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Operating instructions en
DS-WSS 30
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ORIGINAL OPERATING INSTRUCTIONS
Contents
General information 3
1. General description and technical data for the DS-WSS 30 wire saw 4
2. General warnings 6
3. Warnings and safety precautions for the DS-WSS 30 wire saw 7
4. D-LP 32 (30) / DS-TS 32 (30) modular saw system 10
5. D-LP 32 (30) / DS-TS 32 (30) / DS-WSS30 modular wire saw system 10
6. Setting up the wire saw system 11
7. Basic applications 14
8. Diamond wire store 19
9. Instructions for connecting Hilti DS-W 10.5 diamond wire 20
10. DS-WSS 30 wire saw system - checks, operation, and sawing procedure 24
11. Care and maintenance 27
12. Troubleshooting 28
13. Disposal of the DS-WSS 30 / D-LP 32 wire saw 32
14. Manufacturer's warranty – tools 33
15. EC declaration of conformity (original) 34
Congratulations!
On purchasing the Hilti DS-WSS 30 wire saw as an addition to the D-LP 32 (30) / DS-TS 32 (30) wall saw system, you
have acquired a quality product that provides the highest level of performance, safety and reliability. Uncompromising
quality assurance during its manufacture ensures that the system will have a long service life.
This manual describes the operating procedures for the DS-WSS 30 only. The saw system functions only in conjunction with the Hilti D-LP 32 hydraulic power unit. Please refer to the D-LP 32 / DS-TS 32 operating instructions for information about operation of the power unit.
These operating instructions are intended for the use of concrete cutting service contractors and their experienced personnel, referred to on the following pages as “the operator”. Before operating the Hilti D-LP 32 (30) / DS-TS 32 (30) /
DS-WSS 30 wire saw system, the operator must read and understand these operating instructions and receive training from a Hilti specialist.
Thanks to its modular design, the DS-WSS30 wire saw system can be quickly and easily fitted to the standard saw
system. Its new design concept, offering maximum convenience and safety in use, opens up an almost endless range
of applications in demolition, cutting and remedial work in steel reinforced concrete, masonry and stone. The variable
oil flow rate of the D-LP 32 (30) / DS-TS 32 (30) wall saw system used to power the wire saw ensures smooth, gentle
starting, and automatic regulation of the wire sawing process and greatly reduces strain on the operator.
This system therefore provides the prerequisites for efficient, economical and safe operation. We would like to wish you
every success in your work and thank you for placing your confidence in Hilti products.
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General information
The operating instructions must be read carefully
before the equipment is put into operation.
Always keep these operating instructions with the
equipment.
The wire saw system should be handed over to
other persons only complete with the operating
instructions.
Safety notices and their meaning
DANGER
Draws attention to imminent danger that will lead to
serious bodily injury or fatality.
WARNING
Draws attention to a potentially dangerous situation
that could lead to serious personal injury or fatality.
CAUTION
Draws attention to a potentially dangerous situation
that could lead to slight personal injury or damage to
the equipment or other property.
NOTE
Draws attention to an instruction or other useful information.
Explanation of the pictograms and other information
General warning Warning:
electricity
Warning:
avoid hand injuries
Wear protective gloves.
Wear safety footwear. Wear respiratory
protection.
Wear ear protection.
Wear eye protection. Wear a hard hat.
Warning signs
Obligation signs
Warning:
Risk of cutting injury
Return waste
material for
recycling.
Read the operating
instructions before use.
Symbols
A
Amps
V
Volts Alternating current
∅
Diameter
W
Watts
Hz
Hertz
n
o
Nominal speed
under no load
mm
Millimeters
/min
Revolutions per minute
rpm
Revolutions per minute
STOP
Stop
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1.2 Single-pair pulley stand
Fastening spindle/nut for rail support or pulley stand
DS-WSSP single-pair pulley stand
Water supply to kerf
DS-WSW 200 guide pulley
DS-WSW 500 drive wheel
DS-WSTA tensioning arm
DS-WSWD wire distributor
DS-WSRP wire length adjustment pulley
DS-WSRF rail support (2×)
Drive wheel guard
Diamond wire guard
DS-WSWS water supply
D-LP 32 (30) power unit
1.1 System
1.2
1. General description and technical data for the DS-WSS 30 wire saw
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1. General description and technical data for the DS-WSS 30 wire saw
1.3 Technical data
DS-DS 30
Drive wheel: 500 mm dia.
Guide pulley: 200 mm dia.
Speed (DS-TS 30, 1stgear): 800 r.p.m.
Cutting speed: approx. 20 m / sec.
Wire store capacity: 8 m diamond wire
Max. diamond wire length: 30 m
D-LP 32 hydraulic power unit
Rated power input at 63A 43 kW
Rated output 32 kW
Rated voltage 400 V / ~ 50 Hz, 3P+N+PE or 3P+PE
Ground fault circuit breaker (30 mA) in mains supply on site
Max. operating pressure 210 bar
Oil flow rate 30–100 l/min
Dimensions (L×W×H) 790×540×1090 mm
Weight 220 kg
IP protection code IP 44
Water cooling with 7 l/min. at max. 6 bar and water temperature 20° C
D-RC-LP32 remote control unit
Control voltage 24 V = (direct current)
Dimensions (L×W×H) 390×180×120 mm
Weight 2.2 kg
IP protection code IP 65
Cable length 10 m
Cable length with extension 20 m
Noise information (measured in accordance with EN 15027)
Wear ear protection!
