Diamond SL User Manual
Circular wire saw system SL
Operating instructions
Spare parts list
SL
0.1 Introduction
Dear customer,
you have decided in favor of a progressive, proven
HYDROSTRESS equipment, hence for a stand-
ard of technological leadership.
Due to our efforts in the field of quality assurance the
Circular Rope Saw Type SL represents a Swiss top
performance product:
• High sawing performance
• Reliable operation
• High mobility
• Convenient handling
• Low maintenance cost
Only original HYDROSTRESS spare parts assure
quality and compatibility.
If proper maintenance work is neglected or done
incompetently we can not fulfill the guarantee obliga-
tions set forward in our terms of delivery.
All repair work is to be made by professionally trained
persons only.
0.2 Validity of this Operation
Instruction
This Operating Instruction is exclusively valid for
the following equipment:
Circular Rope Saw Type SL Index 000
0.3 System range definition
This Operation Instruction describes the use of
the Circular Rope Saw Type S including the
matching electric drive motor type EM and the
hydraulic drive motors.
The Circular Rope Saw Type SL must only be
operated after the respective Operating Manual
has been paid attention to.
Spare parts and maintenance instructions for
the drive unit engaged in the individual case can
be found in the respective Operating Manual.
Our customer service is at your disposal to maintain
your equipment in perfect condition.
We wish you trouble-free and unproblematic wor-
king with your HYDROSTRESS equipment.
HYDROSTRESS AG
The Management
Copyright © HYDROSTRESS AG, 1998
HYDROSTRESS AG
Witzbergstrasse 18
CH-8330 Pfäffikon
Switzerland
Telefon 0041 1 950 10 74
Telefax 0041 1 950 10 18
Hotline 079 / 608 19 07
0.3.1 Operating Manuals of drive units
Indications for the use of drive units are meant
to increase the safety of operators. However for
safe operation of drive units the respective Operating Manual consulting the respective Operating Manual is indispensable!
page 2 sl9806e
SL
0.4 Table of contents
0.1 Introduction 2
0.2 Validity of this Operation Instruction 2
0.3 System range definition 2
0.4 Table of contents 3
1 Safety instructions 4
1.1 Basic provisions 4
1.2 Designated usage 6
1.3 Before starting work 6
1.4 During sawing 7
1.5 After finishing work 7
2 Technical Data 8
2.1 Dimensions 8
2.2 Attachable equipment, hydraulic 8
2.3 Attachable electric motor, electric 9
2.4 Design 10
2.5 Function with hydraulic drive 11
2.6 Funktion electric drive 12
2.7 Protection material 13
3 Preparation for work 14
3.1 Procedure 14
3.2 Select drive unit and sawing
motor (hydraulic) 15
3.3 Calculation of rope length 16
3.4 Secure construction site 17
3.5 Secure part to be sawn out 17
4.5 Mount protection hoods 23
4.6 Water cooling 23
4.7 Connection of water in case of using a
hydraulic unit 23
4.8 Connection of water in case of using
electric motor "EM" 24
5 Sawing 25
5.1 Before sawing 25
5.2 Sawing, hydraulic 25
5.3 Sawing, electric 26
5.4 Trouble shooting 27
5.5 After sawing 27
6 Maintenance 28
6.1 Maintenance table 28
7 Repair 29
7.1 Connection and repair of rope 29
7.2 Connecting the rope by joint lock 29
7.3 Connecting the rope by repair sleeve 30
7.4 Connecting the rope by threaded lock 31
8 Transportation, shut-down , storage,
disposal 32
8.1 Transportation 32
8.2 Shut-down, storage 32
8.3 Disposal 32
8.4 Accessories 32
4Set-up 18
4.1 Fastening of system 18
4.2 Connecting the drive unit 20
4.3 Connecting the electric module 21
4.4 Mounting of rope 22
9 Spare parts list 33
sl9806e page 3
Safety instructions SL
1 Safety instructions
1.1 Basic provisions
1.1.1 Dangers at work on construction
sites
The equipment is built in accordance with state-
of-the-art and generally accepted rules of safety
techniques. Nevertheless its operation may ef-
fect hazards to life and limb of the user or third
persons resp. damage to the equipment or to
other objects of value. Pay attention to the
special working conditions at a construction site.
Protect yourself and others within your area of
responsibility extensively against the multiple
dangers!
1.1.2 Qualification of operating personnel
The operators need to be introduced and
trained for work by experienced experts.
For maintenance and repair specifically trained
personnel has to be engaged.
HYDROSTRESS can assist you for training.
1.1.3 Read the Operating Manual and
inform your co-workers!
This Operating Manual contains important indications for
operating the equipment both
safely and economically.
The owner of the equipment needs to make sure
that the instructions of the Operating Manual are
paid attention by each and every person who
will in any possible way be dealing with the
equipment or the connected auxiliary and ope-
rating materials.
