all setup, maintenance, and inspection activities and schedules prescribed by the operating
manual, including all information about the replacement of parts / assemblies! These activities may
only be carried out by experts.
1.2.12 Inform operating personnel before beginning special and maintenance work! Name a supervisor!
1.2.13 Workshop equipment suitable for the work is absolutely necessary for performing maintenance
actions.
1.3. Personnel choice and personnel qualification; basic responsibilities
1.3.1 Only qualified personnel 18 years of age or older may operate the masonry saw independently. All
persons must be trained in the operation.
1.3.2 Establish responsibilities of the personnel for operating, changeover, servicing, and repairing the
machine!
1.3.3 Make sure that only authorized personnel works at the machine.
1.3.4 The operator must wear personal safety equipment according to the safety regulations, such as
safety shoes, safety gloves and safety glasses.
1.3.5 Remaining by the running machine unnecessarily is prohibited! Direct unauthorised personnel, who
are not working on the machine, away from the work area. Block off the working area, if necessary.
1.3.6 Work on the electrical equipment of the machine may only be carried out by qualified electricians or
trained personnel under the management and supervision of a qualified electrician, and in
accordance with the rules of electronics.
1.3.7 Any personnel training, learning, being instructed, or currently involved in general education may
only work with the machine under the continual supervision of an experienced person!

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1.4. Safety instructions and residual risks for the operation phases of the machine
1.4.1. Transport, assembly and installation
1.4.1.1 Transport, assembly and installation on/with the masonry band saw may only be carried out in
transport position.
1.4.1.2 Lift the machine only according to the instructions in the operating manual and with proper lifting
gear! Observe the attachment points (crane eyes) for load lifting system.
1.4.1.3 Transport in compliance with the maximum operating weight, this should be exclusively done by
crane. When moving the machine only for a short distance the machine can also be pushed using
the wheel set.
1.4.1.4 Even when moving the machine only for a short distance, disconnect the machine from the power
source! To recommission the machine, it must be connected properly to the power supply.
1.4.2. Moving the masonry band saw
1.4.2.1 The masonry band saw may only be moved with the saw belt at a standstill and the drive motor
turned off. Disconnect the machine from the power source!
1.4.2.2 Before leaving the operating position, the electric motor must be shut down and the saw belt must
no longer rotate. There is a danger of injury on the saw belt.
1.4.3. Commissioning
1.4.3.1 The commissioning of the machine may only be carried out in transport position.
1.4.3.2 Make sure that the foundation meets the load carrying capacity. All obstacles must be cleared
away from the working area and make sure there is sufficient lighting.
1.4.3.3 When inserting the saw belt, observe the running direction.
There is a danger of injury on the saw belt.
1.4.3.4 Visual inspection for damages and defects. Special check of the safety equipment and the saw
belt.
1.4.3.5 The safety of the masonry band saw is only guaranteed if tested TYROLIT saw belts are used.
1.4.3.6 It is forbidden to connect the machine to the power mains without GCFI protection in the mains
supply line or the junction box.
1.4.3.7 The condition of the saw belts must be checked daily before starting the cutting operation.
Cracked saw belts must be replaced immediately.

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1.4.4. Operation
1.4.4.1 Refrain from working in any manner that is questionable in regard to safety!
1.4.4.2 Take measures to ensure that the masonry band saw is only operated in a safe, functional
condition!
1.4.4.3 At least once per shift check the machine for externally recognisable damage and deficiencies!
Any changes which occur (including operating behaviour) must be reported immediately to the
responsible post/person! If necessary, immediately stop the machine and secure it against restart!
1.4.4.4 Immediately stop and secure the machine in case of malfunctions! Immediately correct
malfunctions! Electrical work may only be carried out by qualified electricians.
1.4.4.5 Any contact with the rotating saw belt is prohibited.
1.4.4.6 If the saw belt tears, first wait until the saw belt stops before opening the side doors.
1.4.4.7 Cutting curved or uneven workpieces is only allowed if the workpiece lies flatly between the saw
table and stop, has a secure guide and must not additionally be held with the hands.
1.4.4.8 The masonry band saws may only be operated by one person.
1.4.4.9 Do not pull the power plug from the power source when power is on.
1.4.4.10 Reaching into the saw belt during cutting is prohibited. These works may only be carried out with
the saw belt at a standstill and the drive motor turned off.
1.4.4.11 After finishing work the saw belt must be released to take the tension off the bearings of the saw
belt wheels. Before starting work the saw belt must be tightened again.
1.4.5. Blockage of the masonry band saw
1.4.5.1 When the saw belt is blocked the machine must be switched off immediately.
1.4.5.2 Check the saw belt, saw belt wheels and the rubber coating on the saw belt wheels for damage.

