Operating Instructions
Contents
1. Ring saw HRG500 XXX Page 302. Ring saw HRG500 XXX 2 3 4 2 3 5 2 4 2 4 1 2 4 2 2 4 3 Ring saw HRG500 XXX TYROLIT Hydrostress AG Operator user User is the term employed by TYROLIT Hydrostress to designate a person who independently performs the following work e Setting up the machines and systems of TYROLIT Hydrostress within the scope of correct purpose of use Independent performance and monitoring of work e Localisation of faults and organisation of troubleshooting and independent fault remedying e Maintenance Testing the correct operation of safety equipment Personnel qualifications e Completed training as a concrete expert or relevant professional experience e 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 e Installs TYROLIT Hydrostress machines and systems e Makes adjustments to machines and systems for which certain access rights are required e Complex service and repair work Personnel qualifications e Specialist professional training mechanical electrotechnical e Product specific 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 responsib
3. breathing problems Breathing in the water fog and exhaust that is emitted is a health hazard gt Wear a breathing mask Provide adequate ventilation in confined spaces Risk of slipping Do not work on uneven surfaces Wear safety shoes with non slip soles The sludge resulting from cutting is very greasy gt Remove sludge or ensure that people cannot slip in it Risk of ring saw restart in the event of an accident Ensure that the ring saw can be stopped quickly Ring saw HRG500 XXX TYROLIT Hydrostress AG 2 8 14 Physical condition Do not work whilst under the influence of alcohol drugs or medication Do not work when you are overtired Do 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 2 8 15 Reduced cutting ring quality gt Do not use damaged disk grinding rings gt Check disk grinding ring for damage before installation Do not equip disk grinding ring with new diamond segments 2 8 16 Fuel refuelling Contact with petrol and oil can cause allergic reactions gt Wear protective gloves If petrol or oil come into contact with skin wash affected areas immediately with plenty of water Refuelling Switch motor off when refuelling the motor saw Smoking and naked flames are prohibited gt Allow machine to cool
4. 1 2 8 12 2 8 13 Uncontrolled movements and vibration gt Always hold ring saw by the handles with both hands during operation Thumbs and fingers must be closed around the handles Keep the handles clean Never saw above shoulder height Never stand on ladder when sawing Guide 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 gt Ensure 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 gt Always work with the protective covers fitted gt Do not wear loose items of clothing at work gt Wear a hair net if you have long hair Particles flying off Flying particles can cause eye injuries Wear safety goggles or a visor gt Ensure that danger area is properly cordoned off Falling parts Falling parts can cause serious head and foot injuries gt Wear helmet and safety shoes with steel toecaps gt Lumps of concrete that have been cut loose must be secured against falling gt Safeguard 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 Wear hearing protection Damaging vapours and aerosols Inhaling damaging vapours and or aerosols can cause
5. Fuel tank capacity Mixing ration fuel 2 stroke oil when using DOLMAR oil when using Aspen alkylate 2 stroke fuel when using other oils 9 4 Water supply Water supply Parameter Working pressure Flow rate Temperature Page 28 50 1 100 1 HP 100 50 1 2 50 1 quality grade JASO FC or ISO EGD Value min 3 bar max 6 bar At least 5 l min Ring saw HRG500 XXX TYROLIT Hydrostress AG 9 5 Disk grinding ring and cutting depth 9 5 1 Disk grinding ring Disk grinding ring Parameter Value Diameter max 510 mm 20 9 5 2 Cutting depth Cutting depth Disk grinding ring diameter Cutting depth Ring saw HRG500 XXX Page 29 TYROLIT Hydrostress AG 10 EC Declaration of Conformity Description Ring saw with petrol motor Type designation HRG500 XXX Year of construction 2012 We declare under our sole responsibility that this product complies with the following direc tives and standards Directive applied 2006 14 EC 08 05 2000 2006 42 EC 17 05 2006 2004 108 EC 15 12 2004 Applied standards EN ISO 12100 2010 EN ISO 19432 2008 Manufacturer TYROLIT Hydrostress AG Witzbergstrasse 18 CH 8330 Pfaffikon Switzerland Authorised agent for technical documentation TYROLIT Hydrostress AG Pascal Schmid Development Manager Witzbergstrasse 18 CH 8330 Pfaffikon Switzerland Pfaffikon 24 04 2012 Cour DIN EN 180 3001 2000 Pascal Schmid Development Manager