The Operating Manual has to be made available
at the working site at all times
Noise impact (sound level)
The noise level during work lies
above 90 dB(A). This noise
strain may permanently damage your hearing. Therefore during operation always wear ear
protection devices.
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SL Safety instructions
1.1.4 Recognize the Safety Alerts!
Danger: Pay attention to the following phrases,
their symbols (characteristics, displays, mar-
kings) and their meaning:
Danger:
Specific information for prevention of bodily injuries
Attention:
Specific information for prevention of da-
mage to the equipment
1.1.5 Personal protective clothing
During drilling, sawing, biting, and pressing of
concrete and stone
wearing protective clothing is necessary to give
protection against the following dangers:
Source of danger protective clothing:
falling pieces: helmet, steel
reinforced footwear
moving, sharp-
gloves
edged pieces:
flying stone pieces,
goggles
flying sparks:
slipping: footwear with non-slip
soles
Advice:
Specific information for economic use
of the equipment
.
noise: earmuffs
contamination of
breathing mask
respiratory tract:
sl9806e page 5
Safety instructions SL
1.2 Designated usage
The system is designated for sawing with dia-
mond ropes of Ø11mm into the materials
quoted below.
Any different usage may create risks which are
not described in this Operating Manual and will
void any warrantee by HYDROSTRESS.
Process with this equipment exclusively:
• Concrete, rock, masonry, asphalt
Other materials are not allowed for proces-
sing, especially:
– Wood, plastics and glass
1.2.1 Sawed-off pieces
These pieces may weigh heavily. Example: A
cube of concrete of 1m edge dimension (~33")
weighs about 2.5 tons (~5600 lb.). Secure such
pieces against dropping or tipping over and
close off that area of the construction site!
1.2.2 Drive units and accessories
1.3 Before starting work
1.3.1 Static of the edifice
The sawing of large openings can impair the
static of an edifice. Therefore the sawing of large
openings must be planned in coordination with
construction static experts.
1.3.2 Tension reinforced concrete
Inform yourself if any tension rods are situated
within the range of your planned cuts. Sever
these only after explicit authorization.
1.3.3 Emergency Stop
Make sure that you can promptly stop the
machine in case of emergency (see “Emergen-
cy Stop” in this Operation Instruction)!
1.3.4 First Aid in accidents
Find out how to organize help fastest possible
in case of accident!
Use the machine or equipment exclusively with
the recommended drive units or equipment and
1.3.5 Water-, Gas and Power-lines
accessories (see “Attachable units” or “Attacha-
ble equipment” and “Accessories” in this Ope-
ration Instruction)
Make sure that such lines within your cutting or
drilling range are out of operation! Obtain infor-
mation whether such lines may be cut through!
1.2.3 Accident prevention regulations in
your country
Observe the general and particular accident
prevention regulations of trade associations and
federations in your country!
1.3.6 Reinforcement rods
Obtain information whether you may sever pos-
sibly present reinforcement rods in the course
of the cut or bore.
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SL Safety instructions
1.3.7 Organize your working place
Organize your working place properly! Thereby
you will considerably reduce accident hazard!
1.3.8 Lighting of working place
Provide for sufficient lighting of working place.
1.3.9 Protection gear
Never start sawing before all protection gear is
attached and in place.
1.3.10 Flushing water
Ascertain that flushing water can not spill over
into electric installations. Avoid material dama-
ges by flushing water by exercising good con-
trol of the water’s draining flow.
1.4.3 Rotating and moving parts
Keep away from the rope and the pulleys. In
order to avoid being caught by rotating or mo-
ving parts wear tight clothes, and if having long
hear, wear a hair net!
1.5 After finishing work
After work pull out the power plug of the drive
unit to prevent unintentional switching on!
1.5.1 Removal of concrete and rock
pieces
Utilize suitable lifting equipment for the removal
of those pieces, in order to avoid injuries!
1.4 During sawing
1.4.1 Rope ruptures
A rope rupture must be taken into account at any
time.
Observe the measures for avoiding rope ruptu-
res (see “Malfunction remedy”).
1.4.2 Motorized forward feed
Equipment with motorized forward feed are not
automates. During operation they must be su-
pervised at all times. A emergency shut-off must
be possible at any time.
sl9806e page 7
Technical Data SL
2 Technical Data
2.1 Dimensions
2.1.1 Sawing diameters
min. 50 cm
max. 200 cm
2.1.2 Thickness
max. 60 cm
2.1.3 Weights
Weight 122 kg (~276 lbs.)
separable into subassemblies of max. 20 kg ea. (~43
lbs.)
