TYROLIT WSE811 (01) PDF DOCUMENT

Failure to comply with safety instructions may result in serious injury or even death. Please ensure all operating instructions have been read and understood in full.

Laceration from the saw blade: Always wear protective gloves when working on the wall saw, particularly the saw blade. Always use the blade guard when operating the wall saw.

Uncontrolled movements: Never connect or disconnect cables when the wall saw is running.

Sudden start-up: Before switching on the system, ensure no other persons are present in the danger areas. On leaving the system, switch it off and ensure that it cannot be switched on again.

Machine running after an accident: Ensure that the EMERGENCY STOP button can be reached quickly.

Electric shock: Switch off the wall saw WSE811 before connecting or disconnecting cables. Ensure the power supply is earthed and fitted with a residual current circuit breaker (FI Type B) with a maximum residual current of 30 mA.

Fire risk from incorrect voltage: Make sure that the mains voltage and mains frequency correspond with the mains settings of the wall saw WSE811.

The safety signs indicate the following required personal protective equipment and actions:

1. Wear safety shoes

2. Wear gloves

3. Wear a breathing mask

4. Wear a helmet, goggles, and hearing protection

5. Read the instructions

6. Before working on the equipment, unplug from the mains

In an emergency, follow these steps:

1. Press the EMERGENCY STOP button on the remote controller. If the EMERGENCY STOP is activated on the radio remote controller, the LED warning light will flash rapidly.

2. In an emergency, the sawing machine can also be switched off using the main switch on the saw head of the WSE811.

The TYROLIT WSE811 is a transportable wall saw for use on construction sites, for cutting (reinforced) concrete, stone, and masonry. It is intended for industrial use only and is not suitable for use in potentially explosive atmospheres.

The main components are:

1. Radio remote controller

2. Mains cable with connector

3. Rail

4. Rotating rail support

5. Wall saw head with integrated control unit

6. Undercarriage

7. Diamond wire saw

8. Blade guard

The remote controller for the TYROLIT WSE811 has three operating modes:

Rechargeable battery operation: The interchangeable rechargeable battery is inserted in the base of the casing. A fully charged battery provides approximately 12 hours of operation with a reception distance of approx. 25 m.

Ordinary battery operation: A battery holder for three 1.5-V AA batteries can be used. The reception distance is approx. 25 m.

Cable operation: A 10 m cable insert allows connection of the remote controller to the control unit. This mode is for areas where radio operation is not allowed (e.g., hospitals). The rechargeable/ordinary battery holders must not be inserted during cable operation.

Follow the visual instructions in the manual to correctly position and lock the wall saw onto the guide rail. Ensure the swiveling handle engages properly. If the handle fails to engage or the wall saw sits too loosely on the guide rail, you must adjust the guide rollers.

You will need a size 22 fork wrench and a size 8 Allen key.

The guide rollers are set correctly when it is just not possible to turn them by hand. To ensure the machine travels parallel to the rail, both guide rollers must be adjusted identically.

DANGER: Serious injury can be caused by a sudden start-up. Always switch off the wall saw and isolate it from the mains supply before working on the saw blade. Only use original screws and bolts.

For a saw blade diameter of Ø650 mm or Ø750 mm, you will need a size 19 fork wrench and a size 5 Allen key.

1. Ensure the direction of rotation of the saw blade matches the direction of rotation of the machine. The countersinking of the fixing holes should be against the blade cover.

2. Secure the blade using six screws, tightened to 10 Nm.

3. Secure the central bolt, tightened to 50 Nm.

The TYROLIT WSE811 can accommodate diamond saw blades with uptake drill holes of Ø60 mm and Ø25.4 mm.

For diamond saw blades with an uptake drill hole of Ø25.4 mm, the support spindle of the blade flat flange needs to be rotated by 180°.

For disassembly of the support spindle, two M5 screws can be used as a disassembly help.

For saw blades with a diameter of Ø650 mm or Ø750 mm, you will need a size 5 Allen key, a size 6 Allen key, and an M12x12 set screw.

1. Mount the saw blade using the six fixing screws, tightened to 10 Nm.

2. If the distance from the saw blade to the wall is more than 10 mm in places, a set screw (M12x12 mm) must be screwed flush into the center of the saw blade uptake for controlled cooling water distribution.

To assemble the blade guard, follow the instruction leaflet provided. You will need a size 19 fork wrench.

