DIAMOND PRODUCTS HYDRAULIC CHAIN SAW MODEL HCH50 OPERATOR MANUAL September 2009 Part # 1801446
Operating instructions Manufacturer’s address: TYROLIT Hydrostress AG Witzbergstrasse 18 CH-8330 Pfäffikon Switzerland Telephone +41 (0) 44 / 952 18 18 Fax +41 (0) 44 / 952 18 00 TYROLIT Hydrostress AG reserves the right to make technical changes without prior notice. Copyright © 2003 TYROLIT Hydrostress AG, CH-8330 Pfäffikon ZH All rights reserved, in particular copying and translation rights. Reprinting of extracts from this safety manual is prohibited.
Operating instructions Overview Overview Page 0 0.1 0.2 0.3 0.4 1 1.1 1.2 1.3 1.4 2 2.1 2.2 2.3 2.4 2.5 2.6 3 3.1 3.2 3.3 4 4.1 4.
Overview Operating instructions 9 9.1 9.2 9.3 10 10.1 10.2 11 11.1 11.2 11.
Operating instructions Introduction 0 Introduction 0.1 Congratulations! You have decided to buy an advanced, tried and tested Hydrostress system and have thus acquired a highly sophisticated and reliable state-ofthe-art unit. Thanks to the stress we place on quality assurance, your Hydrostress system is another top-of-the-range Swiss product: • High performance • Reliable operation • High portability • Easy handling • Low maintenance costs Only original Hydrostress interchangeability.
Introduction Operating instructions 0.2 Validity of these operating instructions These operating instructions are only valid for the following system: Chain saw HCH5011 0.3 Standards These operating instructions have been prepared in accordance with CE Machinery Directive Appendix I and with the relevant standards in force at the time of printing. 0.4 Delimitation of the system These operating instructions describe the use of the Chain saw HCH5011.
Operating instructions Product description 1 Product description 1.1 Important information on the Chain saw HCH5011 1.1.1 Main components 2 5 6 1 7 3 10 4 8 9 Fig.
Product description Operating instructions 1.1.2 Intended purpose The Chain saw HCH5011 is designed and built for the following application: • Cutting of concrete (including reinforced), masonry and natural stone • Cutting of severance cuts, flush cuts and cross-cuts in ceilings, floors and walls • Only original TYROLIT Hydrostress AG tools (chains) should be used The information provided in Chapter 1 “Technical Data” 1.2, 1-4 represents the mandatory usage limits and rated data 1.1.2.
Operating instructions Product description 1.1.4 EC statement of conformity Designation Hydraulic chain saw Type designation Chain saw HCH5011 Year of construction 2007 We declare under our own liability that this product complies with the following directives and standards: 1.1.4.1 Directive applied: European Machine Directives (Machinery Directive) 98/37/EC 1.1.4.2 Standards applied: EN 292-1 Safety of Machines EN 292-2 Basic concepts, general design principles 1.1.
Product description Operating instructions 1.2 Technical data 1.2.1 Chain saw HCH5011 • Can be used with any hydraulic actuator (use a flow divider with pressure limiter >40 l/min or >140bar) • Flush cutting possible without removing the protective cover 1.2.1.1 1.2.1.2 1.2.1.3 Hydraulic system Maximum pressure 140 bar Maximum flow 45 l/min. Hydraulic hose Length 2 m Water Minimum working pressure 2.5 bar Minimum flow 7.5 l/min. Weight Chain saw HCH5011 incl. bar and chain 10.5 kg 1.2.1.
Operating instructions Product description 1.2.2 Noise level Depending on the working environment, the Chain saw HCH5011 can cause excessive noise during operation. The noise can permanently harm the hearing of operating personnel and of other people nearby within a short time. Ear protectors must therefore always be worn while working. Danger Noise danger When using the Chain saw HCH5011 hearing protection must be worn. If this instruction is not followed irreparable hearing damage may result. 1.2.
Product description Operating instructions 1.2.4 Diamond chains The Chain saw HCH5011 is fitted as standard with the Hydrostress Universal O-Ring diamond chain 20“ with double pumper. 1.2.4.1 Hydrostress Universal O-Ring diamond chain with double pumper Application: – Concrete with a moderate degree of reinforcement (reinforcing irons of up to dia. 12mm) – Brick and limestone – Hard and soft natural stone Hydrostress Universal O-Ring diamond chain 20“ with double pumper Part No.