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1.4.6. Special work while using the machine
1.4.6.1 Follow all setup, maintenance, and inspection activities and schedules prescribed by the operating
manual, including all information about the replacement of parts / assemblies! These activities may
only be carried out by technical personnel.
1.4.6.2 Inform operating personnel before beginning special and maintenance work! Name a supervisor!
1.4.6.3 If the machine is completely turned off during maintenance and repair work, it must be secured
against unexpected application of power.
1.4.6.4 Before cleaning the machine with water or other cleaning agents, cover/glue all openings in which
no water/cleaning agent should penetrate due to safety and/or functional reasons. Electric motors,
switches and plugs are especially at risk. After cleaning, remove the covers/tape completely.
1.4.6.5 During service and repair work, always tighten again loose bolt joints.
1.4.6.6 If dismantling is required for fitting, servicing and repair, the safety fittings must be remounted and
checked immediately following the service and repair work!
1.4.6.7 Please ensure the safe, environmentally friendly disposal of operating and auxiliary materials and
replacement parts!
1.5. Safety instructions for special types of dangers
1.5.1. Danger for the operator by the machine
1.5.1.1 Working on the masonry band saw and moving with rotating saw belt is prohibited.
1.5.1.2 The electric motor of the masonry band saw must only be put in operation for intended use cutting.
1.5.1.3 Never clean the running saw belt holding a brush or scraper in the hand. Switch off the machine
and then clean it.

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1.5.2. Electric power
1.5.2.1 Use only original fuses with the specified current rating! In case of malfunctions, turn off the
masonry band saws immediately! Electrical work may only be carried out by technical and
qualified personnel.
1.5.2.2 The machine's electrical equipment must be inspected/checked regularly. Faults such as loose
connections or damaged cables must be corrected immediately. The machine must be labelled so
that it cannot be started by others.
1.5.2.3 Carry out maintenance or repair work only when the machine is disconnected from the power
mains.
1.5.2.4 A voltage drop of more than 10% leads to damage of the electrical switches.
1.5.3. Dust
1.5.3.1 When working in close quarters, follow any applicable national guidelines!
1.5.3.2 The masonry band saw can be equipped for use in interior areas with a dust extraction.
1.5.4. Noise
1.5.4.1 Noise value (see 2.4)
1.6. Transport
1.6.1 Name expert instructors for the lifting process
1.6.2 Only use suitable transport vehicle with sufficient load capacity!
1.6.3 Secure loads reliably according to the regulations. Use suitable attachment points!
1.6.3 Lift the machine only according to the instructions in the operating manual and with proper lifting
gear! Observe the attachment points (crane eyes) for load lifting system.
1.6.3 Even when moving the machine only for a short distance, disconnect the machine from the power
source! Before restarting the machine, connect it to the power mains correctly!
1.6.4 When recommissioning, follow the operating manual!
1.6.5 Transport of the masonry band saw may only be carried out in transport position.

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1.7.
Packaging and Storage
To ensure sufficient protection during shipping and transport, the machine and its components are
carefully packaged. When receiving the machine, the machine should be checked for damage. The
packaging of the device consists of materials which can be recycled. Put these by type into the
relevant recycling containers, so that they can be recycled properly.
In the case of damage, the machine must not be put into operation. Even damaged cable and plugs
represent a safety risk and must not be used. In this case, please contact the manufacturer.
If the machine is not immediately put into operation after unpacking, it must be protected from
moisture and dirt. Tools that are not used must be protected from moisture. The applied segments
around the saw belt must be protected from damage.
1.8.
Environmental protection
Packaging material, cleaning agents, used or residual operating materials, as well as removed
wear parts, such as drive belts or motor oils must be taken to recycling corresponding to the valid
regulations for environmental protection at the place of use.
1.9.
Disposal
If the expiry date of the device has been reached, in particular if functional errors happen, make
the used machine unusable.
Dispose of the device according to the valid regulations for environmental protection of your
country. Electrical waste may not be disposed of in household waste. Take the used device to a
central rubbish collection centre.

