DSW 1510-CA English
DSW 1510-CA Original operating instructions
Original operating instructions Contents 1 Information about the documentation . . . . . . . 1.1 About this documentation . . . . . . . . . . . . . . . . . 1.2 Explanation of symbols used . . . . . . . . . . . . . . . 1.2.1 Warnings . . . . . . . . . . . . . . . . . . . . . . . . 1.2.2 Symbols in the documentation . . . . . . . . . 1.2.3 Symbols in the illustrations . . . . . . . . . . . . 1.3 Additional symbols for this product . . . . . . . . . . 1.3.1 Symbols on the type identification plate . . . 1.3.
4.4 4.5 4.6 5 5.1 5.2 5.3 6 6.1 6.2 6.3 6.4 6.5 6.6 7 7.1 7.2 7.3 8 8.1 8.2 8.3 8.4 8.5 8.6 2 DST WRC-CA wireless remote control unit . . . . . . . . . . . . . . . . . . . . Noise emission values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DSW-SPP 240 single-pulley stand . . . . . . . . . . . . . . . . . . . . . . . . . . Tools and accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DS-W diamond wires . . . . . . . . . . . . . . . . . . . . . . . . . .
9 Care and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1 Cleaning drive unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2 Blow remaining traces of water out of the cooling water circuit and motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3 Carrying out maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.
Instructions for use and other useful information Dealing with recyclable materials Do not dispose of electric equipment and batteries as household waste 1.2.
Do not grip the diamond wire! Do not enter the danger zone! Use of high-pressure cleaning equipment prohibited Do not cross the danger zone! 1.4 Product information products are designed for professional users and only trained, authorized personnel are permitted to operate, service and maintain the products. This personnel must be specifically informed about the possible hazards.
Electrical safety ▶ Power tool plugs must match the outlet. Never modify the plug in any way. Do not use any adapter plugs with earthed (grounded) power tools. Unmodified plugs and matching outlets will reduce risk of electric shock. ▶ Avoid body contact with earthed or grounded surfaces, such as pipes, radiators, ranges and refrigerators. There is an increased risk of electric shock if your body is earthed or grounded. ▶ Do not abuse the cord.
▶ Maintain power tools and accessories. Check for misalignment or binding of moving parts, breakage of parts and any other condition that may affect the power tool’s operation. If damaged, have the power tool repaired before use. Many accidents are caused by poorly maintained power tools. ▶ Keep cutting tools sharp and clean. Properly maintained cutting tools with sharp cutting edges are less likely to bind and are easier to control. ▶ Use the power tool, accessories and tool bits etc.
▶ ▶ ▶ ▶ ▶ ▶ ▶ dust mask. Comply with national regulations applicable to the materials you will be working with. Wear suitable work clothes. Do not wear jewelry or loose clothing that could be snagged by moving parts. If your hair is long, wear a hair net. Avoid skin contact with drilling and sawing slurry. Keep children clear. Keep everyone clear of your work zone. Do not allow other persons to touch the equipment or the extension cord.
▶ Do not start work until the drive unit and the pulley stands have been securely and firmly secured to a solid sub-base. A toppling or dropped part can result in serious damage or injury. ▶ Connect the electric power and compressed air supply only once the wire saw has been set up completely. ▶ Do not start up the product before all covers have been correctly installed and closed. ▶ Entry into the danger zone (e.g. to adjust the pulleys or water supply, hammer in wedges, etc.
2.5.1 Description of the danger zone The danger zone for wire saws includes zones in which: • (A) Persons could be hit by a whipping diamond wire. • (B) Persons could be hit by flying parts. 2.5.2 Danger zone A (shown here colored yellow) Protection against whipping diamond wire. In principle, you must assume that the diamond wire can break at any point. If this happens, the free ends of the wire can be deflected in any direction at the next relay point (in the direction of pull)of the sawing wire.
these operating instructions and must have been trained by a Hilti specialist on the safe application of these instructions. The operator in charge must be aware of the possible dangers and of his responsibility for safety, both with regard to himself and to others. The operator is responsible for securing the danger area by cordoning it off and taking protective measures (guards, etc.) as necessary.