Operating instructions Product description 1.2.4.2 Hydrostress concrete O-Ring diamond chains The Hydrostress “concrete O-ring diamond chain” is characterised by a long service life and high cutting power in highly reinforced concrete. Application: – Concrete with a high degree of reinforcement (reinforcing irons of up to dia. 19mm) – Brick and limestone – Hard natural stone Hydrostress Concrete O-Ring diamond chain 20“ Part No. 10977642 Number of segments 43 Segment dimensions: Height 5.
Product description Operating instructions 1.3 Accessories • Flow divider / Pressure limiter 40 l/min, 140 bar • Pressure control valve 140 bar 1.4 Scope of supply Complete chain saw system HCH5011: • Chain saw HCH5011 • Carrying case HCH5011 • Tool kit HCH5011 • Operating Instructions / Spare parts list 1.4.1 Tool kit comprises: 3 4 6 1 Fig. 1-4 5 Tool kit 1. 2. 3. 4. 5. 6.
Operating instructions Safety instructions 2 Safety instructions 2.1 General 2.1.1 Target audience This chapter describes the safety instructions that it is essential to follow when using the Chain saw HCH5011. All persons who work on and with the Chain saw HCH5011, have a duty to read and understand the chapters of the Operating instructions relevant to their particular activities. This applies in particular to the “Safety instructions” chapter which is mandatory for all persons and activities. 2.
Safety instructions Operating instructions 2.2 Safety principles 2.2.1 Delimitation of the safety concept The Chain saw HCH5011 has no effect on the safety concept of the connected systems, apparatus and installations. 2.2.2 Safety elements Protection from personal injury is based primarily on a safety concept and design safety. 2.2.2.1 Passive safety elements Protection from live parts All functional units that contain parts which carry hazardous voltages, are shock-protected by suitable covers.
Operating instructions Safety instructions 2.3 General safety rules 2.3.1 Statutory provisions The generally applicable national and local safety and accident prevention provisions and the supplementary operator regulations must be followed and complied with. 2.3.2 Inspection and maintenance obligation The operator is under an obligation to only use the Chain saw HCH5011 when it is in a perfect and undamaged condition.
Safety instructions Operating instructions 2.3.7 Safety clothing 1 2/3 4 5 6 Fig. 2-1 Safety clothing 1. 2. 3. 4. Helmet with ear protectors Visor or goggles Breathing mask Waterproof gloves 5. Waterproof, sturdy, comfortable clothing 6.
Operating instructions Safety instructions 2.4 Information and symbols In these Operating instructions information panels are used to draw attention to residual dangers and to point out important technical requirements. 2.4.1 Danger symbols in the Operating 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. Fig. 2-2 2.4.
Safety instructions Operating instructions 2.5 Generally applicable warnings of residual dangers In the following warnings of residual dangers are shown that are generally applicable to all work (with and on the saw systems and during all phases of the life of the systems). Danger Electric shock due to defective electronic equipment. The electrotechnical equipment must be checked prior to each use and from time to time during prolonged usage.
Operating instructions Safety instructions 2.6 Responsibility 2.6.1 Authorised personnel Work on or with TYROLIT Hydrostress AG machines or systems should only be performed by authorised personnel. Personnel are considered by TYROLIT Hydrostress AG to be authorised if they meet the necessary training and know-how requirements and they have been assigned a precise functional role.
Safety instructions Operating instructions 2.6.6 Qualification and training 2.6.6.1 Operator • A technical trained person in a specialist role. • Has extensive experience in personnel training and danger assessment. • Has read and understood the “Safety instructions” chapter. 2.6.6.2 User • Has completed concrete expert training or has professional experience. • Has received an introduction (basic training) to operation of the Chain saw HCH5011 from a service engineer.
Operating instructions Design and function 3 Design and function 3.1 Design The Chain saw HCH5011 is comprised the following components. • Chain saw unit • TYROLIT Hydrostress AG bar • TYROLIT Hydrostress AG diamond chain Safety component: • Chain guard 1 4 2 3 Fig. 3-1 Chain saw HCH5011 design 1. 2. 3. 4. 3.2 Chain saw unit Bar Diamond chain Chain guard Function The overall function of the Chain saw HCH5011 remains exactly the same.
Design and function Operating instructions 3.3 Component description 3.3.1 Chain saw unit 3.3.1.1 Design 2 1 4 3 5 6 8 9 10 11 7 Fig. 3-2 Chain saw unit 1. 2. 3. 4. 5. 6. 3.3.1.2 Operating handle with manual starter Water level housing Drive wheel Fitting aid (chain-engraving) Cutting mandrel Hydraulic connection 7. Water connection 8. Name plate 9. Valve block 10.Chain guard 11.T-handle Function The chain saw unit is the central component of the Chain saw HCH5011.