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2.
DESCRIPTION OF THE DEVICE
2.1. Name of machine parts
Pos. 1
Side door with rotary knob
Pos. 9 Saw belt protection clamping lever
Pos. 2
Saw belt
Pos. 10 Tensioning lever for saw belt
Pos. 3
Saw table
Pos. 11 Crane eye
Pos. 4
Saw table clamp screw
Pos. 12 Handle eyes
Pos. 5
Handle on saw table
Pos. 13 Adjustment of saw blade
Pos. 6
Power supply ON/OFF
Pos. 14 Handle to shift
Pos. 7
Safety switch
Pos. 15 Drive motor
Pos. 8
Frame
2.2. Safety guards
Pos. 1 Side door with rotary knob
Pos. 6 Power supply ON/OFF
Pos. 7 Safety switch
Pos. 9 Saw belt protection clamping lever

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2.3.
Technical data
TBS510
Motor output 1,5 kW 1,5 kW 1,1 kW
Power consumption 20 A 12,5 A 2,7 A
Connection values 110 V 230 V 400 V / 16 A
Protection class IP 55
Cutting height max. 515 mm
Cut length 700 mm
Dimensions (LxWxH) 1080 x 1050 x 1840 mm
Maximum operating
weight 173 kg
Saw table load carrying
capacity 50 kg
Max. dimension of the
workpiece to be cut
500
400
515
Änderung der technischen Daten ohne vorherige Ankündigung.
2.4. Noise power level
Danger
In an environment with a high noise level, for example when working near loud machinery,
wearing hearing protection in the workplace is prescribed for above 85dB(A).
The details define volume of noise level, related to the operator workspace and the noise power
level of the masonry band saws.
Noise power level LwA
Measurement unit 2.5 dB
Workplace related emissions
noise level LpA
Measurement safety factor 4 dB
Porous concrete 101.8 dB(A) 83.8 dB(A)
The workplace related emissions value is based on an eight hour work shift and reduces
correspondingly with shorter exposed time.
The values are determined by the noise emission measurement.
Testing is done without load with the largest permitted saw belt of the masonry band saws.
Measurement tolerances:
2.5 dB for the A-value noise power level
4 dB for the A-value emission noise pressure level
Emission noise pressure is done in compliance with the standard directive 2000/14/EC.

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3.
COMMISSIONING
3.1. Connections and operating materials
Connection of electricity
A reliable power source with an operating voltage and corresponding fuses as shown on the model
plate must be available. Supply lines must not be damaged.
A voltage drop of more than 10% leads to damage of the electrical switches!
Lubrication points
Moving parts must be lubricated on the lubrication points at regular intervals. The manufacturer
uses a qualified heat-resistant multi-purpose grease.
3.2. Setting up the masonry band saw
Note
The masonry band saws are packaged on a pallet for delivery. The packaging and pallet must be
removed before the first commissioning.
•The masonry band saws must stand cleanly on the floor when set up and must not tip.
Check secure positioning before commissioning
•Hold the saw table (Pos. 1) on the handle, at the same time unscrew the clamp screw
(Pos. 4) and put the saw table in the horizontal position
•Tighten the clamp screw (Pos. 4) under the saw table
•Release the saw table lock using the spring lock (Pos. 3)
•Set the saw belt protection (Pos. 2) to the total height of the masonry stone being cut

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3.3. Check distance between saw belt and guide rollers
•Switch off masonry band saws
•Open side doors
•Check the distance between the saw belt (Pos. 2) and guide rollers (Pos. 1)
Note In standstill the distance between the saw belt (Pos. 2) and guide rollers (Pos. 1) must be approx.
1 mm.
Changing the distance
•Open clamping lever (pos. 3)
•Release the clamping lever (Pos. 3) and turn on star handle (pos. 4)
Turn to the right - distance becomes smaller
Turn to the left - distance becomes larger
•Tighten the position via the clamping lever (Pos. 3)
Danger
Before the current position of the saw belt is tested the side doors must be closed!
•Briefly switch on the masonry band saw (job mode!)
•Check the distance between the saw belt (Pos. 2) and guide rollers (Pos. 1)
•Repeat process until the distance is correct
1 mm

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3.4. Preparing to Start and Setting Operating Range
During the preparation of the saw the following steps must be completed:
•Both side doors are closed and locked
•Power source is connected on the main switch
•Saw belt is tightened via the tensioning lever (Pos. 1)
•Place the brick or stone to the stop (Pos. 3) on the saw table (Pos. 4)
•Adjust the saw belt protection (Pos. 2) to the brick or stone dimensions
Note The saw belt protection (Pos. 2) must be placed as tight as possible on the masonry stone to keep
the uncovered section of the saw belt as small as possible.

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4.
TRANSPORT
4.1. Transport position
Note Transport with the forklift is prohibited!
Included in the transport setup of the masonry band saw:
•Power source is disconnected
•Side doors are closed
•Saw table is secured via the spring lock
•Saw belt protection is moved completely up
•Saw table is folded up and the clamping screw is tightened
•Saw belt is tightened