Mean A-weighted sound power level LwA105 dB (A)
Mean A-weighted emission sound pressure level at the workplace LpA85 dB (A)
Uncertainty for the stated sound level: 3 dB (A)
1.4 Special accessories
Special stand with 140 mm dia. plunging pulley
Release pulley
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2. General warnings
2.1 Don’t attempt to use the hydraulic saw system and DS-WSS 30 wire saw accessory modules without having
received the appropriate training from an authorised Hilti specialist.
2.2 Always use the hydraulic saw system in accordance with the wall saw operating instructions and supplementary
wire saw system operating instructions. The operating instructions must always be kept at hand. The instructions
on anchoring and securing the system must be observed.
2.3 Approval must be obtained from the site engineer or site management before sawing. Sawing work can negatively
affect the stability of a building or other structure, particularly when reinforcing bars or supporting members are
cut through. Ensure that there are no concealed gas, water, electricity or other supply lines in the area in which
sawing work is to be carried out.
2.4 The area in front of, behind or below the surface where sawing work or drilling is to be carried out must be secured
in such a way that persons or equipment cannot be injured or damaged by falling blocks of concrete or by concrete slurry. Where necessary, cores or blocks of concrete should be secured to prevent them from falling.
2.5 Operators and all other persons must stay clear of the area when a load is being lifted by a crane.
2.6 Concrete blocks with a weight of several tons may be sawn out with the Hilti saw. Measures for securing and
transporting these concrete blocks must be planned and implemented. Make use of the steel wedges contained
in the set of tools for securing concrete blocks. Keep the working area clean and tidy and cordon off openings.
2.7 National regulations and laws, as well as the operating instructions and the safety information applicable to
the accessories employed must be observed.
2.8 The D-LP 32 (30) / DS-TS 32 (30) / DS-WSS 30 saw system must NOT be operated in environments where a risk
of explosion exists unless special safety precautions are taken.
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3.1 Make sure sufficient space is available for working safely. If possible, the wire saw should be set up on the floor
in an upright position.
3.2 Check the entire system, accessories, power unit, electric cables, hydraulic hoses and accessories for damage and
proper functioning before use. Wearing parts, accessories and safety-relevant devices, such as the diamond wire
drive wheel, return pulleys, diamond wire and couplings, diamond wire guard and drive wheel guard, end stop,
drive wheel mounting screw, hydraulic couplings, etc., must be checked particularly carefully. Check that all parts
have been assembled correctly and consider all other factors that could influence operation of the equipment.
Contact your Hilti representative or Hilti service centre if faults or deficiencies are found. Repairs to electrical parts
must be carried out by a qualified electrical specialist.
3.3 Metal anchors of M12 size should be used for fastening the DS-WSRF rail support and DS-WSSPP single-pair pulley stand. The fastening used must be suitable for the base material in question and must not work loose. Suitable
Hilti anchors are, e.g. HKD-D, HSA-A, HIT or HEA. If masonry is loose or crumbling, we recommend that through
holes are drilled and M16 threaded rods with clamping nuts used for fastening.
3.4 Fastening screws of at least 8.8 grade as per ISO should be used for the rail supports or, alternatively, use the
DD-CS M12 S-SM clamping spindle with DD-CN-SML quick-release clamping nut.
3.5 An end stop must always be fitted at the end of the rail to prevent unintentional advance beyond this point (prevents the saw head coming off the end of the rail).
3.6 It is essential that the specified checks are carried out before sawing.
3.7 The drive wheel guard (see fig. 3.7, no. 1) and diamond wire guard (see fig. 3.7, no. 2) MUST ALWAYS BE FITTED
when the saw is in use. These guards prevent parts flying out in the direction of tension should the diamond wire
break. NEVER stand in a position in line with the diamond wire while the saw is running.
12
2
1
3.7
3. Warnings and safety precautions for the DS-WSS 30 wire saw
3.8 ■ Safety measures must be implemented in the area where sawing is taking place so that operators and
bystanders cannot be injured or property damaged by a broken sawing wire or debris that may fly off
during the sawing operation (wire connectors, diamond beads, spacing springs, small stones, sawing slurry, etc.). Safety measures must also be implemented in the area not directly visible to the operator, i.e. behind where sawing is taking place.
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■ Persons must NEVER enter the danger area while sawing is in progress.
■ Always keep the free wire lengths between the drive unit and object being cut as short as possible
(max. 3.5 m) and mount guide pulleys at the wire entry and exit points in order to reduce the risk of
whiplash in the event of wire breakage. The whiplash effect causes great acceleration of the sawing
wire, resulting in parts of the wire lashing out or flying off with great force.
■ Make sure there are no objects such as scaffolding etc. within the wire whiplash area. In the event of
wire breakage, the whiplashing end of the wire may be deflected in an unexpected direction by such
objects.
■ The danger area has a radius of at least twice the free length of wire that would be unleashed in the
event of wire breakage (shown in yellow) and also includes the areas in the extended axes of the direction in which the wire is running (shown in gray). The danger area cannot be limited unless suitable
means of protection are employed (protective walls, curtains or wire guards etc.). The protective
devices must be arranged and mounted in a way that stops the wire lashing out in the event of wire
breakage and reliably prevents objects or fragments flying off.
■ The operator is responsible for cordoning off the area. If necessary, safety personnel must be posted
to prevent access to a wide area around the workplace
■ When setting up and operating the saw system and when removing parts that have been cut away,
always ensure that no persons are below the area in which you are working. Falling objects could
cause serious injury.
■ Children must be instructed not to play with the machine.
■ The machine is not intended for use by children, by debilitated persons or those who have received
no instruction or training.
■ Before beginning work, check the working area (e.g. with a metal detector) to ensure that no concealed electric cables or gas and water pipes are present.
External metal parts of the machine may become live if, for example, an electric cable is damaged
inadvertently. This presents a serious risk of electric shock.
