ICS CWS-200 Operator's Manual

CWS-200

CHAIN WALL SAW

OPERATOR’S MANUAL

TABLE OF CONTENTS

TITLECWS-200 OPERATOR’S MANUAL

INTRODUCTION

This manual outlines the operation and basic maintenance of the ICS® CWS-200 Chain Wall Saw.

The CWS-200 combines ICS® Diamond Chain Technology (DCT™) with a mechanized, trackmounted and hydraulic powered design for use by Professional Sawing & Drilling Contractors.

To achieve the maximum benefit from your machine and to ensure safe operation, please read this manual thoroughly and periodically review the safety instructions.

PRIMARY COMPONENTS 4

SYMBOLS & LABELS 5

SAFETY 6

TECHNICAL SPECIFICATIONS 8

MACHINE REFERENCES & SET-UP 9

OPERATION 13

MAINTENANCE 17

TROUBLESHOOTING 19

3

PRIMARY COMPONENTS

TITLE CWS-200 OPERATOR’S MANUAL

PRIMARY MACHINE COMPONENTS

WATER SUPPLY

VALVE KNOB

ROTATION CONTROLS

HANDLE FRAME

GUARD CLAMP BRACKETS

TRAVERSE CONTROLS

HYDRAULIC HOSE CONNECTIONS

TR AVERSE CARRIAGE

WARNING LABEL LOCATIONS

GUARD ENCLOSURE

SIDE COVERSIDE COVER BASE

WARNING

• Do NOT exceed hydraulic flow of 25 gpm (95 lpm) at 2500 psi (172.5 bar) hydraulic pressure.

1

• Do NOT operate the machine if the work piece, rail and/or machine are not properly supported and secured.

• Do NOT operate with machine directly over head.

• ALWAYS disengage the machine from the rail before repositioning or removing.

• Fluids escaping under pressure can penetrate the skin.

• Failure to observe these precautions can result in serious injury.

F/N 541813

F/N 541814

WARNING

Valve Knob must be in

2

4

center “OFF” position

before powering on

hydraulic supply.

WARNING

F/N 541812

• Do NOT operate the machine without side cover or guard enclosure installed.

• Do NOT tension chain, install or remove guide bar, chain or side cover without powering off hydraulic supply.

• Failure to observe these precautions can result in serious injury.

3

SYMBOLS & LABELS

TITLECWS-200 OPERATOR’S MANUAL

THE FOLLOWING SYMBOLS AND DEFINITIONS ARE FOUND THROUGHOUT THIS MANUAL AND ARE DESIGNED TO MAKE YOU AWARE OF POTENTIAL HAZARDS OR UNSAFE PRACTICES

WARNING

could result in death or serious injury.

A potentially hazardous situation exists which, if not avoided,

CAUTION

may result in minor or moderate injury or property damage.

THE FOLLOWING SYMBOLS & LABELS MAY BE FOUND IN THIS MANUAL OR ON THE MACHINE

Read the operator’s manual carefully and understand the contents before you use this equipment.

Always use:

• Protective helmet

• Ear protection

• Protective glasses or full face protection

Wear hand protection

1 2

WARNING

• Do NOT exceed hydraulic flow of 25 gpm (95 lpm) at 2500 psi (172.5 bar) hydraulic pressure.

• Do NOT operate the machine if the work piece, rail and/or machine are not properly supported and secured.

• Do NOT operate with machine directly over head.

• ALWAYS disengage the machine from the rail before repositioning or removing.

• Fluids escaping under pressure can penetrate the skin.

• Failure to observe these precautions can result in serious injury.

F/N 541813

WARNING

Valve Knob must be in

center “OFF” position

before powering on

hydraulic supply.

F/N 541812

3

WARNING

• Do NOT operate the machine without side cover or guard enclosure installed.

• Do NOT tension chain, install or remove guide bar, chain or side cover without powering off hydraulic supply.

• Failure to observe these precautions can result in serious injury.

F/N 541814

5

TITLE CWS-200 OPERATOR’S MANUAL

SAFETY

THE FOLLOWING SYMBOL APPLIES TO ALL THE ITEMS LISTED ON THIS PAGE

WARNING

could result in death or serious injury.