2.1.4 Drive wheel
effective diameter
2.2 Attachable equipment, hydraulic
for rope grip Ø 180mm(~7-1/8”)
2.1.5 Diamond ropes
Diameter Ø 11mm (~7/8”)
Length 621 cm max. (~20’4-11/16”)
351 cm min. (~11-1/2’)
2.1.6 Cutting speed with electric motor
V = 26m/s
2.1.7 Cutting speed with hydraulic motor
See chapter 3.2
Fig.sl_conn.tif
Do not use any other
equipment!
page 8 sl9806e
SL Technical Data
2.2.1 Particular characteristics of the
various drive units
The power output differs from drive unit to drive
unit. Therefore:
– choose correct sawing motor
– choose correct level at the drive unit
(see "Selecting drive unit and sawing motor",
Chapter 3.2.)
2.3 Attachable electric motor, electric
2.3.1 Which extension arm for what
diameter?
Fig. sl_conn2.tif
Do not use any different
electric motor or control unit!
Fig.auslzent.tif
Extension arm Ø
750 mm (~2-1/2’) 500 - 700 mm (~1’7-
1/2” – 2’3-1/2”)
1500 mm (~5’) 700 - 2500 mm (~2-
1/2’ – 8’2-1/2”)
2.3.2 The center tube
Center tube thickness "D" max.
1000 mm (~3’3-3/8”) 0.6 m (~2’)
sl9806e page 9
Technical Data SL
2.4 Design
Fig.aufbau.tif
1) Electric motor or hydraulic motor
2) Drive wheel
3) Crank for rope tension
4) Swivel rack
5) Central reversal pulley, top
6) Forward feed motor electric or hydraulic
7) Extension arm, bottom
8) Central reversal pulley, bottom
9) Deflection pulley, bottom
10) Guiding pulley, bottom
11) Diamond rope
12) Center tube
13) Guiding pulley, top
14) Deflection pulley, top
15) Extension arm, top
page 10 sl9806e
SL Technical Data
2.5 Function with hydraulic drive
Hydraulic drive
2.5.1 Guiding and tightening of rope
The rope is being guided by ...
– the drive wheel (2)
– two central deflection pulleys - top and
bottom (5 and 8),
– two deflection pulleys top and bottom
(9 and 14),
– and by the guiding reels top and bot-
tom (10 and 13).
> which engages with the gearwheel circumfe-
rence at the support.
2.5.3 Rope drive, hydraulic
> When the Main circuit of the drive unit is
opened,
> the sawing motor (1) will turn and will drive
> the drive wheel (2) and thereby
> will drive the rope.
The speed of the rope is determined by...
1) ... the oil flow from the drive unit
2) ...flow intake of the sawing motor
(controllable)
2.5.4 Emergency Stop
The rope is being tightened by ...
> turning the tension spindle (3) clockwise,
> by which the swivel rack (4) tilts outward
> and the diamond sawing rope is being
tightened across the drive wheel (2)
2.5.2 Circular motion /Forward feed,
hydraulic
The movable portion of the system turns around
the center tube (12), when...
> the connected forward feed circuit at the dri-
ve unit is being opened,
> the hydraulic forward feed motor (6) will turn
> and through the transmission gear in front of
the feed motor
The system can only be stopped at the drive unit. Observe
also the Operating Manual of
the drive unit.
> will drive the cogwheel (on the feed transmis-
sion gear)
sl9806e page 11
Technical Data SL
2.6 Funktion electric drive
Electric drive
2.6.1 Guiding and tightening of rope
The rope is being guided by ...
– the drive wheel (2)
– two central deflection pulleys - top and
bottom (5 and 8),
– two deflection pulleys top and bottom
(9 and 14),
– and by the guiding reels top and bot-
tom (10 and 13).
> which engages with the gearwheel circumfe-
rence at the support
2.6.3 Rope drive, electric
> When the main drive unit is switched on at
the electric control,
> the electric sawing motor (1) will run
> and drive the drive wheel (2)
> and thereby the rope.
The speed of the rope is determined by...
1) ...the number of revolutions of the
electric drive motor (not controllable)
2) ...the diameter of the drive wheel
(not controllable)
The rope is being tightened by ...
> turning the tension spindle (3) clockwise,
> by which the swivel rack (4) tilts outward
>and the diamond sawing rope is being
tightened across the drive wheel (2)
2.6.2 Circular motion/Forward feed,
electric
The movable portion of the system turns around
the center tube (12), when...
> the connected forward feed is switched on
at the electric control,
> the electric feed motor (6) runs
> and through the transmission gear (in front
of the feed motor)
2.6.4 Emergency Stop
The system can only be stopped at the electric control unit.
Observe also the Operating Manual of the electric control unit.
> drives the cogwheel (at the feed transmissi-
on gear)
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SL Technical Data
2.7 Protection material
Fig.schutz.tif
1) Splash channel long/short, top (2
pcs. ea.)
2) Splash channel long/short, bottom (2
pcs. ea.)
3) Splash shielding, deflection pulleys
(4pcs.)
4) Splash shielding, tension reel (1 pc.)
2.7.1 Protective provisions
Never start sawing before having all protective devices in
place
sl9806e page 13
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