3.9 ALWAYS SWITCH OFF THE WIRE SAW BEFORE ADJUSTING THE WATER SUPPLY. Readjustment of the water supply nozzle at the single-pair pulley stand or at any other position while the saw is running, in order to bring it into
line with the diamond wire, is STRICTLY PROHIBITED.
3.10 The wire length adjusting pulley (DS-WSRP wire store) must always be fitted, even when not in use. The flexible
wire guard can then be fitted in accordance with the instructions.
276377 05.06
r2=l2 x 2
l
2
l
1
r
1
=l
1
x 2
3.8
3. Warnings and safety precautions for the DS-WSS 30 wire saw
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3. Warnings and safety precautions for the DS-WSS 30 wire saw
3.11 Never connect or disconnect hydraulic hoses while the power unit is running or while the hoses are under pressure.
3.12 Wear suitable clothing. Don’t wear loose clothing or jewellery which could become caught in moving parts of the
machinery. Wear a hard had, protective goggles, protective gloves, safety shoes, ear protectors and a hairnet if
you have long hair. A face mask should be worn to protect the respiratory system when working in enclosed areas.
3.13 Avoid body positions in which the back is bent when carrying motor units or other heavy components. Maintain
a secure stance and always stay in balance, especially when using ladders or when working from scaffolding.
3.14 Check all screws on the DS-TS 32 (30) saw, tensioning arm, diamond wire guard and drive wheel guard which
could work loose due to vibration.
3.15 Disconnect the electric extension cable from the mains supply when the equipment is not in use, during transport and before inspection or maintenance. Ensure that the hydraulic power unit is switched off before changing
the diamond wire or before adjusting the position of the guide pulleys. As an additional safety measure, it is recommended that the EMERGENCY STOP button is pressed and left in the OFF position.
3.16 Use of the Hilti diamond wire saw system is permitted only in conjunction with the other DS-WSS 30 components
listed in these instructions. The use of individual components for wire sawing, e.g. only the drive wheel, is prohibited as this could present a serious hazard to the operating personnel.
3.17 For further information, please refer to the D-LP 32 (30) / DS-TS 32 (30) operating instructions.
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4. D-LP 32 (30) / DS-TS 32 (30) modular saw system
5. D-LP 32 (30) / DS-TS 32 (30) / DS-WSS30 modular wire saw system
DS-R 230L
DS-TS32
DS-RF
D-PH34-10 (2x)
D-FH4/14-10
DS-RF
D-LP 32
D-RC-LP 32
comprising:
1 D-LP 32 (30)
2 D-RC- LP 32 (DS-CB)
3 D-PH34-10 (2x)
4 D-FH4/14-10
5 DS-RF
6 DS-R 230L
7 DS-TS32 (30)
1
6
5
3
/
4
7
2
2x DS-WS-SPP
7
DS-WSWS
6
2x DS-WSRF
5
DS-WSRP
4
DS-WSWD
3
DS-WSTA
2
DS-WSW500
1
DS-W10.5
7
6
5
7
4
123
DS-WSS30 comprising:
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6. Setting up the wire saw system
6.1 Through-holes for the diamond wire
– Plan the working procedure carefully and precisely before beginning to install the system and before drilling the
through-holes.
– Drill the through-holes for the diamond wire (see fig. 6.1, no. ).
Use a suitable drilling machine, depending on the situation and the base material:
킞 Combihammer TE 70 with 16 mm dia. drill bit
킞 Diamond drilling machine DD 200 with the core bit DD-BS 52
6.2 Fastening to the base material
WARNING
Use an anchor suitable for the material on which you are working and observe the anchor manufacturer’s instructions.
NOTE
Hilti M12 metal expansion anchors are usually suitable for fastening diamond core drilling equipment
to uncracked concrete. Under certain conditions it may be necessary to use an alternative fastening
method. Please contact Hilti Technical Service if you have any questions about secure fastening.
– Rigid and secure fastenings are the basic prerequisite for efficient and safe sawing. We recommend the use of
Hilti drilling and anchoring systems.
– Fasteners suitable for the base material in question should be used to fasten the rail supports and single-pair
pulley stands. For example, a minimum edge distance of 18 cm must be observed when setting the Hilti HKD
M12 metal expansion anchor. As a general rule, this anchor should be set ≥ 5 mm below the surface of the concrete. After drilling the hole, the dust should be blown out.
– Hilti HIT adhesive anchors can be used in masonry etc. or, alternatively, through-holes drilled and threaded rods
used.
6.3 Recommended fastening method using the clamping spindle and clamping nut
For fastening the rail supports and single-pair pulley stands, Hilti recommends use of the HKD-D anchor in conjunction with the double-thread clamping spindle and clamping nut with pivoting baseplate.
Advantages
1. Flexible clamping nut / baseplate provides secure fastening even on uneven surfaces and when anchor holes
are drilled at an angle.
2. Coarse thread pitch for rapid assembly and disassembly
3. The anchor can be set deeper.
6.1 6.2
Clamping nut with pivoting baseplate
Double-thread clamping spindle
Through-hole for the diamond wire
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Accessories for fastening the wire saw and pulley stands
Description Use Package Ordering designation Item no.
contents
Combihammer Drilling anchor holes 1 TE70
000000
Hammer drill bit
Drilling anchor holes 1 TE-YX-16/35
333760
Blow-out bulb Cleaning anchor holes 1 BB
059725
Flush anchor
Fastening the wire saw / pulley stands 50 HKD-D M12x 50
252961
Manual setting tool Expanding the anchors 1 HSD-G M12x 50
243743
Clamping spindle
Fastening the wire saw / pulley stands 1 DD-CS M12 S-SM
251830
Clamping nut Fastening the wire saw / pulley stands 1 DD-CN-SML
251834
Accessories for drilling through holes
Description Use Package Ordering designation Item no.
contents
Combihammer Drilling through holes 1 TE 70
000000
Hammer drill bit
Drilling through holes 1 TE-YX 16/55
333761
Hammer drill bit Drilling through holes 1 TE-YX 16/92
370564
Pointed chisel
Rounding edges of holes 1 TE-YP-SM28
282263
Diamond coring machine Drilling through holes 1 DD 200
000000
Diamond core bit
Drilling through holes 1 DD BS52/430
000000
Extension Drilling through holes 1 11/4" UNC
009850
Diamond coring is recommended for corner holes in very thick walls, in heavily reinforced concrete and where very precise
cuts must be made.