• Do NOT operate the machine with loose, modified, missing or damaged side cover, side cover base or guard enclosure. (To perform flush cutting, temporary removal of the side cover and guard enclosure may be necessary.)

• ALWAYS use the extended speed wrench to operate the rotation and traverse controls.

• Do NOT operate the machine with modified, missing or damaged components. Prior to operation, check that the machine is in full working order.

• Do NOT exceed hydraulic flow of 25 gpm (95 lpm) at 2500 psi (172.5 bar) hydraulic pressure.

• Do NOT power on the hydraulic supply without making sure the Valve Knob is in the center “OFF” position.

• Do NOT tension chain, install or remove guide bar, diamond chain or side cover without powering off hydraulic supply.

• ALWAYS disconnect the hydraulic hoses from the machine if not in use and prior to performing maintenance or service.

A potentially hazardous situation exists which, if not avoided,

• Do NOT operate the machine if the work piece, rail and/or machine are not properly supported and secured.

• Do NOT operate with the machine directly over head.

• ALWAYS disengage the machine from the rail before repositioning or removing.

• Fluid escaping under pressure can penetrate the skin.

6

TITLECWS-200 OPERATOR’S MANUAL

SAFETY

THE FOLLOWING SYMBOL APPLIES TO ALL ITEMS LISTED ON THIS PAGE

CAUTION

may result in minor or moderate injury or property damage.

• ALWAYS closely inspect the machine for worn, damaged or broken components that may have occurred during use or due to an accidental impact or drop.

• Do NOT operate the machine if the diamond chain, guide bar and/or drive sprocket show evidence of significant wear or damage. Replace if necessary.

A potentially hazardous situation exists which, if not avoided,

• ALWAYS use genuine ICS

®

repair and replacement parts.

• Do NOT modify the machine or use components from other machines.

• ALWAYS ensure at least 20 psi (1.5 bar) water pressure is supplied to the machine.

• Avoid inserting the diamond chain into a slot narrower than the diamond segments. Ref: The diamond segments used for the CWS-200 are .245" (6.45 mm) wide.

• ALWAYS complete the pre-cut checklist prior to each use (refer to p. 12).

• ALWAYS wear protective clothing, including hard hat, eye protection, hearing protection, and appropriate gloves and boots.

• Avoid loose fitting clothing.

• NEVER use equipment that is poorly maintained or not functioning properly.

• ALWAYS operate and/or lift the machine with solid footing and proper positioning.

• Remove or control slurry to prevent slippery conditions in the working area.

• ALWAYS check for and remove any obstructions (plumbing, electrical conduit, air ducts, etc.) that may interfere with the cut.

• Do NOT allow unnecessary bystanders within the working area.

• Set up a well-marked, properly organized working area with a roped boundary and clear signs.

• ALWAYS ensure adequate ventilation when working in an enclosed area.

7

TECHNICAL SPECIFICATIONS

TITLE CWS-200 OPERATOR’S MANUAL

CWS-200 SPECIFICATIONS

BASE MACHINE W/OUT

BAR, CHAIN, & GUARD

12" GUARD 9 lbs (4 kg)

18" GUARD 11 lbs (5 kg)

HYDRAULIC SUPPLY 25 gpm (95 lpm) @ 2,500 psi (172.5 bar)

TORQUE 284 in-lbs (32 Nm)

HORSEPOWER 36.5 hp (27.2 kW)

WATER S U PPLY Minimum 20 psi (1.5 bar)

OPERATING SPEED 8,100 rpm (avg. free running)

75 lbs (34 kg)

8

GUIDEBAR AND DIAMOND CHAIN INSTALLATION

REFERENCES & SET-UP

TITLECWS-200 OPERATOR’S MANUAL

STEP 1 Loosen the side cover knob and pivot the clamp stud forward to disengage from the side cover base. Remove the side cover.

STEP 2 Loosen the guide bar clamp nut a couple of turns.

STEP 3 Slide the guide bar between the bar pad plate and the clamp plate until the tail of the guide bar engages with the alignment pins.

STEP 4 Turn the tensioning knob counter clockwise until the guide bar nearly contacts the drive sprocket.

9

REFERENCES & SET-UP

TITLE CWS-200 OPERATOR’S MANUAL

GUIDEBAR AND DIAMOND CHAIN INSTALLATION

STEP 5 Mount the chain on the guide bar starting at the drive sprocket and continuing over the guide bar nose.