To disassemble the blade guard, perform the assembly steps in the reverse order.

Mains Connection:

✓ Connectors/plugs must be clean.

✓ Cables must be undamaged.

✓ The power supply must be earthed and fitted with a residual current circuit breaker (FI type B; max. residual current 30 mA).

✓ Use sufficient cable cross-sections: up to 25 m long use 4 x 2.5 mm², and for more than 25 m long use 4 x 4 mm².

Water Connection:

The TYROLIT WSE811 can be used for both wet and dry cutting.

For wet cutting, connect the water supply to the designated inlet.

For dry cutting, the water is led away via a bypass. Note that continuous operation is not possible for dry cutting, as the gearbox will overheat. After 15 minutes of use, a 30-minute break must be maintained for cooling. Only special TYROLIT diamond saw blades may be used for dry cutting.

No. Sawing without the blade guard is prohibited. There is a danger from segments or concrete chips flying off from the cutting tool. If the blade guard is not mounted, water will also emerge in an uncontrolled manner over the blade guard uptake.

Before starting, ensure:

✓ The rail is firmly connected to the subsurface.

✓ The wall saw head is correctly mounted on the rail.

✓ The protective cup on the remote controller cable connector is locked securely.

✓ The diamond tool is correctly secured using the blade flange.

✓ The blade guard is correctly mounted.

✓ The wall saw is connected to the mains and the water supply.

✓ The remote controller EMERGENCY STOP has been deactivated.

Starting Procedure:

1. Move the following controls on the remote controller to the 0 position: Feed potentiometer, Starter switch, Main motor On/Off, Water switch.

2. Switch on the wall saw using the main switch on the wall saw head.

3. Switch on the radio remote controller using the starter switch. The warning light will light up red, then flash green.

4. Press the pulse button on the remote controller briefly. The reset indicator will light up blue.

5. Press the reset button on the remote controller. The ready indicator will flash green.

6. Press the pulse button briefly again. The ready indicator will light up green.

7. Open the water valve on the system supply line.

8. Press the water On/Off switch on the remote controller to position 1. Water should flow from the diamond tool.

9. Using the diameter selector, choose the correct diamond tool diameter.

10. Press the main motor On/Off switch on the remote controller to position 1. The electric motor will start.

The TYROLIT WSE811 has started and is ready for operation.

If the radio connection is interrupted or malfunctioning, the system will immediately go into the EMERGENCY STOP state. To find a new frequency:

1. Switch the start switch on the remote controller off and then on again. This selects the next frequency.

2. This process is limited to four attempts (channels).

3. If the system does not find a suitable frequency after four attempts, you must change over to cable operation.

Selecting the tool station: After the wall saw has been started correctly, you can select between the tool stations Ø650 mm or Ø750 mm using the diameter selector switch. The tool stations must not be changed during operation. They are set for the optimum rotational speed and cutting performance for the selected tool diameter.

Adjusting the feed: The feed movements (travel and swivel) are selected with the joystick. During the cutting process, the feed speed is automatically supported by an assisted feed.

Manually adjusting feed speed: Once the wall saw is started, you can select the required feed speed via the potentiometer on the remote controller.

Locking the feed: To lock the travel feed so you don’t have to hold the joystick:

1. Push the joystick in the desired travel direction.

2. At the same time, press the locking switch (traverse feed button).

3. When the joystick and the locking switch are released, the feed is locked.

To release the feed lock, move the joystick slightly in any direction or press the locking button again.

Proceed as follows:

1. Press the start switch on the remote controller to the 0 position.

2. Turn off the cooling water by setting the water switch to 0/1.

3. Switch off the WSE811 wall saw using the main switch on the remote controller.

4. Switch off the WSE811 wall saw using the main switch on the wall saw head.

Caution: Frost can damage the wall saw. If there is a risk of frost, blow out any water from the machine.

Only use the EMERGENCY STOP function in an actual emergency.

With the main switch set to OFF:

1. Disconnect the mains plug.

2. Disconnect all water lines.

3. Connect a purge pump to the water nipple.

4. Blow out water until all of the cooling water has been removed.

5. Remove the pump.

When the EMERGENCY STOP is activated, the radio and battery light on the remote controller will flash quickly.

