DIAMOND PRODUCTS WIRE SAW OPERATION AND SAFETY MANUAL MODEL WS-25 (SEPTEMBER 2006) Page 1
Table of Contents Overview ..........................................................................................................3 Safety ...............................................................................................................3 Equipment........................................................................................................4 Diamond wire..............................................................................................................
Overview Wire sawing can be a very efficient method of removing large pieces of concrete. As with any type of construction task, attention must be paid to proper setup and safety. This manual will outline some of the critical aspects or wire saw safety and operation. Local ordinances and safety regulations should always be strictly adhered to. Safety As with many construction and destruction operations, safe working practices must always be adhered to.
FIG. 1 ! ! ! ! Ensure that the wire saw itself and all pulleys are anchored and secured. Ensure that all guards are in place. Never saw without all guards installed. Ensure that all unauthorized and unnecessary people are out of the sawing area. Never enter the danger zone during sawing, even for a short time. Proper personal safety equipment should always be worn. This equipment includes a hard hat, safety glasses and safety shoes.
Crimping the wire To crimp the wire you must first have a clean surface to crimp. The spring must be removed by pulling it off with pliers (FIG. 3). Remove the remainder of the rubber. Slide the crimp on, ensuring that all strands of the wire are in the crimp. Use the proper crimping tool to crimp wire and crimp (FIG. 6) together. Feed the wire through the material to be cut. Make sure you check the wire direction to ensure that it will be cutting in the proper direction.
Hydraulic Power Supply and Controller Connecting the hoses (FIG. 8) Connect the supply hoses form the power pack to the P port and return hoses to the R1 port of the BS-2. Take the hoses that are supplied with the BS-2 and connect them as follows: Take one set of the ¼” hoses with the straight ends. Connect the male coupling to the V1 port on the BS-2 then connect the female coupling to the V2 port directly across from it. The other set of 1/4 lines are not used.
Cutting with Wire Securing the machine The machine must be secured so it does not move when cutting. This is generally done with drop-in anchors through frame. Introducing water for cooling Water must be introduced at the beginning of the cut line and also at the exit of cut line. The water at the entry of the cut will get pull trough the cut by wire. The water at exit of the cut will help clean and cool the wire before reentering the machine.
Starting the machine To start cutting perform the following steps: Make sure there is sufficient tension is on wire. Screw out the travel pressure control knob (FIG. 10) of the BS-2/ BS control. The travel pressure valve is used to increase and decrease wire tension. Engage Direction Lever A (FIG. 10) so tension is set. Turn on the main hydraulic flow slowly (Saw Motor Control – see FIG. 8). The wire should start to move.
Proper tension is important. This can be visually verified; you should see a slight wave in the slack side of the wire during cutting (FIG. 11). FIG. 11 Ending the cut As you start to get close to the end of the cut, shim the cut with steel shims to avoid pinching the wire during the cutting operation and when the cut is complete. Ensure that pulleys are set up so they can catch the wire when it exits the cut.
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