Operating instructions Design and function 3.3.2 TYROLIT Hydrostress AG bar 3.3.2.1 Design 1 3 Fig. 3-3 2 Bar 1. Water inlet 2. Chain guide 3. Assembly bore hole for chain tensioner 3.3.2.2 5 4 4. Assembly opening 5. Reversing wheel Function The bar is securely fixed to the chain saw unit. The chain runs and is guided on the bar. The bar provides lateral support for the chain. The cutting pressure is absorbed via the bar. Information The bar serves solely to guide the diamond chain.
Design and function Operating instructions 3.3.3 Diamond chain 3.3.3.1 Design The diamond chain has a so-called O-ring design (SEAL-PRO). For the chain specification see “Chapter 1” 1.2.4, 1-6 Dimensions of a new chain 5.8 mm 5.7mm Fig. 3-4 Dimensions of new chain Dimensions of a worn chain 1.5 mm 4.7mm Fig. 3-5 Dimensions of worn chain Danger When working with a worn chain there is a danger of the chain breaking. A worn chain must be replaced by a new chain.
Operating instructions Design and function Direction of travel and position of diamond chain Ensure the correct position and direction of travel when fitting a chain. The engraved mark on the chain saw unit is intended as a fitting aid. 1 2 Fig. 3-6 Diamond chain position and direction of travel 1. Fitting aid (engraving) 2. Chain direction of travel Danger Working with an incorrectly fitted chain will reduce the lifetime of the chain and there is a danger of the chain breaking.
Design and function 3-6 Operating instructions HCH5011 / 001
Operating instructions Controls and displays 4 Controls and displays 1 2 3 Fig. 4-1 4 Controls 1. Water level housing 2. Locking cut-out 3. T handle 4.1 5 4. Operating handle with manual starter 5. Couplings Controls Locking cut-out Pressing the locking cut-out enables the ON/OFF function. This cut-out ensures secure locking of the Chain saw HCH5011. T handle The T handle is used to hold and carry the Chain saw HCH5011.
Controls and displays 4-2 Operating instructions HCH5011 / 001
Operating instructions Putting into operation 5 Putting into operation The Chain saw HCH5011 is supplied ready for use. The information provided in “Chapter 6”, Operation, also applies to the putting into operation of your apparatus.
Putting into operation 5-2 Operating instructions HCH5011 / 001
Operating instructions Operation 6 Operation 6.1 General Before proceeding read Chapter 2 «Safety instructions», 2-1 in these Operating instructions. Be sure also to take note of all the danger information given here and follow the instructions on how to avoid physical injury and damage to property. 6.1.1 Safety instructions It is essential to observe the following safety instructions, in particular in relation to the operation of the HCH5011. Danger Danger of falling heavy parts.
Operation Operating instructions Danger Working with an incorrectly fitted chain will reduce the lifetime of the chain and there is a danger of the chain breaking. Use the fitting aid (chain engraving) to correctly insert the chain. Failure to comply with this regulation may lead to serious physical injury or death. Danger Noise danger When using the Chain saw HCH5011 hearing protection must be worn. If this instruction is not followed irreparable hearing damage may result.
Operating instructions Operation Danger Danger from segments or stone chips flying off from the tool. The danger area must be property secured. Failure to observe this regulation may lead to serious injury to body parts, and possibly even death. Danger Danger of the Chain saw HCH5011 restarting in the event of an accident Ensure that you can quickly stop the Chain saw HCH5011 (see Emergency Stop in the Operating instructions of the drive assembly you are using).
Operation Operating instructions Warning Warning of slippery floors The water feed and abrasion can make standing surfaces smooth and slippery. You should therefore always ensure you have a firm footing. Failure to adhere to this regulation may result in slight or serious physical injury. Warning Warning against working when not in a fit state to do so. Do not use the Chain saw HCH5011 if you are under the influence of sedatives or alcohol or if you are overtired.
Operating instructions Operation 6.2 System requirements In order to use the Chain saw HCH5011 a hydraulic drive assembly is needed. Drive assembly power requirements: Minimum power: Maximum power: Minimum flow 35 l/min. Max. pressure 140 bar Maximum flow 45 l/min. Max. pressure 140 bar If the basic power of the drive assembly used is higher, a flow divider / pressure limiter or a pressure relief valve can be used.