3.1.2 DSW 1510-CA drive unit @ ; = % & ( Guide pulley (slack-wire side) Guide pulley (taut-wire side) Drive pulleys Wire storage pulleys (fixed) Wire storage pulleys (movable) Box for electrical components ) + § / : Drive motors Connections, water supply for water nozzles Starting lock Compressed-air cylinder guide Compressed-air cylinder 3.1.
3.1.4 Operating panel @ ; = % Main switch Connection for remote control cable 'Wire tension' operating button LED light & ( ) + § Antenna Connection, compressed-air hose Connection, main water supply Guard (electricity connection) Connection, power supply & ( ) Anti-twist locking pin Grease nipple Clamping lever (for adjustment of guide pulleys) Guide-pulley axle with mounting adapter (protective tubes) 3.1.5 DSW-SPP 240 pulley stand @ ; = % 3.
Only specialists who have received training in concrete cutting techniques, designated "users" below, are permitted to operate the wire saw. These persons must be completely familiar with the content of these operating instructions and must have been trained in safe operation by a Hilti specialist. The user in charge must be aware of the possible dangers and of his responsibility for safety, both with regard to himself and to others. 3.
Max. wire storage capacity in drive unit Net wire storage capacity 4 Technical data 4.1 DSW 1510-CA drive unit Dimensions (L x W x H) Weight Drive power (total) Engine speed Cutting speed Diameter (drive pulley) Diameter (guide pulley) Protection class in accordance with IEC 60529 Ambient temperature (operation) Ambient temperature (storage) Wire storage capacity Diameter (diamond wire) 4.2 63.8 in x 30.9 in x 38.
Air volume Power supply 4.4 26 liq. galUS/min (100 ℓ/min) 120 V DST WRC-CA wireless remote control unit Weight in accordance with EPTA Procedure-01 3.5 lb (1.6 kg) 65 ft - 10 in Range (20 m) 2,400 MHz …2,483.5 MHz Frequency band 10.9 dBm Maximum emitted transmission power 4.5 Noise emission values Sound (power) level Sound pressure level Uncertainty for the sound power level 4.
5.2 Accessories for diamond wire saws Accessories Designation Description Single-pulley stand DSW-SPP Guides the diamond wire from the drive unit to the structure to be cut. Release pulley DS-WSRW At the start of a new cut, reduces friction at the edges. 315834 Plunge wheel DSW-PW Permits a plunging initial cut (plunge cut) whenever there is no access to the rear of the structure. Permits cutting of the bottom, final section after cutting with the plunge wheel.
Arrange the cutting sequence so that the diamond wire cannot become trapped by parts that are cut away. ▶ Plan the sequence of operations before setting up the system. ▶ Plan the cooling water supply system and water disposal system. ▶ Observe the safety instructions. ▶ Define the danger zone. Cordon off the danger zone with barriers and adopt appropriate safety measures. ▶ Plan how the section to be cut away is to be secured, removed and transported away and prepare measures for these steps.
Vertical cut (release pulley) Fast cutting process with high load and lesser longevity of diamond wires Horizontal cut Doorway cut, right Doorway cut, bottom Doorway cut, top *2238935* 2238935 English 19
Doorway cut, left Column cut using the horizontal/vertical sawing device Beam cut with horizontal/vertical device Plunge cut Bottom cut with plunge cut device using the plunge pulley accessory 6.
Approximate calculations Required wire storage capacity ×2 6.4 4.4 + Wire length + + + ×2 Power source Fuse rating Make sure that the site-provided electricity supply, regardless of whether it is from the electricity grid or from a generator, incorporates a ground conductor and ground fault circuit interrupter and that these components are correctly connected.