STEP 6 Ensure all of the drivelinks are engaged in the guide bar groove and turn the tensioning knob clockwise to tension the chain. Do not over tension the chain. The chain should be snug, but should be able to be pulled around the guide bar by hand.

STEP 7 Firmly tighten the guide bar clamp nut using a 3/4" open-ended wrench.

STEP 8 Re-install the side cover, first by orienting the side cover at a slight forward leading angle and inserting the side cover hinge bar on to the side cover base locating pins. Then rotate the side cover down on to the side cover base. Pivot the clamp stud rearward allowing it to ‘hook’ under the side cover base. Firmly tighten the side cover knob by hand. Before operation, ensure the side cover is properly secured.

10

MACHINE FIT-UP TO 360 RAIL

REFERENCES & SET-UP

TITLECWS-200 OPERATOR’S MANUAL

STEP 1 Prior to installing the machine on the rail, ensure the (4) lower retractable rollers on the traverse carriage are in the outward position. Place the machine on the rail and while maintaining full support, push the (4) lower retractable rollers inward to secure the machine to the rail.

STEP 2 To adjust the machine to the side of the rail, loosen the cap screws securing the (2) adjustable side rollers on the traverse carriage (motor side). Using an open-ended wrench turn the adjustable side rollers until making light contact with the rail. After completing the adjustment, retighten the cap screws.

STEP 3 To adjust the machine to the underside of the rail, loosen the cap screws clamping the (4) retractable rollers to the traverse carriage. Turn the entire body of the retractable rollers until making light contact with the underside of the rail. After completing the adjustment, retighten the cap screws.

ALWAYS ensure the machine is adequately secured to the rail before operation. The machine should travel freely along the rail with use of the traverse controls. Play between the machine and the rail should be minimal, but still allow for easy installation and removal.

11

REFERENCES & SET-UP

TITLE CWS-200 OPERATOR’S MANUAL

GUARD INSTALLATION

STEP 1 To install the guard enclosure on the machine, align with the guide bar and insert the guard frame into the guard clamp brackets.

STEP 2 Hold the guard enclosure in position and firmly tighten the guard knob. Before operation, ensure the guard enclosure is properly secured.

STEP 3 ALWAYS ensure the guard enclosure is positioned and oriented properly to the guide bar during

operation.

12

OPE R ATION

TITLECWS-200 OPERATOR’S MANUAL

PRE-CUT CHECKLIST

• Verify proper chain tension and that the guide bar clamp nut is firmly tightened.

• Ensure the side cover and guard enclosure are properly secured and in good working condition.

• Be sure that any obstructions (plumbing, electrical conduit, air ducts, etc.) that may interfere with the cut are removed or avoided.

• ALWAYS wear protective clothing including; hard hat, eye protection, hearing protection, appropriate gloves and boots, and avoid loose fitting clothing.

• ALWAYS ensure at least 20 psi (1.5 bar) water pressure is supplied to the machine.

• Do NOT exceed hydraulic flow of 25 gpm (95 lpm) at 2500 psi (172.5 bar) hydraulic pressure.

• Do NOT power on the hydraulic supply without making sure the Valve Knob is in the center “OFF” position.

• Ensure the rail is properly secured to the work piece and that it is positioned correctly to the cut line. (This machine uses the same cut line offset from the rail as a 360 Wall Saw.)

6.5"

5.5"

13

TITLE CWS-200 OPERATOR’S MANUAL

OPE R ATION

OPERATING REFERENCES

• The valve knob is off when it is in the center position. Turn the knob clockwise and the motor will energize, but will stop when the knob is released. Turn the knob counter clockwise to the detented “ON” position and the motor will energize and remain so when the knob is released. To stop the motor, rotate the knob back clockwise to the center “OFF” position.

• Both manual rotation and traverse controls have two operation speeds. Commonly, “SLOW” is best suited for the cutting operation and “FAST” is used to rapidly re-position the guide bar or machine.

VALVE KNOB

ON

OFF

PULSE

SLOW

ROTATION

FAST

SLOW

TRAVERSE

FAST

MANUAL MACHINE CONTROLS

14

TITLECWS-200 OPERATOR’S MANUAL

OPE R ATION

OPERATION GUIDELINES

• Avoid pinching by cutting bottom of opening first.