Operation Operating instructions 6.3.1 Sort out fundamental conditions • Determine the position of pipes and cables in walls, floors and ceilings. • Where does the cooling water used for sawing flow to? (Think about water damage to the electrical supply). 6.3.2 Securing the site • See “Chapter 1” Workplace and danger areas 1.1.3, 1-2 6.3.3 Securing cutouts Secure cutouts from walls and especially from ceilings and floors by suitable means, e.g. crane, supports, etc. Check the weight of concrete.
Operating instructions Operation 6.3.5 Perform a visual inspection of the Chain saw HCH5011 6.3.5.1 Check the chain tension 6 mm Fig. 6-3 Chain tension – The chain tension is correctly set if with a moderate pull the chain can be pulled away from the bar by a maximum of 6 mm. – It must be possible to turn the chain one full rotation with ease by hand. For chain tensioning see “Chapter 7” 6.3.5.2 Check the diamond chain for wear If chain is worn see “Chapter 3” 3.3.
Operation Operating instructions 0 Check the reversing wheel on the bar for wear 0.8 mm 6.3.5.4 Fig. 6-5 Worn reversing wheel When the reversing wheel is in the new condition the distance between the chain and bar edge is 0.8 mm. If the chain is running on the bar edge, the reversing wheel must be changed. Repairs to be performed by an authorised TYROLIT Hydrostress AG service centre. 6.3.6 Connecting the Chain saw HCH5011 6.3.6.
Operating instructions Operation 6.3.6.2 Hose connections Before connecting check couplings, Chain saw HCH5011 and feed lines for cleanliness. The following hose connections must be established: Fig.
Operation Operating instructions 6.4 Working with the Chain saw HCH5011 Following the preparatory operations, see “Chapter 6” 6.3, 6-5 the Chain saw HCH5011 is ready for use. 6.4.1 Areas of use The Chain saw HCH5011 is suited to the following cutting work: • Small cutouts / cutting throughs • Flush cuttings • Narrow corner cuts • Irregular shaped cuts 6.4.2 Starting the Chain saw HCH5011 Always proceed as follows: • Start the drive assembly (see Operating instructions for the drive you are using).
Operating instructions Operation 6.4.4 Working with cutting mandrel The cutting mandrel (1) has been developed as a mechanical aid that can be used for horizontal and vertical cuts. 1 Fig.
Operation Operating instructions 6.5 After the work Proceed as follows: • Close off and decouple the water feed • Blow out water from all lines • Remove plug from mains (drive assembly) • Uncouple hydraulic hoses • Clean the Chain saw HCH5011 with water • Lubricate the chain and the bar 6.5.1 Chain and bar lubrication Fig. 6-8 Chain and bar lubrication Proceed as follows: • After final use rinse chain and bar with water.
Operating instructions Maintenance 7 Maintenance 7.1 General Before proceeding read Chapter 2 «Safety instructions», 2-1 in these Operating instructions. Be sure also to take note of all the danger information given here and follow the instructions on how to avoid physical injury and damage to property. 7.1.1 Safety instructions It is essential to observe the following safety instructions, in particular in relation to the maintenance of the HCH5011. Danger Danger of falling heavy parts.
Maintenance Operating instructions Warning Danger from uncontrolled escaping of oil. Never connect or disconnect hoses when the unit is running. Failure to adhere to this regulation may result in cut wounds or injury to body parts and damage to property. 7.1.2 Personnel qualifications The Chain saw HCH5011 should not be maintained by unauthorised persons. Personnel are only authorised where they meet the following requirements. • Have completed concrete expert training or professional experience.
Operating instructions Maintenance 7.2 Maintenance and servicing table The following maintenance work must be performed according to the prescribed cycles. Wear parts that are not subject to particular maintenance intervals should also be checked regularly for wear and adjusted or exchanged as necessary.
Maintenance Operating instructions Information Wear in the drive and reversing wheel / diamond chain and bar is highly dependent upon the thickness, condition and degree of reinforcement of the concrete being worked. Information In order to achieve an optimum balance between the diamond chain and the drive wheel, whenever the chain is exchanged due to wear the drive wheel should also be replaced.
Operating instructions Servicing 8 Servicing 8.1 General Before proceeding read Chapter 2 «Safety instructions», 2-1 in these Operating instructions. Be sure also to take note of all the danger information given here and follow the instructions on how to avoid physical injury and damage to property. 8.1.1 Safety instructions It is essential to observe the following safety instructions, in particular in relation to the servicing of the HCH5011. Danger Danger of falling heavy parts.