▶ When working outdoors, use only extension cables that are approved and correspondingly marked for this application. Recommended minimal gauge (conductor cross section) and maximum extension cable length Extension cable Conductor cross section Conductor cross section Extension cable length AWG 12 3.3 mm² AWG 10 5.3 mm² AWG 8 8.4 mm² AWG 6 13.3 mm² 6.53 kcmil 10.4 kcmil 16.5 kcmil 26.3 kcmil <60 m >60 ... <100 m >200 ... <330 ft >100 ... <160 m >330 ... <530 ft >160 ... <260 m >530 ...
7.1.2 Setting up drive unit WARNING Risk of injury! Risk of injury if the pulley stand falls! ▶ Use only anchors suitable for the base material to secure the pulley stands. Comply with the instructions for use in the operating instructions of the anchor. In principle, the Hilti HKD M16 metal expansion anchor is suitable for setting as anchor in concrete to secure the equipment. An alternative method of attachment might be necessary however, depending on circumstances.
WARNING Risk of injury! Risk of injury if the pulley stand falls! ▶ Use only anchors suitable for the base material to secure the pulley stands. Comply with the instructions for use in the operating instructions of the anchor. 1. 2. 3. 4. Mark the position of the anchor hole for the pulley stand. Drill the anchor hole and clean it out. Insert the anchor in the hole and use the setting tool to expand the anchor.
1. Set up the drive unit on the jobsite. → page 23 2. Connect a cooling-water hose to the inlet on the drive unit and to an outlet of the on-site water supply. 3. Connect both cooling-water hoses to distributors (A) and (B). 4. Route the cooling-water hoses to the cutting location and connect the cooling water hoses to the flexible cooling-water spray nozzles. 5. Open the water valves at the distributors. 6. Open the on-site water supply. Water can flow through, because the main switch is set to OFF. 7.
7.3 Diamond wire 7.3.1 Fitting wire connectors and connection of diamond wire Read and follow the instructions given in the operating instructions of the diamond wire and the connectors. 7.3.2 Diamond-wire path and cutting direction The illustration shows the path of the diamond wire through the structure and the drive unit in the cutting direction. Use the guide pulleys to control the diamond wire and restrict the free lengths of the diamond wire to a minimum.
4. From the rear of the structure, feed the diamond wire back through the second hole (3). 5. Feed the diamond wire through the hollow axle of the pulley stand (taut-wire side) (4). 6. Open the cover of the drive unit. 7. Feed the diamond wire through the hollow axle of the guide pulley (slack-wire side) (6). 8. Loop the diamond wire clockwise round the drive pulley (A). 9. Loop the diamond wire counter-clockwise round the second drive pulley (B).
7.3.5 Tensioning diamond wire 1. Lay the diamond wire on the drive pulleys and the pulleys of the wire storage unit. → page 26 2. Set the main switch to ON. 3. Switch the air compressor on. 4. Tension the diamond wire by pressing the Wire tension operating button on the drive unit. 5. Align all the guide pulleys of the drive unit with the drive pulleys of the pulley stands. 6. Check that the wire is centered in the grooves of the drive pulleys, wire storage pulleys and guide pulleys. 7.
▶ Comply with the instructions for installation in the operating instructions of the guards. 8 Operation 8.
8.3 During operation of the wire saw DANGER Serious injury hazard! Risk of injury due to entry into the danger zone or unforeseen situations. ▶ Press the EMERGENCY STOP button immediately if a dangerous, unforeseen or critical situation arises (e.g. if the diamond wire jumps off a guide pulley or if a person enters the danger zone). ▶ Before entering the danger zone, always press the EMERGENCY STOP button or the ON/OFF switch on the remote control unit.
8.4 Changing storage levels When the cylinder reaches its maximum stroke the wire storage unit is full and you have to resume operation using the lay on a new wire storage level. The drive has a limit switch that stops the drive automatically when it is reached. • Valve position (air compressor) remains at Extend cylinder. • Water supply is shut off (if water supply is set to AUTO or MANUAL). A message to this effect appears on the display of the DST WRC-CA wireless remote control. 1.