• Rotate saw head to plunge cut into the wall.

• For straightest cuts use the “Angled Bar” method. Long traverse cuts can be completed in a single pass as long as the bar is rotated to the greatest angle possible while maintaining a full depth cut.

• Once near a corner, rotate the saw head perpendicular to wall to square the finished corner.

Note: The guard enclosure is not shown for purposes of clarity.

STEP 1 Mount to track.

STEP 2 Rotate 45°.

STEP 3 Traverse in direction of cut maintaining 45° angle. Do not apply excessive feed load.

45°

STEP 4 Rotate final 45° to complete cut/corner or traverse unit back from corner, rotate the final 45°, and traverse unit through remaining corner area to be cut.

15

TITLE CWS-200 OPERATOR’S MANUAL

OPE R ATION

FEED LOAD & CHAIN SPEED

Excessive feed load can lead to premature guidebar wear and undesirable diamond segment wear patterns, which may reduce straightness of cut.

• Apply moderate pressure to the manual controls and maintain steady chain speed to achieve optimum cutting performance.

• Do not attempt to operate both rotation and traverse controls at the same time, as this increases the likelihood of overloading.

• Reduce pressure applied to the manual controls if "screeching" sound is generated, as this is a sign of overloading.

• Use lighter feed load with a new chain until the diamonds are exposed.

For indicators of excessive feed load, please reference the Troubleshooting section, page 19.

16

SYSTEM CLEAN-UP

• After cutting, thoroughly wash the slurry from the machine.

Do not use high pressure washer

• Remove the guide bar and chain from the machine. Clean the chain tensioner mechanism and bar clamp area thoroughly.

• After cleaning, apply light weight oil to the machine, guide bar, chain, etc.

FREQUENT MAINTENANCE & INSPECTION

• Using the zerk fittings, gently apply grease (use Mobilgrease XHP 222 or equivalent) to all of the guide rollers on the traverse carriage.

TITLECWS-200 OPERATOR’S MANUAL

MAINTENANCE

• Closely inspect the machine for worn, damaged or broken components that may have occurred during use or due to an accidental impact or drop.

• Inspect the diamond chain, guide bar and/or drive sprocket for evidence of significant wear or damage. Replace if necessary.

17

TITLE CWS-200 OPERATOR’S MANUAL

MAINTENANCE

DRIVE SPROCKET REMOVAL

• To prevent the drive sprocket from rotating during removal, insert a screw driver into the slot(s) of the drive sprocket and align with the hole in the saw head base plate.

• Remove the (4) cap screws from around the periphery of the drive sprocket and remove it from the mounting hub. It is not necessary to remove the center cap screw.

DRIVE SPROCKET INSTALLATION

• Install the drive sprocket on to the hub adapter.

• Apply Loctite 242 Thread Locker to the (4) cap screws and tighten firmly. Again, use a screw driver to prevent rotation of the drive sprocket during assembly.

18

CWS-200 OPERATOR’S MANUAL

PROBLEM Possible Cause

Diamonds not exposed

POOR CUTTING SPEED

Hydraulic flow rate too low

Inadequate water pressure

CHAIN STRETCH

Hydraulic flow rate > 25 gpm (95 lpm)

Guide rollers improperly adjusted or damaged

MACHINE DIFFICULT TO TRAVERSE

Slurry build-up on rail or machine gearing

Guide bar ports plugged with debris

WATER NOT FLOWING

Water hose kinked or damaged

Hydraulic flow rate

MOTOR WON’T TURN

Hydraulic flow in incorrect direction

TROUBLESHOOTING

STRAIGHTNESS OF CUT

GUIDEBAR RAIL CHIPPING

UNEVEN GUIDEBAR RAIL WEAR

UNEVEN SEGMENT WEAR

Excessive feed load

Call 800.321.1240 or visit our website at: icsbestway.com

Further questions?

19

CWS-200 OPERATOR’S MANUAL

ICS, Blount Inc.

4909 SE International Way

Portland, OR 97222

Tel 800.321.1240 Fax 503.653.4393

icsbest way.com

ICS CWS-200 Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual