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Diamond Products HCH50 Operator's Manual

Hydraulic chain saw
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DIAMOND
P R O D U C T S
HYDRAULIC CHAIN SAW
MODEL HCH50
OPERATOR MANUAL
September 2009
Part # 1801446

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Summary of Contents for Diamond Products HCH50

  • Page 1 DIAMOND P R O D U C T S HYDRAULIC CHAIN SAW MODEL HCH50 OPERATOR MANUAL September 2009 Part # 1801446...
  • Page 2 Operating instructions Manufacturer’s address: TYROLIT Hydrostress AG Witzbergstrasse 18 CH-8330 Pfäffikon Switzerland Telephone +41 (0) 44 / 952 18 18 +41 (0) 44 / 952 18 00 TYROLIT Hydrostress AG reserves the right to make technical changes without prior notice. Copyright ©...

  • Page 3: Table Of Contents

    Tensioning the diamond chain- - - - - - - - - - - - - - - - - - - - - Changing the diamond chain- - - - - - - - - - - - - - - - - - - - - -...
  • Page 4 Overview Operating instructions Taking out of service and storage Taking out of service - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1 General - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1 Storage - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2 Transport, Packing...

  • Page 5: Introduction

    Operating instructions Introduction Introduction Congratulations! You have decided to buy an advanced, tried and tested Hydrostress system and have thus acquired a highly sophisticated and reliable state-of- the-art unit. Thanks to the stress we place on quality assurance, your Hydrostress system is another top-of-the-range Swiss product: •...

  • Page 6: Validity Of These Operating Instructions

    Introduction Operating instructions Validity of these operating instructions These operating instructions are only valid for the following system: Chain saw HCH5011 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.

  • Page 7: Product Description

    Operating instructions Product description Product description Important information on the Chain saw HCH5011 1.1.1 Main components Fig. 1-1 Main components 1 Bar 7 Operating handle with manual starter 2 Chain 8 Coupling FD (flow) 3 T-handle 9 Hose stem (water) 4 Valve block 10 Nipple FD (return) 5 Cutting mandrel...
  • Page 8 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 •...
  • Page 9 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:...

  • Page 10: Technical Data

    Product description Operating instructions 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 Hydraulic system Maximum pressure 140 bar Maximum flow...
  • Page 11 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.
  • Page 12 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.
  • Page 13 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.

  • Page 14: Accessories

    Product description Operating instructions Accessories • Flow divider / Pressure limiter 40 l/min, 140 bar • Pressure control valve 140 bar Scope of supply Complete chain saw system HCH5011: • Chain saw HCH5011 • Carrying case HCH5011 • Tool kit HCH5011 •...

  • Page 15: Safety Instructions 1 2.1 General

    Operating instructions Safety instructions Safety instructions 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.

  • Page 16: Safety Principles

    Safety instructions Operating instructions 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.

  • Page 17: General Safety Rules

    Operating instructions Safety instructions 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.
  • Page 18 Safety instructions Operating instructions 2.3.7 Safety clothing 2 / 3 Fig. 2-1 Safety clothing 1. Helmet with ear protectors 5. Waterproof, sturdy, 2. Visor or goggles comfortable clothing 3. Breathing mask 6. Work boots with steel toecaps 4. Waterproof gloves and non-slip soles Safety clothing must always be worn when drilling, sawing, nibbling or compressing concrete or stone in order to protect against the following...

  • Page 19: Information And Symbols

    Operating instructions Safety instructions 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.

  • Page 20: Generally Applicable Warnings Of Residual Dangers

    Safety instructions Operating instructions 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.

  • Page 21: Responsibility

    Operating instructions Safety instructions 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.
  • Page 22 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 •...

  • Page 23: Design And Function 1 3.1 Design

    Design and function 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 Fig. 3-1 Chain saw HCH5011 design 1. Chain saw unit 2.

  • Page 24: Component Description

    Design and function Operating instructions Component description 3.3.1 Chain saw unit 3.3.1.1 Design Fig. 3-2 Chain saw unit 1. Operating handle with manual starter 7. Water connection 2. Water level housing 8. Name plate 3. Drive wheel 9. Valve block 4.
  • Page 25 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. Never use the bar as a lifting tool or a crow bar. HCH5011 / 001...
  • Page 26 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, Dimensions of a new chain 5.7mm Fig. 3-4 Dimensions of new chain Dimensions of a worn chain 4.7mm...
  • Page 27 Failure to comply with this regulation may lead to serious physical injury or death. 3.3.3.2 Function The diamond chain constitutes the tool for the Chain saw HCH5011. It is with the help of the chain that the cut is performed. HCH5011 / 001...
  • Page 28 Design and function Operating instructions HCH5011 / 001...

  • Page 29: Controls And Displays 1 4.1 Controls

    Operating instructions Controls and displays Controls and displays Fig. 4-1 Controls 1. Water level housing 4. Operating handle with manual starter 2. Locking cut-out 5. Couplings 3. T handle 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.
  • Page 30 Controls and displays Operating instructions HCH5011 / 001...

  • Page 31: Putting Into Operation

    Operating instructions Putting into operation 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. HCH5011 / 001...
  • Page 32 Putting into operation Operating instructions HCH5011 / 001...

  • Page 33: Operation

    Operating instructions Operation Operation 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...
  • Page 34 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.
  • Page 35 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...
  • Page 36 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.

  • Page 37: System Requirements

    Operating instructions Operation System requirements In order to use the Chain saw HCH5011 a hydraulic drive assembly is needed. Drive assembly power requirements: Minimum power: Minimum flow 35 l/min. Max. pressure 140 bar Maximum power: 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.
  • Page 38 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 •...
  • Page 39 – 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” 3.3.3, To replace the chain see “Chapter 7” 6.3.5.3 Check the bar for wear •...
  • Page 40 Operation Operating instructions 6.3.5.4 Check the reversing wheel on the bar for wear 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.
  • Page 41 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. 6-6 Hose connections Hoses Chain saw HCH5011 Drive assembly hoses Water inlet (1) Water outlet (2) (Coupling –...

  • Page 42: Working With The Chain Saw Hch5011

    Operation Operating instructions 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: •...
  • Page 43 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. Fig. 6-7 Cutting mandrel HCH5011 / 001 6-11...

  • Page 44: After The Work

    • Store the Chain saw HCH5011 in the dry state Information Frequent lubrication will extend the life of the diamond chain and the bar. Information In order to avoid frost damage, if there is a danger of frost once work is complete or prior to extended breaks in work the entire water system must be emptied and blown out.

  • Page 45: Maintenance

    Danger Danger from segments flying off from the tool. In no event should diamond chains have new segments fitted by unauthorised operators. Failure to observe this regulation may lead to serious physical injury, and possibly even death, and to property damage.
  • Page 46 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...

  • Page 47: Maintenance And Servicing Table

    Blow out water (frost hazard) Chain saw unit Tightness / cleanliness Retighten accessible screws and nuts Water cleaning Lubrication Check for wear Diamond chain Water cleaning Lubrication Chain tension Check for wear Major service May only be carried out by TYROLIT...
  • Page 48 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.

  • Page 49: Servicing

    Danger Danger from segments flying off from the tool. In no event should diamond chains have new segments fitted by unauthorised operators. Failure to observe this regulation may lead to serious physical injury, and possibly even death, and to property damage.
  • Page 50 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...

  • Page 51: Tensioning The Diamond Chain

    Fig. 8-1 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 •...

  • Page 52: Changing The Diamond Chain

    Servicing Operating instructions 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. Fig. 8-3 Changing the diamond chain 8.3.1 Removing the diamond chain Proceed as follows: •...

  • Page 53: Changing The Bar

    • Remove the chain guard (4) and the chain tensioning device (5) • Loosen both nuts (1) Fork wrench SW19 • Release the tension in the diamond chain via the adjusting screw (2) Fork wrench SW19 • Remove the diamond chain •...

  • Page 54: Changing The Drive Wheel

    Servicing Operating instructions 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, To change the drive wheel you will need the wheel stop and Allen key SW 5 supplied with the tool kit.

  • Page 55: Troubleshooting

    Incorrect cutting sequence Observe cutting sequence see “Chapter 6” 6.3.4, Diamond chain can no longer be Diamond chain has stretched Lift bar from tensioning cam A and tensioned, since the chain tensioner through normal wear...
  • Page 56 Water valve on feed line is closed Open water valve. Insufficient water pressure Ensure a minimum water pressure of 7.5 l/min Diamond chain jumps from bar Chain tension too low Tension diamond chain correctly see “Chapter 8” 8.2, Worn chain guide on bar...

  • Page 57: Taking Out Of Service

    Operating instructions Taking out of service and storage Taking out of service and storage Taking out of service 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.

  • Page 58: Storage

    Taking out of service and storage Operating instructions 9.2.2 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. •...

  • Page 59: Transport, Packing 10.1 Transport

    Operating instructions Transport, Packing 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 •...
  • Page 60 Transport, Packing Operating instructions 10-2 HCH5011 / 001...

  • Page 61: Disposal 11.1 General

    Operating instructions Disposal 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.

  • Page 62: Disposal Regulations

    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.

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