To deactivate it:

1. Move the following controls to the 0 position: Potentiometer, Feed joystick, Main motor On/Off switch.

2. Turn the EMERGENCY STOP button clockwise to release it.

3. Push the pulse button to the ON position to re-establish connection.

Proceed as follows:

1. Disconnect the water hoses from the wall saw.

2. Blow out the water from all lines to prevent damage.

3. Turn the main switch on the wall saw to the 0 position.

4. Disconnect the mains plug.

5. Clean the wall saw, the remote controller, and the cables with a damp cloth.

Important: Cleaning using high pressure cleaning equipment is not permitted. Products containing cleaning agents can damage parts of the wall saw, remote controller, and cables.

The lights on the remote controller indicate the status of the machine. Refer to the table below:

Symbol/Response	Possible Cause	Action
Flashes orange	Rechargeable battery voltage too low	Recharge rechargeable battery
Flashes green rapidly	No radio connection. The EMERGENCY STOP has been activated.	Switch on the remote controller. Check for defective receiver or mismatched connection.
Flashes red	Group alarm on the remote controller. On operating the pulse switch, the main motor On/Off switch is in the On position.	Turn the potentiometer to the 0 position. Put the main motor On/Off switch into the Off position.
Lights up yellow	Service indicator: After the first 100 operating hours, then after every 200 operating hours.	Service must be carried out only by an authorised representative.
Lights up green	The motor is ready to start.	After 30 seconds of inactivity, the pulse button must be pressed again.
Flashes green	The machine is in the stand-by position.	Press the pulse switch on the remote controller.
LED bar graph	Shows the current power range.	Ideally, the power should be at the second, orange-coloured diode (in iron, the third, red diode).

The flash code is displayed in red on the group alarm light and helps detect faults.

Flash Code	Fault	Possible Cause	Action
2x	Mains phase is missing	Fault during installation; Fuse defective	Check phases and fuses
3x	DC motors are overheating	Absence of cooling	Allow machine to cool for 3 minutes. Avoid direct contact with sunlight.
	Blade motor is overheating	Absence of cooling; No, too little or too hot cooling water	See Technical data for water requirements.
4x	Short circuit fault	–	Contact TYROLIT Hydrostress AG after-sales service
	Short circuit detection	Earth fault
	Main motor overcurrent	Main motor blocked; Overcurrent earth fault
	Main motor earth fault	Electrical connection earth fault
5x	Overcurrent DC axis	Feed motor overloaded	Reduce feed
	DC motor short circuit	Blocked feed motor; Defective feed motor	Contact TYROLIT Hydrostress AG after-sales service
6x	The safety relay no longer switches properly	Hardware defect
	The safety contact no longer functions properly	Hardware defect
7x	Transformer fault	Motor outside of possible parameters
8x	Direct current link voltage too low	Incorrect mains voltage	Check the power supply. See Technical data.
	Direct current link voltage too high	Mains overvoltage; The saw blade feeds back too much energy.	Check the power supply. Use only diamond saw blades with Ø650 mm and Ø750 mm.
9x	Communication fault	Communication fault due to interference	Contact TYROLIT Hydrostress AG after-sales service

Component	Task	Before starting up	On finishing work	Weekly	Annually	After faults	After damage
Electrical system	Check the condition and cleanliness of electric cables, plugs/connectors and switches.	X	X			X	X
	Check the condition and cleanliness of couplings.	X	X			X	X
Wall saw head	Retighten loose bolts, screws and nuts.	X				X	X
	Check cleanliness	X	X			X	X
Lock unit	Clean latching recesses and guide grooves	X	X			X	X
	Lubricate			X		X	X
Guide rollers	Check the bearing clearance for wear	X	X			X	X
	Clean	X	X			X	X
	Replace						X
Rotating chassis	Clean with water		X
	Check the saw blade uptake for wear	X				X	X
	Change the gear oil				Every 100 h
Water economy	Check the water line for cleanliness and leak-tightness	X	X			X	X
	Blow out water		X
Saw blade	Clean with water		X
	Check for wear	X	X			X	X
Service	To be performed by an authorised workshop	After 100/300/500/700 hours

Lubricating the lock unit:

1. Treat joints and the lock unit with a spray lubricant.

2. Lubricate the grease points using a grease gun with EP Grease 2.

Cleaning the water filter:

1. Using a size 18 fork wrench, disassemble the water filter.

2. Clean the water filter with warm water and reassemble.

The use of unsuitable oil can damage the wall saw. Use only TYROLIT Hydrostress AG oil containers (0.4 dl).