Servicing Operating instructions Warning Danger from uncontrolled escaping of oil. Never connect or disconnect hoses when the unit is running. Failure to adhere to this regulation may result in cut wounds or injury to body parts and damage to property. 8.1.2 Personnel qualifications The Chain saw HCH5011 should not be serviced by unauthorised persons. Personnel are only authorised where they meet the following requirements. • Have completed concrete expert training or professional experience.
Operating instructions Servicing 8.2 Tensioning the diamond chain 2 Fig. 8-1 1 Tensioning the diamond chain Proceed as follows: To tension the diamond chain you will need the fork wrench SW 19 supplied with the tool kit. • Loosen both nuts (1) • Adjust the adjusting screw (2) for the correct chain tension • Tighten both nuts (1) 8.2.
Servicing Operating instructions 8.3 Changing the diamond chain To change the diamond chain you will need the fork wrenches SW 19 and SW 10 supplied with the tool kit. 4 3 Fig. 8-3 8.3.
Operating instructions Servicing 8.4 Changing the bar To change the bar you will need the fork wrenches SW 19 and SW 10 supplied with the tool kit. 4 1 3 2 5 3 Fig. 8-4 8.4.
Servicing Operating instructions 8.5 Changing the drive wheel In order to be able to change the drive wheel you must first dismantle the bar, see “Chapter 8” 8.4.1, 8-5 To change the drive wheel you will need the wheel stop and Allen key SW 5 supplied with the tool kit. 1 2 Fig. 8-5 8.5.1 Changing the drive wheel Dismantling the drive wheel Proceed as follows: • Fit the drive wheel stop (1) • Loosen the left-hand thread Allen screw (2) Allen key SW 5 • Remove the drive wheel and the V-seal 8.5.
Operating instructions Servicing 8.6 Troubleshooting Proceed systematically when looking for the causes of a fault. Refer to the operating instructions of the drive assembly you are using when doing this. The following table will help you to narrow down and rectify the source of the fault.
Servicing Operating instructions Fault Possible cause Solution No water coming from the bar and diamond chain Water line is blocked Clean water line Water valve on feed line is closed Open water valve. Insufficient water pressure Ensure a minimum water pressure of 7.5 l/min Chain tension too low Tension diamond chain correctly see “Chapter 8” 8.
Operating instructions Taking out of service and storage 9 Taking out of service and storage 9.1 Taking out of service 9.2 General Before proceeding read Chapter 2 «Safety instructions», 2-1 in these Operating instructions. Be sure also to take note of all the danger information given here and follow the instructions on how to avoid physical injury and damage to property. 9.2.
Taking out of service and storage 9.2.2 Operating instructions Personnel qualifications The Chain saw HCH5011 should not be taken out of service by unauthorised persons. Personnel are only authorised where they meet the following requirements. • Have completed concrete expert training or professional experience. • Have received an introduction (basic training) to the operation of the Chain saw HCH5011 from a service engineer. Have read and understood chapter 2 “Safety instructions”. 9.
Operating instructions Transport, Packing 10 Transport, Packing 10.1 Transport The Chain saw HCH5011 is a high-tech apparatus. Protect it against transport damage: • Do not place anything on or against the Chain saw HCH5011 • Protect the Chain saw HCH5011 from impacts • Transport the Chain saw HCH5011 in the carrying case provided for this purpose 10.2 Packing The Chain saw HCH5011 is packed in the carrying case included in the scope of supply.
Transport, Packing 10-2 Operating instructions HCH5011 / 001
Operating instructions Disposal 11 Disposal 11.1 General The operator can recycle or dispose of the Chain saw HCH5011 himself provided he observes the statutory provisions. In order to dismantle the apparatus correctly and to properly remove the materials some knowledge in the area of mechanics and knowledge about differentiation of waste materials is necessary. Before proceeding read Chapter 2 «Safety instructions», 2-1 in these operating instructions.
Disposal Operating instructions 11.2 Disposal regulations The normal local and regional rules and guidelines must be observed when disposing of the Chain saw HCH5011. 11.3 Disposal of the Chain saw HCH5011 To allow proper disposal the components of the HCH5011 must be dismantled. This is performed by the client’s personnel. The dismantled parts of the apparatus are sorted by material and sent separately to the appropriate collection points.