6. WAOLIY Operating Instructions Ring saw HRG500 X x x Index 000 PE Ne lt AY NN 10992852 en 17 04 2012 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 Witzbergstrasse 18 CH 8330 Pfaffikon Switzerland Tel 0041 0 44 952 18 18 Fax 0041 0 44 952 18 00 Page 2 Ring saw HRG500 XXX Ring saw HRG500 XXX TYROLIT Hydrostress AG 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 e Read the instructions carefully before use particularly the safety instructions Keep the instructions for the entire service life of the equipment e Ensure that th
7. X 2 7 2 8 2 8 1 2 8 2 2 8 3 2 8 4 2 8 5 Ring saw HRG500 XxX TYROLIT Hydrostress AG 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 gt Do not touch the tool during operation gt Always wear gloves when handling the stationary tool Diamond segments flying off Before use always ensure that the ring guard is correctly fitted and undamaged Do not start sawing if any other persons are in the danger zone gt Ensure that a safety distance of 15 mis maintained from the ring saw Replace the disk grinding ring if diamond segments start to break off Recoil Erroneous positioning of the disk grinding ring or cutting the wrong materials can make the ring saw recoil and seriously injure the operator gt Only cut materials that are permitted within the scope of the correct purpose of use Do not apply disk grinding ring above the middle of a workpiece edge Unintentional start up Before 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 Page 7 TYROLIT Hydrostress AG Page 8 2 8 6 2 8 7 2 8 8 2 8 9 2 8 10 2 8 1
8. before refuelling Fuel 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 gt Do 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 gt Ensure that no fuel or oil gets into the soil environmental protection Use a suitable surface Do not refuel in confined spaces Fuel vapour accumulates at floor level risk of explosion gt Ensure that screw plugs of fuel tank and oil tank are closed properly gt Change location before starting the motor saw at least 3 metres away from refuelling sta tion Fuel has a limited storage time Only buy as much as you intend to use within a foreseeable time gt Always transport and store fuel and oil in approved and marked canisters Keep children away from fuel and oil 2 817 Explosion hazard Starting of fires and smoking in the immediate vicinity of the ring saw is strictly prohibited 2 8 18 Transport Never transport the motor saw while it is running Always carry motor saw with the bow type handle Ring saw HRG500 XXX Page 9 TYROLIT Hydrostress AG 2 9 Risk of property damage 2 9 1 Lateral cutting Cut
9. d stone Incorrect use Working without protective equipment or inadequate protective equipment e Cutting other materials e Removal of protective devices e Cutting in potentially explosive areas e Cutting loose parts e 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 e 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 qualifications A technical trained person in a management position e Relevant experience in personnel management and risk assessment e Has read and understood the safety instructions
10. e instructions are available to the operator and the service engineers at all times e Pass the instructions on to all subsequent owners or users of the equipment e 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 Page 3 TYROLIT Hydrostress AG 2 1 2 2 2 3 2 3 1 2 3 2 2 3 3 Page 4 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 e Damage caused by improper use and operator error e Damage caused by failure to observe the safety related information in these instructions or the warning signs on the unit e Damage caused by substandard maintenance work Use for correct purpose The ring saw is used by trained personnel for cutting concrete masonry an