1. Using a size 5 Allen key, remove the drain plug.

2. Allow the gear oil to drain completely. To ensure all the gear oil can drain out, turn the hub twice by hand.

3. Refill with the specified amount of new gear oil and replace the plug.

Check the following possible causes and solutions:

• Wall saw is turned off: Switch the wall saw on (see chapter 4).

• Defective mains cable: Replace the mains cable.

• No voltage at the power supply (building site): Check the power supply.

• Power supply phases incorrectly connected: Check the power supply.

• Phase missing: See the chapter on “Reacting to indicators”. Check for flash code 2x.

If the power supply fuse at the building site trips, check and if necessary adapt the fuse protection. If necessary, change the power supply. Refer to the chapter on “Reacting to indicators”.

Check the following:

• Incorrect voltage: Make sure that the control unit voltage and frequency match the mains supply specifications.

• Defective main motor: Contact TYROLIT Hydrostress AG after-sales service.

• Power range indicator within the red zone: This indicates the blade is jammed. Switch off the main motor and loosen the deadlock.

This could be due to:

• Over or undervoltage: Check the power supply. Refer to the fault flash code.

• Cross section of power supply cable too small: Check the power supply cable specifications.

• Defective plug connection: Check the plug connection and the power supply.

• Group alarm: Refer to the fault indicator.

• Defective main motor On/Off switch on remote controller: Contact TYROLIT Hydrostress AG after-sales service. Switch on the control unit as per chapter 4.2.

• The remote controller ready light does not come on: The EMERGENCY STOP may be activated. Deactivate it as per chapter 4.10.

• Overheating: Check the water circuit and the plug-in couplings. Refer to the fault indicator.

• No water: Turn on the water. Refer to the fault flash code.

The rechargeable battery may have too little charge (indicator lights flash orange). Replace and recharge the battery, install cable operation, or replace the disposable batteries.

If the saw blade jams, the wall saw will produce a rattling noise and show flash code 4x. Immediately put the main motor On/Off switch on the remote controller into the 0 position and wait until no more rattling noises can be heard. Lift the saw blade from the cut and loosen the jammed blade.

• Remote controller potentiometer is defective or in the 0-position: See chapter 4.5. If defective, contact after-sales service.

• Automatic feed power range indicator is in the red zone: The blade is jammed. Switch off the main motor and loosen the deadlock.

• Defective motor: See “Reacting to indicators” for flash code 3x. Contact after-sales service.

• Water line or filter clogged: Clean the water line and the water filter (see chapter 5.5).

• Water valve on the supply or water hose is closed: Open the water valve.

• Insufficient water pressure: Make sure that the water pressure is at least 2 bar.

• Defective switch on the remote controller or defective water valve: Contact TYROLIT Hydrostress AG after-sales service.

• Water valve on the wall saw head is faulty or switch on remote is defective: Stop the water outlet using the hose water valve. Contact TYROLIT Hydrostress AG after-sales service.

• Blade guard not assembled: Assemble the blade guard.

Parameter	Value
Construction	Light aluminium/steel construction
Disc rotor drive	360°
Power transmission	Toothed wheel
Grips	4 pieces, 1 grip with locking function
Guide rollers	Low-wearing
Rail mounting	Locking and safety function on grip
Main motor	High-frequency, water-cooled
Feed motor/swivelling motor	Electric motor with gearbox
Flush cutting	Flange without blade cover
Normal cutting	Flange with blade cover
Water	Water connection on chassis

Parameter	Value
Saw blade max.	Ø750 mm
Fully detachable saw blade	Ø650 mm
Blade uptake	Ø60 mm/Ø25.4 mm
Blade flange fixing at wall saw	Flange
Saw blade fixing on blade flange (also for flush cuts)	6 countersunk screws M8x12 10.9 reference circle 90 mm
Blade cover fixing on blade flange	1 x hexagon head cap screws, M12x25 8.8
Cutting depth	Ø600 mm: 240 mm
	Ø650 mm: 265 mm
	Ø750 mm: 315 mm

Parameter	Value
Gear oil (swivel arm)	Klüber EG 4
Grease (lock unit)	Penetration: 265 to 295
	NLGI: 2
Universal Spray 250 ml (lock unit)	–
Grease (travel and swivel gear)	Penetration: 400 to 430
	NLGI: 00

Parameter	Value
Pressure	Min. 2 bar/max. 6 bar
Quantity	Min. 4 l/min
Max. temperature	25 °C