5. Before entering the danger zone, always press the EMERGENCY STOP button or the ON/OFF switch on the remote control unit. 6. Set the cylinder to neutral position by pressing the Wire tension button. 7. Set the main switch to OFF. 8. Find the wire connector and open it. 9. Remove the diamond wire from the drive. 10.Clean the drive unit and the pulley stands. → page 32 11.Set the wire storage pulleys to the transport position and secure the wire storage pulleys with a ratchet strap. 12.
• Clean the drive unit with running water at low pressure (e.g. from a water hose). • Do not use running water to clean the wireless remote control unit, air compressor or plug connections. • If necessary, also clean the drive unit and the pulley stands between individual cutting operations. Do not wait too long before cleaning. The sawing slurry adhering to parts dries very quickly.
3. Move the piston to make sure that you also clean the areas of the piston rod covered by the guide bearings. 4. Connect the tube of the grease gun to the grease nipple. 5. Inject grease into the 2 grease nipples. Continue injecting grease until the grease squeezes out at the piston rods. In this way you clean the bearings. 6. Lubricate the guide pulleys on the drive unit and the pulley stands. 9.4 Replacing rubber-tired pulleys on the DSW-SPP 240 single-pulley stand 1. Remove the pulley. 2.
11.Use a suitable screwdriver to tighten the screws (8 TX 45 screws) of the locating ring to 25 Nm. ▶ The pulley is serviced and ready for installation. 10 Transport and storage Transport ▶ Use the grips provided for transportation. Keep the grips clean and free from oil and grease. ▶ Avoid lifting and carrying heavy loads. Use suitable lifting equipment and means of transport and, when necessary, share the weight of heavy items between several persons.
1. Disengage the lock securing the transport handle. 2. Swing the transport handle into a horizontal position. ▶ The teeth of the lock are securely intermeshed. 3. Tighten the lock of the transport handle. 4. Insert the lifting bar into the socket at the swivel mechanism. 5. Release the catch and use the bar to pivot the wheel down into position. ▶ The catch is re-engaged. 6. Repeat these steps on the opposite side. ▶ The drive unit is now ready for transport.
Trouble or fault The wire saw doesn’t start. Possible cause A new sawing wire jams in a kerf made by a worn sawing wire. Sawing-wire-to-concrete contact length is excessive. Tension on the wire is too high. Sawing wire installed wrong way round. The drive pulley slips / the wire is not driven by the pulley. The wire jumps off the drive wheel or guide pulley when starting the saw. The wire is defective. Insufficient wire tension. The drive pulley is too badly worn. The starting lock was not used.
Trouble or fault The sawing wire is pulled out of the connector. Sawing wire jumps and oscillates severely. Sawing wire vibrates very strongly at a high frequency. Excessive sawing wire wear. 12 Possible cause Action to be taken Sawing wire was not pushed ▶ Push the sawing wire into far enough into the connecthe connector all the way tor. to the front stop. ▶ Cut the sawing wire to length correctly and cleanly. Insufficient wire tension. ▶ Increase the wire tension.
Malfunction Er200: Wire storage unit full. Action to be taken ▶ Stop the sawing operation and change the wire storage level. → page 31 ▶ Shorten the diamond wire. ▶ Reposition the drive unit farther away from the cut. Er202: Cover of the Cover of the wire storage ▶ Close the cover of the wire storage unit open. unit is not closed. drive unit. Er204: Electrical fault. Fault in the electrical system. ▶ Switch the product off and then on again. ▶ Contact Hilti Service.
▶ Do not dispose of power tools, electronic equipment or batteries as household waste! 14 FCC statement (applicable in US)/IC statement (applicable in Canada) This equipment has been tested and found to comply with the limits for a class B digital device, pursuant to part 15 of the FCC rules. These limits are designed to provide reasonable protection against harmful interference in a residential installation.
*2238935* 2238935 Hilti = registered trademark of Hilti Corp.