6.4 Recommended fastening set
Advantages
■ Can be set deeper: special HKD-D anchor without collar
■ High holding power: HKD-D M12 metal expansion anchor with 16 mm outside diameter
■ Flexible clamping nut / baseplate for secure fastening even when anchor holes are drilled at an angle or on
uneven surfaces
■ Coarse thread pitch for rapid assembly and disassembly
■ Avoids damage to the baseplate or rail support
6. Setting up the wire saw system
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6. Setting up the wire saw system
DSW-WG wire guards
(Item no. 365426)
Wire guards must be fitted in situations where it cannot be ensured that persons do not enter the area in
which flying objects present a risk of injury while the
equipment is in operation or where there is a risk of
damage to property or other equipment within this
area. When wire guards are used, check to ensure
they are fitted correctly.
DS-WS-SPP single-pair pulley stand
(Item no. 365427)
In applications where, due to restricted access, it is
impossible to mount the compact wire saw directly on
the object to be cut or where longer cuts of up to a
maximum of 2 meters are to be made, the sawing wire
is guided to the cutting face by the pulley stand.
DS-WSRW release pulley
(Item no. 315834
)
The release pulley is used to reduce the length of wire
in contact or to increase the radius of the arc followed
by the wire (avoiding a tight radius) at the rear of the
object to be cut.
DSW-PW plunge wheel
(Item no. 365428)
For plunge applications of all kinds. At least 2 are
required. Can also be mounted on the single-pair pulley stand if necessary.
DS-WSS 30 guard
(Item no. 276388)
DS-WSS 30 guard
(Item no. 276379)
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7.1 Standard vertical cut
– Optimum cutting length
– No tight diamond wire radius in the
concrete
– Average cutting performance
– Normal rate of wire wear
7.2 Vertical cut with release
pulley
1
st
step
– Relatively short cutting / contact
length
– High cutting performance
– High rate of wire wear
Note
When the kerf is at the height of
pulley , the pulley should be
turned and positioned below the
wire.
2
nd
step
Note
At the end of the cut, when the diamond wire is pulled out of the kerf, it
is caught by pulleys and .
– No danger of the wire lashing
back
– Avoids damage to the wire
Note
The optimum cutting length for the Hilti DS-WSS 30 wire saw system is 1 to 4.5 metres, i.e the diamond wire is
in contact with the workpiece over a length of 1 to 4.5 metres.
12
12
12
Water
Water
Water
Water
WaterRelease pulley
Diamond wire
Tension side
Diamond wire
Tension side
Diamond wire
Tension side
Release pulley
7. Basic applications
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7.3 Standard horizontal cut
7.4 Flush horizontal cut
A At the beginning of the cut
Wall saw
Pivoting pulley
with ball-bearing
pivot
Pivoting pulley
with ball-bearing
pivot
7. Basic applications
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Note
In order to prevent the diamond wire from jumping off the pivoting guide pulleys, we recommend that the wire saw
is switched off shortly before completing the cut and that a combihammer is used to break away the small amount
of remaining material.
B At the end of the cut
Pivoting pulley
with ball-bearing
pivot
Pivoting pulley
with ball-bearing
pivot
Side view
Diamond wire
Pivoting pulley
Saw kerf
7. Basic applications
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7.6 Flush cutting
– For flush cutting, the pulleys
with ball-bearing pivot must
always be used. These pulleys
are designed to pivot easily
and follow the movement of
the diamond wire. They can be
easily differentiated from the
type with plain bearings (see
fig. 10.3).
– The pulleys with ball-bearing
pivot should always be positioned at the points where the
diamond wire enters or leaves
the concrete.
7.5 Aligning the guide pulleys
As a general rule, all guide pulleys must be aligned with each other so that the diamond wire always runs in the
middle of the pulley (minimises pulley wear and reduces the risk of the diamond wire jumping off).
Exception
Two guide pulleys on the slack
side, between the wire distribu-
tor pulleys and the pulley stand
at the point the diamond wire
enters the concrete, should be
set up at a slight angle (see fig.
7.5). This assists the diamond
wire to rotate about its own axis
while cutting, thereby achieving
more even wear.
12
Water
Water
Diamond wire
Tension side
7.5
Slack side
7. Basic applications
Pulley with
ball-bearing pivot
Pulley with
ball-bearing pivot
Diamond wire
Clamping screw
Ball bearing
Pivoting pulley
Kerf
Plain bearing
Can be clamped
in position
Clamping screw
Loosen screw
for flush cutting
7.6
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7.7 Wire saw application using plunging pulleys
Note
When cutting over a length of 2–3 m, the plunging pulleys must always be positioned 20 to 30 cm below the
desired depth as a slight curve always remains at the end of the cut.
7.7a
7.7c
7.7b
Special stands
Pivoting plunging pulleys
140 mm dia.
Radius at end of cut
20–30 cm
Desired
depth of cut
Tubular
extension
2ʺ dia.
Tubular
extension
2ʺ dia.
Length of cut
Pivoting pulleys (to saw head)
200 mm dia.
Hole
162 mm dia.
Pivoting plunging pulleys
140 mm dia.
Radius at end of cut
20–30 cm
Tubular
extension
2ʺ dia.
Tubular
extension
2ʺ dia.
Length of cut
Pivoting pulleys (to saw head)
200 mm dia.
Hole
∅ 162 mm
20–30 cm
Radius at end of cut
Length of cut
Tubular
extension
2ʺ dia.
Tubular
extension
2ʺ dia.
Pivoting plunging pulleys
140 mm dia.
Pivoting pulleys (to saw head)
200 mm dia.
7. Basic applications
7.7d
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The built-in return pulley and wire store pulley can be used to reduce the effective length of the diamond wire by up
to 8 m with a rail length of only 2 m (DS-R 200 L).
Important
No matter how the wire saw is set up, the DS-WSRP wire length adjusting pulley must always be fitted and the
diamond wire guard belonging to it attached at the bottom of the drive wheel guard.
Configuration 1
Configuration 2
Configuration 3
Configuration 4
2×1.5 m
2×0.5 m
2×0.5 m
2×1.5 m
= 3 m
+
+
+
= 1 m
= 1 m
= 3 m Total 8 m
Drive wheel guard End stop
Diamond wire guard
Wire length adjusting pulley
2 m rail (DS-R200 L)
8.Diamond wire store
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Cutting direction
Important: The connectors must be fitted, relative to the cutting direction, as shown in the illustration. The
diamond wire must be used to cut in one direction only (see arrows).
Preparations for the first cut
■ Connectors are already fitted to new diamond wires.
■ The diamond wire must be twisted before joining the connectors by inserting the pin. Twist the diamond wire,
approx. 1–1.5 turns per metre length of wire, in a counter-clockwise direction (to the left) as seen when looking straight at the cut face of the end of the wire.
■ The corners on the workpiece should be rounded off to a radius of approx. 10 cm (using a hammer and chis-
el or a Hilti combihammer) and/or the diamond wire pulled through by hand.
■ Mount the water supply nozzle at the point where the wire enters the workpiece. Depending on the length of
the cut, it may be necessary to apply cooling water at several points. It is essential that the wire is cooled
perfectly if good cutting results are to be achieved.
■ Use the advance movement to tighten the wire. Move away from the machine to a safe distance and start the
motor. Start the saw gently and then increase the running speed gradually until the optimum drive speed
(r.p.m.) and cutting speed is reached.
■ The sawing operation must be monitored continuously.
■ The wire saw must be stopped before making adjustments to the water supply nozzles.
General information
■ Do not kink or bend the wire sharply.
■ Do not join diamond wires of different diameters together.
■ To ensure even wear of the beads, the diamond wire must be retwisted after each long cut, applying a dif-
ferent number of turns, before beginning the next cut.
9. Instructions for connecting Hilti DS-W 10.5 diamond wire
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10 mm
13 mm
1
쩸
쩹
2
4
쩺
5
3
1 mm
Instructions for fitting
DS-WC connectors
(Item no. 340427)
Fitting the connector (first
end, clevis piece)
Clamp the diamond wire
in the vice with the cutting direction as shown
(see arrow) and use an
angle grinder to cut off
the end 13 mm from the
first bead.
Use pliers to remove the
spring (pull out).
Remove the rubber neatly
over a length of 10 mm
(using a knife, cigarette
lighter or wire brush).
Fit an O-ring 쩸 (Item no.
235844) pushing it onto
the wire until seated
against the bead. Fit the
clevis piece 쩹 onto the
wire so that the end of the
bare wire section contacts
the base of the hole.
Use the crimping pliers
쩺 (Item no. 235845) and
the corresponding crimping jaws to crimp the
connector fully in one
operation. When doing so, the crimping jaws should be positioned 1 mm from the end of the connector.
Worn or deformed crimping jaws should not be used.
Fitting the connector (second end, opposite piece) and joining the connectors
■ To fit and crimp the second part of the connector (opposite piece) proceed as described at steps to .
■ Joining the connectors
Twist the diamond wire, approx. 1–1.5 turns per metre length of wire, in a counterclockwise direction (to
the left) as seen when looking straight at the cut face of the end of the wire. Bring the connectors together
and insert the pin (item no. 235842) using a hammer to drive it in flush.
Opening the connectors
■ Use a punch to drive the pin out of the connector. Replace the pin if it is badly worn (replacement pin, item
no. 235842).
9. Instructions for connecting Hilti DS-W 10.5 diamond wire
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Instructions for fitting
DS-WS repair sleeves
(Item no. 235841)
Fitting a repair sleeve (first
end)
Important: The service life of
the connectors is several
times that of the repair sleeve.
Clamp the diamond wire
in the vice and use an
angle grinder to cut off
the end 13 mm from the
first bead.
Use pliers to remove the
spring (pull out).
Remove the rubber neatly
over a length of 10 mm
(using a knife, cigarette
lighter or wire brush).
Fit an O-ring 쩸 (Item no.
235844) pushing it onto
the wire until seated
against the bead. Fit a
repair sleeve 쩺 onto the
wire so that the end of the
bare wire section contacts
the base of the hole.
Use the crimping pliers
쩺 (Item no. 235845) and
the corresponding
crimping jaws to crimp
the connector fully in oneoperation. When doing so, the crimping jaws should be positioned 1 mm from
the end of the connector. Worn or deformed crimping jaws should not be used.
Fitting a repair sleeve
(second end)
■ Proceed as described at steps to .
■ Twist the diamond wire, approx. 1–1.5 turns per metre length of wire, in a counterclockwise direction (to the
left) as seen when looking straight at the cut face of the end of the wire.
■ Proceed as described at steps to .
ED
CA
E
D
C
B
A
13 mm
A
B
10 mm
C
쩸
쩻
D
쩺
E
9. Instructions for connecting Hilti DS-W 10.5 diamond wire
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Hilti sawing wires and accessories
Special wires
(electroplated beads)
Standard diamond wires
(sintered beads)
DS-W10.5 diamond wires
Hilti DS-W10.5 diamond wires for DS-W 15, DS-WS 30 and DS-WS10 wire saw systems
Designation
Wire length DS-W 10.5 BC DS-W 10.5 LC DS-W 10.2 steel 20% DS-W 10.8 steel 100%
(m)
10 m 235835 * 235834 * – –
14 m 235836 * 235838 * 376982 371987
18 m 315019 * 315020 * 371983 371988
22 m 315022 * 315023 * 371984 371989
26 m 315025 * 315026 * – –
30 m 315028 * 315029 * – –
50 m 370500 376630 371985 371990
100 m 370426 376631 371986 371991
150 m 376633 376632 373130 –
per/m 376635 376634 377830 377781
* with factory-fitted flexible connectors
Recommendations: Which specification for which material?
Material
Desired characteristics
Reinforced concrete
Fast cutting Long life – –
Heavily reinforced
concrete
Solid steel
BC LC Steel 20% Steel 100%
Accessories for Hilti diamond wires
Designation Use Package Ordering designation Item no.
contents
Crimping pliers For crimping connectors / repair sleeves 1 DS-WSTHY
235845
Flexible connectors
Quick-release type 1 DS-WCMV
340427
Set of flexible connectors* Quick-release type with pin and O-ring 5 DS-WCSet
371383
Pin
Replacement pin for quick-release connectors 10 DS-WP
235842
Sleeve Repair sleeve 5 DS-WS
!
235841
O-ring
Fitted between connector and bead 10 O-ring 10/4.7×2.5
"
235844
Crimping jaws Replacement jaws for crimping pliers 2 DS-WJ
#
340426
Angle grinder
For cutting diamond wire 1 AG 125-S
$
000000
* Includes a special tool for opening the flexible connector
"
!
#
$
9. Instructions for connecting Hilti DS-W 10.5 diamond wire
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10.1 Checks before sawing
– The rail supports and guide pulley stands must be correctly fastened (all screws tightened securely.
– The saw head must be mounted without play, the saw arm in the vertical position (at 90° to the rail), the cam-
action rollers engaged (DS-TS 30 1
st
gear).
– The wire tensioning pulley and drive wheel guard must be fitted and secured in position with the clamping
screw at the side of the blade guard holder.
– The drive wheel must be fitted and secured with the standard saw blade flange and central mounting screw.
– The drive wheel guard cover must be fitted.
– The wire distributor assembly must be fitted at the front end of the rail using the standard rail taper and eccen-
tric pin.
– The end stop must be fitted at the rear end of the rail.
– The wire length adjusting pulley and rolled-up diamond wire guard must be fitted and the rubber diamond wire
guard attached to the drive wheel guard.
– The hydraulic hoses and water hoses must be connected correctly. (The two control hoses for the saw arm
plunge movement do not have to be connected as only the longitudinal advance movement is required for wire
sawing.)
– Electric power and water must be available. The EMERGENCY STOP buttons on the hydraulic power unit and
remote control unit must be disengaged (pulled out) and all controls on the electric remote control unit set to
the OFF / 0 or neutral position.
– The working area must be cordoned off. All safety distances must be observed.
– The diamond wire must be connected correctly, aligned properly and it must be possible to pull the wire through
easily by hand.
32-50 A
D-RC-LP 32
Start
Ampere
II
I
32 63
45
100
1
6
0
0
1
2
0
0
1
0
0
0
9
0
0
8
0
0
m
m
60
40
80
10. DS-WSS 30 wire saw system - checks, operation and the sawing procedure
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10.2 Remote control unit: controls
Pos.1: Electric motor ON (I 킞 II 킞 Start 킞 Release 킞 II)
Electric motor OFF (II 킞 I)
Pos.2: Hydraulic oil flow rate 0 –100 l / min. (controls speed of diamond wire drive wheel)
Pos.3: Plunge movement (right / left). As the control hoses necessary for this function may not be connected to
the wall saw when used for wire sawing, this rotary switch has no function.
Pos.4: Advance (right / left, diamond wire tension / release tension)
Pos.5: Speed of advance for (4)
Pos.6: Power input setting in amps, depends on mains supply
Pos.7: EMERGENCY STOP button
10.3 Remote control unit: starting and operating the saw system
1. Adjust the current (6) to a value between 32 amps and approx. 50 amps depending on the mains supply available on the jobsite.
2. Switch on the water supply.
3. Knobs (3), (4), (5) and (7) should be set to the «0» (neutral position). Switch on the electric motor (1) and check
that the hydraulic unit switches from star to delta ( takes approx. 2–5 seconds).
4. Use the longitudinal advance control (4) to select the correct direction of movement for wire tension and use the
advance speed control (5) to tension the diamond wire slightly.
5. Use the potentiometer (2) to start the drive wheel motor slowly and, at the same time, adjust the advance speed
control knob (5) in order to maintain or increase tension on the diamond wire.
As soon as the diamond wire is running correctly, the speed of the drive wheel can be increased to maximum,
by adjusting the potentiometer (2). This corresponds to a speed of 800 r.p.m. The cutting speed of the diamond
wire is then 20 m / sec.
Subsequently, only the advance speed control (5) requires adjustment in order to control the diamond wire tension and, thus, the sawing performance. A visible indication of correct tension is given by the wire tensioning arm,
which should rise approx. 10 to 15 cm.
The saw should be operated at a pressure of approx. 120 bar (max. 140 bar) in the main hydraulic circuit in order
to achieve optimum sawing performance without excessive strain on the diamond wire.
D-RC-LP 32
Start
Ampere
II
I
32 63
45
1
0
0
1
6
0
0
1200
1000
9
0
0
800
m
m
8
0
6
0
40
3 4 7 8 9 2
6 1 10 5
10. DS-WSS 30 wire saw system - checks, operation and the sawing procedure
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Once initially set, the system regulates itself by way of the automatic advance system. This means that when the diamond wire encounters heavy reinforcement, the drive unit advance speed is reduced automatically until the reinforcement is cut trough. The rate of advance then returns automatically to the speed previously set.
10.4 Switching off the saw system
1. Switch off the saw advance control – turn the knob (4) to the “0” or neutral position
2. Switch off the drive wheel motor – turn the knob (2) to the “0” position.
3. Switch off the electric motor – turn the knob (1) to the “I” position.
4. Press the EMERGENCY STOP button.
10. DS-WSS 30 wire saw system - checks, operation and the sawing procedure
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CAUTION
Disconnect the supply cord plug from the power outlet.
CAUTION
Keep the machine, especially its grip surfaces, clean and free from oil and grease. Do not use cleaning agents
which contain silicone.
11.1 Cleaning using high-pressure or steam-cleaning systems
Avoid directing the jet towards the bearings and seals when systems of this kind are used for cleaning the guide
pulley stands and saw head.
11.2 Maintenance of the single-pair pulley stand
As the guide pulleys used for flush cutting are
equipped with two ball bearings at the pivot, these
should be lubricated at least once a month.
Procedure: Unscrew the locking bolt completely and
inject a little oil into the threaded opening. Reinsert
the bolt (see fig. 11.2).
11.3 Rubber rim on the pulleys
The rubber rim on the drive wheel and guide / return pulleys should be checked at regular intervals. A wheel or
pulley should be replaced as soon as the aluminium beneath the rubber is visible (rubber worn through).
11.4 Diamond wire guard and drive wheel guard
These parts should be cleaned daily and checked to ensure that the rolling-up mechanism of the diamond wire
guard always functions correctly.
11.5 Maintenance of the hydraulic power unit, saw head and other saw modules
Please refer to the D-LP 32 (30) / DS-TS 32 (30) operating instructions.
11. 2
Locking bolt
11. Care and maintenance
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Solution / measures
– Use a Hilti combihammer to break
away sharp corners and ensure
that the diamond wire can be
moved to and fro initially by hand.
– Use the worn wire to finish the
cut.
– Drill an additional hole where
the new wire can be pulled
through.
– Additional guide pulleys must be
installed.
– Reduce wire tension by adjusting
the saw head advance (observe
the tensioning arm).
– Increase wire tension by adjusting
the saw head advance.
(Observe the tensioning arm.)
– Adjust the guide pulleys to increa se
the length of contact between the
wire and drive wheel perimeter.
– Additional guide pulleys must be
installed.
– Replace the drive wheel.
– Twist the wire in a counter-clock-
wise direction (as seen when looking straight at the cut end of the
wire) approx. 1–1.5 turns for each
metre length of wire.
– The wire must be retwisted after
each large cut by applying a different number of turns.
Problem
1. The diamond wire does not run.
2. The diamond wire slips on the
drive wheel.
3. The diamond wire is badly worn,
irregularly and on one side.
Possible cause
– Corners on concrete too sharp
– A new diamond wire is being used
in a cut made by a worn diamond
wire.
– The section of diamond wire in con -
tact with the concrete is too long.
– Excessive tension on the diamond
wire
– Insufficient tension on the diamond
wire
– Insufficient length of contact bet -
ween the wire and drive wheel
perimeter.
– The section of wire in contact with
the concrete is too long.
– The rubber rim on the drive wheel
is too badly worn.
– Diamond wire not twisted before
coupling the ends together
Persons may enter the danger zone only when the
drive unit is switched off and the drive pulley has stopped rotating. Press the EMERGENCY STOP button
before entering the danger zone.
Disconnect the equipment from the electric supply
(unplug the supply cord from the power outlet) before
opening the control unit.
12. Troubleshooting
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Solution / measures
– The guide pulleys on the slack side
of the wire between the wire distributor and the pulley stand, at the
point where the diamond wire enters
the concrete, should be set at a
slight angle. This causes the diamond wire to rotate when running.
– Set up as explained above
(see fig. 12.3).
– Increase the distance between the
wire distributor pulleys and the
single-pair pulley stand at the point
where the diamond wire enters the
concrete (see fig. 12.4).
– Reduce the wire tension by adjust-
ing the saw head advance.
Solution / measures Possible cause
– Guide pulleys at the slack side of
the wire not
set at an angle
12
12
12 .3
12 .4
Water
Water
Water
Water
Slack side
Diamond wire
Tension side
Diamond wire
Tension side
RIGHT!
WRONG!
12. Troubleshooting
– Guide pulleys set at the wrong
angle therefore counteracting the
desired twist
– The slack side of the diamond wire
is too short.
– The saw is operated with the
diamond wire under excessive
tension.
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Solution / measures
– Install additional guide pulleys.
– Reduce the wire tension by adjust-
ing the saw head advance. Don’t
exceed the specified pressure of
120–160 bar in the main hydraulic
circuit.
– Fit shorter wire couplings.
– Use the cardan-type, flexible cou-
plings recommended by Hilti.
– Check the setting of the crimping
pliers.
– Use Hilti crimping pliers with a
minimum pressure of 7 t.
– Check the crimping jaws and
replace if necessary.