11. e setting suction head or carburettor soiled tank ventilation defective cable damaged I STOP switch defective start valve soiled Disk grinding ring not correctly fitted B Fit disk grinding ring correctly to profiled drive roller Drive rollers soiled gt Clean drive rollers Roll pre tensioner not engaged gt Check roll pre tensioner Drive rollers worn Replace drive rollers Defective roller bearings Replace roller bearings Not enough motor power gt Check motor Roll pre tensioner not engaged BP Check roll pre tensioner Too much roller clearance gt Check roll pre tensioner Drive rollers worn Replace drive rollers Disk grinding ring damaged Replace disk grinding ring Roll pre tensioner not engaged BP Check roll pre tensioner Page 25 TYROLIT Hydrostress AG Malfunctions matuncion Possiiecause Remedy OO OOOO Disk grinding ring warped Disk grinding ring not sufficiently gt Endure that water cooling is present cooled Replace disk grinding ring Diamond segments breaking off Disk grinding ring warped Replace disk grinding ring Hard resistance in workpiece Replace disk grinding ring Segments not properly soldering or Replace disk grinding ring welded Disk grinding ring slipping Driver rollers for sliding properly in gt Check roll pre tensioner housing insufficient contact be tween disk grinding ring and drive rollers Drive rollers worn Replace drive rollers e g by chafing drive and in
12. ean rag to prevent dirt particles from falling into the carburettor compartment 6 Disconnect upper and lower part of air filter as shown in illustration Carefully knock out or gently blow out from the inside with compressed air Do not clean with a brush otherwise dirt will be pressed into the fabric Wash out heavily soiled nonwoven fabric filter in lukewarm soapy water using normal washing up liquid Ring saw HRG500 x Page 23 TYROLIT Hydrostress AG 7 Clean filter elements Cleaning the nylon filter the nylon sieve and the filter hood of the pre filter Clean with a paintbrush or other soft brush or gently blow out from the inside with com pressed air Wash out heavily soiled nylon filter in lukewarm soapy water using normal wash ing up liquid In the event of heavy soiling clean several time per day since the full power of the motor can only be attained with a clean air filter Dry air filter properly Re assemble top and bottom part Replace damaged air filter immediately Broken off pieces of fabric and large dirt particles can destroy the motor 8 Installing the filter and the filter hood Before installing the air filter check the choke flap for any dirt particles that may have fallen in Remove if necessary Insert air filter and push down air filter retaining bracket until it engages Push in the choke and depress gas lever once to deactivate the semi throttle position Attach filter hood and secu
13. g crane or supports Take weight of concrete into consideration 1 m corresponds to 2400 to 2700 kg Decide on position and sequence of cuts 4 Perform a visual inspection of the ring saw 4 1 Position and order of cuts 4 1 1 Define position gt Obtain information about the concrete or masonry that is being sawn Where does the reinforcement run Is it heavily or lightly reinforced gt Cut across the concrete if possible 4 1 2 Define the sequence of cuts Using the wrong cut sequence can result in the disk grinding ring getting jammed gt Define cutting sequence for example for a window cutout carry out the bottom cut first then the side cuts and finally the top cut Page 12 Ring saw HRG500 XXX 5 5 1 Ring saw HRG500 x Assembly Disassembly Mounting the disk grinding ring w 24X 1 Remove the housing 2 Undo smooth mounting bolt at drive roll 3 Remove smooth drive roll TYROLIT Hydrostress AG Page 13 TYROLIT Hydrostress AG 4 Clean disk grinding ring thoroughly 6 Replace sliding plate 1 Page 14 Ring saw HRG500 x TYROLIT Hydrostress AG 7 Place disk grinding ring on profiled driver roll When doing this ensure that groove of disk grinding roll is on projection of profiled drive roll 9 Undo roll pretensioner Ring saw HRG500 x Page 15 TYROLIT Hydrostress AG 10 Check freedom of movement of disk grinding ring 11 Fi
14. kly and powerfully until first audible ignition takes place Caution Do not pull starting cord out by more than 50 cm and always lead back slowly by hand Push in starter valve 6 Push 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 Ring saw HRG500 XXX TYROLIT Hydrostress AG Page 20 6 1 2 6 2 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 Do 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 first make a 50 to 70 mm cut Divide the entire cut depth into several cuts Terminating the work 1 Switch off motor using the stop switch Close off water supply and disconnect Blow out water from all lines Clean ring saw with water RUN Ring saw HRG500 x TYROLIT Hyd
15. le person or the manufacturer immediately The maintenance intervals must be adhered to Faults that affect 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 Provide sufficient space to carry out work safely Ensure that the workplace is sufficiently illuminated gt Cordon off the danger area in a clearly noticeable way so that no person can enter the dan ger area during sawing Page 5 TYROLIT Hydrostress AG 2 5 Protective devices and signs on the equipment 2 5 1 Protective devices Protective devices may only be removed if the equipment has been switched off and is at a standstill Safety components in particular should only be removed and refitted by authorised personnel Before switching the equipment back on again check that the safety elements are operating correctly 2 5 2 Signs on the equipment 1 2 3 4 5 6 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 2 6 Spare parts and modifications 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 modifications must be made to the unit without written permission from TYROLIT Hydrostress Page 6 Ring saw HRG500 XX
16. re with locking clips Page 24 Ring saw HRG500 x TYROLIT Hydrostress AG 8 Malfunctions Malfunctions Motor does not start Warm start problems Lack of power Motor starts up but dies again immediately Disk grinding ring does not rotate Disk grinding ring rotating too slowly Disk grinding ring jumping out Ring saw HRG500 XXX Possible cause Remedy Main switch in stop position gt Operate main switch Fuel supply fault b Check petrol and oil level gt Check whether petrol line is kinked blocked or broken Plug connector plug defective Replace plug gt Notify TYROLIT Hydrostress AG after sales service Choke in wrong position gt Correct choke position gt Notify TYROLIT Hydrostress AG after sales service Carburettor defective supply suction head soiled Cylinder base seal defective dam gt Notify TYROLIT Hydrostress AG after sales aged radial shaft seals cylinder or service piston rings damaged gt Notify TYROLIT Hydrostress AG after sales service Fault or short circuit in cabling gt Notify TYROLIT Hydrostress AG after sales service Carburettor setting incorrect Air filter soiled gt Clean filter element see 7 1 gt Notify TYROLIT Hydrostress AG after sales service Carburettor setting wrong silenc er clogged exhaust duct in cylinder clogged spark protection strainer clogged gt Notify TYROLIT Hydrostress AG after sales service Incorrect idl
17. rostress AG 7 Maintenance Servicing and maintenance table Before each use Motor gt Check motor damage leaks cleanliness gt Clean air filter see 7 1 Water supply Check water line X damage leaks cleanliness k X X Blow out water risk of frost X Bb Check rollers for wear Ring guard gt Check ring guard Disk grinding ring B Check the disk grinding ring for wear Guide plate gt Check alignment of guide plate Major service To be performed by TYROLIT Hydro stress AG or an authorised workshop X TM Im gt TE UTE Repairs and maintenance work on the drive motor can be carried out directly by a Dolmar specialist workshop You can find the nearest Dolmar specialist dealer at www dolmar com Ring saw HRG500 XXX Page 21 TYROLIT Hydrostress AG 7 1 Clean air filter The nonwoven fabric filter needs cleaning if you notice a loss of power when working with the saw Replace filter if there is no significant power increase after cleaning v Wear safety goggles to avoid eye injuries v Do not clean air filter with fuel 2 Remove filter hood 2 3 Pull out choke 3 to prevent dirt particles from falling into the carburettor Page 22 Ring saw HRG500 XXX TYROLIT Hydrostress AG 4 Unhook air filter retaining bracket 4 by pushing it in the direction of the arrow as shown in the illustration 5 Pull off air filter from above Cover intake openings with a cl
18. sufficient water supply Shoulders of drive rollers worn by Replace drive rollers more than 50 Inner edge and guide groove of disk Replace drive rollers grinding ring worn insufficiently rinsed out dust or worn drive rollers No water exiting from disk grinding Water line blocked gt Clean the water line rin i Water valve on feed line is Open water valve closed Insufficient water pressure gt Ensure that minimum water pressure of 3 bar is present Sparks coming out of side of disk Low water supply b Check water supply and increase grinding ring Operating handle greasy Motor component seals defective gt Check motor components Page 26 Ring saw HRG500 x x TYROLIT Hydrostress AG 9 Technical data 9 1 Dimensions 20 1040 16 933 640 Measurements in mm 9 2 Ring saw Dimensions and weights Length without disk grinding ring Noise emission EN ISO 3744 Maximum sound pressure level L or Conditions for the measurement Disk grinding ring 510 mm 20 not in cutting operation under full load Vibration EN ISO 5349 Ring saw HRG500 XXX Page 27 TYROLIT Hydrostress AG 9 3 Motor Combustion engine Parameter Type Displacement Bore Stroke Max output at speed of Max torque at speed of Idling speed Clutch engaging speed Carburettor diaphragm carburettor Ignition system Sparkplug Electrode clearance Fuel Motor oil Fuel consumption at maximum power
19. t housing but do not screw in place yet 5 2 Fit safety equipment 1 Position housing on edge of table Ring saw HRG500 x Page 16 TYROLIT Hydrostress AG 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 Page 17 Ring saw HRG500 XXX TYROLIT Hydrostress AG 5 3 Making the hose connection 5 3 1 Preparations for connection gt Ensure that coupling ring saw and supply line are clean Check hose and coupling for damage 5 3 2 Connect water hose gt Connect water hose Ring saw HRG500 x Page 18 TYROLIT Hydrostress AG 6 1 6 1 1 Page 19 Operation Working Starting the motor Cold start v The motor saw must be kept at least 3 metres away from the refuelling location v The disk grinding ring has been checked and is correctly fitted v The water supply is secured Open water supply and check ring saw water outlet Take a secure stance and place motor saw on floor in a position whereby the sawing equip ment is unobstructed Hold bow type handle firmly with one hand and push motor saw downwards Pull out choke lever 4 until it is felt to engage The part throttle lock is engaged at the same time b Push 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 gt Now pull quic
20. ting with the sides of the blade can damage the disk grinding ring Do not cut laterally 2 9 2 Defective water cooling The disk grinding ring can be damaged if the water cooling is defective Do not operate the ring saw without water cooling 2 9 3 Frost damage At the end of work or before long stop periods drain and blow out the water system 2 9 4 Storage Store the motor saw securely in a dry room The saw must not be kept outdoors Keep children away from the motor saw The fuel tank and the oil tank must be drained completely during longer storage periods and when shipping the motor saw Page 10 Ring saw HRG500 x x TYROLIT Hydrostress AG 3 Description 3 1 Ring saw 4 1 Roll pretensioner 8 Ring guard 2 Petrol motors 9 Disk grinding ring 3 Starting handle 10 Water connection 4 Operating handle 11 Fueltank cap 5 Anti vibration element 12 Choke lever and part throttle lock 6 Metal guard 13 Housing 7 Bow type handle 14 Splash guards 3 2 Accessories 1 Allen key WAF 5 32 2 Allen key WAF 1 4 3 Open ended spanner WAF 9 16 Ring saw HRG500 XXX Page 11 TYROLIT Hydrostress AG 4 Preparatory operations The work is prepared in the following way 1 Sort out fundamental conditions Location of supply lines in walls floors and ceilings Cooling water drainage risk of electric shock and water damage 2 Securing the site 3 Secure cut outs in walls ceilings and floors e
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