– With all couplings available
from Hilti, the wire must always
be pushed in as far as it will
go.
– Reduce the wire tension by adjust-
ing the saw head advance.
– Increase wire tension by adjusting
the saw head advance.
– Install additional guide pulley
stands.
– Fit a shorter diamond wire.
– The front rail support (at the wire
distributor) should be fitted as
close as possible to the end of the
rail.
Problem
4. The wire breaks immediately
beside the coupling
5. The diamond wire is pulled out of
the crimped coupling.
6. The diamond wire thrashes about
and vibrates badly.
Possible cause
– The cutting radius of the diamond
wire in the concrete is too small.
– The wire has been used too long
under excessive tension.
– The wire coupling is too long.
– Crimping pliers incorrectly adjusted
– Insufficient pressure applied to the
crimping pliers
– Incorrect or worn crimping jaws
– The wire was not pushed far
enough into the coupling.
– Constantly excessive wire tension
during operation.
– Insufficient wire tension
– The pulley stands are too far apart
(excessively long unsupported wire
length).
– Rail support incorrectly positioned
12. Troubleshooting
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Solution / measures
– Reduce the wire tension by adjust-
ing the saw head advance.
– Reduce speed
– Ensure that the speed potentiome-
ter on the remote control unit is set
to max.
– Install more water jets at the cut-
ting face.
– Increase the length of cut.
– Reduce the wire tension by adjust-
ing the saw head advance.
– Select a different diamond wire
specification.
– The diamond wire should be
installed so that it always runs in
the same direction, as specified.
– Always ensure that sufficient water
reaches the cutting face.
– Steel wedges must be used to pre-
vent movement of the concrete
sections.
– Any loose fragments or aggregates
must be removed from the kerf.
– Also refer to the D-LP 32 /
DS-TS 32 diamond wall saw
system operating instructions.
Problem
7. The diamond wire vibrates fiercely
and at a high frequency.
8. Diamond wire wear is excessively
high.
9. The diamond wire collapses.
(The diamond beads, connecting
pieces and separating springs are
bunched together on the wire.)
10. For information on finding and
eliminating faults in the
D-LP 32 (30) / DS-TS 32 (30)
wall saw system.
Possible cause
– Excessive wire tension
– Speed (r.p.m.) of the drive wheel is
too high.
– Drive wheel running too slowly.
The cutting speed of the diamond
wire is thus also too low.
– Inadequate cooling of the diamond
wire
– Length of cut too short
– Wire tension is too high in relation
to the length of cut.
– Very abrasive base material
– The direction of movement of the
wire is changed constantly.
– Inadequate cooling or no cooling of
the diamond wire
– The diamond wire becomes stuck
in the kerf and stalls during sawing.
12. Troubleshooting
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Only for EU countries
Do not dispose of electric tools together with household waste material!
In observance of European Directive on waste electrical and electronic equipment and its implementation in
accordance with national law, electric tools that have reached the end of their life must be collected separately
and returned to an environmentally compatible recycling facility.
13. Disposal
Most of the materials from which Hilti appliances are manufactured can be recycled.
The materials must be correctly separated before they can be recycled. Hilti has already made arrangements in
many countries for taking back your old appliance for recycling. Please ask your Hilti customer service department or a Hilti sales representative for further information.
Return waste material for recycling
Disposal of drilling and sawing slurry
NOTE
With regard to environmental aspects, allowing drilling or sawing slurry to flow directly into rivers, lakes or the sewerage system without suitable pre-treatment is problematical.
In addition to the following recommended pretreatment procedures, the applicable national regulations must be observed when disposing of drilling or sawing slurry. Ask the local authorities concerned for further information.
We recommend the following pre-treatment
1. Collect the drilling and sawing slurry (e.g. using a suitable industrial vacuum cleaner).
2. The fine content of the drilling and sawing slurry should be separated from the water by allowing it to settle (e.g.
leave standing for some time or add a coagulation agent).
3. Solid material from the drilling and sawing slurry should be deposited at a construction waste disposal site.
4. Water from the drilling and sawing slurry should be neutralized (e.g. by adding a large quantity of water or other neutralization agents) before it is allowed to flow into the sewerage system.
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Please contact your local Hilti representative if you have questions about the warranty conditions.
14. Manufacturer's warranty – tools
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15. EC declaration of conformity (original)
Description: Hydraulic saw system
Designation: DS-WSS 30 / D-LP 32
Year of design: 2001
We declare under our sole responsibility that this product complies with the following directives and standards:
until 19th April 2016: 2004/108/EC, from 20th April 2016: 2014/30/EU, 2006/42/EC, 2011/65/EU,
EN 60204‑1, EN 12100.
This equipment complies with the applicable standard provided that the short-circuit power S
SC
at the interface point between the user’s supply and the public supply network is greater than or equal to 3.2 MVA. It is
the responsibility of the installer or user of the equipment to ensure, by consultation with the supply network
operator if necessary, that the equipment is connected only to a supply with a short-circuit power S
SC
of
greater than or equal to 3.2 MVA.
Technical documentation filed at:
Hilti Entwicklungsgesellschaft mbH
Zulassung Elektrowerkzeuge
Hiltistrasse 6
86916 Kaufering
Deutschland
Hilti Corporation, Feldkircherstrasse 100, FL-9494 Schaan
Paolo Luccini Johannes Wilfried Huber
Head of BA Quality and Process Management Senior Vice President
Business Area Electric Tools & Accessories Business Unit Diamond
06 / 2015 06 / 2015
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*315911*
315911
Hilti = registered trademark of Hilti Corp., Schaan
en I 20150922
Hilti Corporation
LI-9494 Schaan
Tel.: +423 /234 2111
Fax: +423 /234 2965
www.hilti.com
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