Hilti DS WS10 User manual

Operating instructions en
DS WS10/
DS WS10-E
Printed: 08.07.2013 | Doc-Nr: PUB / 5069736 / 000 / 01

Contents
1. General information 4
2. Description 5 11
3. Accessories 13 17
4. Technical data 19 24
5. Safety instructions 25 30
6. Preparations at the workplace 31 35
7. Setting up the saw system 37 44
8. Operation and the sawing procedure 45 49
9. Cleaning, maintenance and repair 51 57
10. Troubleshooting 59 63
11. Disposal 64
12. Manufacturer’s warranty 65
13. EC declaration of conformity (original) 66
It is essential that the operating instructions are read
before the machine is operated for the first time.
Always keep these operating instructions together
with the machine.
Ensure that the operating instructions are with the
machine when it is given to other persons.
2
ORIGINAL O ERATING INSTRUCTIONS
DS WS10 / DS WS10-E diamond wire saw system
Printed: 08.07.2013 | Doc-Nr: PUB / 5069736 / 000 / 01

Parts and equipment
DS WS10 hydraulic wire saw
쐃Compa t wire saw with hydrauli drive
쐇Air ompressor with ontrol panel
쐋Air hoses (2×7 m, 1×1 m)
쐏Positioning template
쐄Water hoses (2×10 m)
쐂Water nozzle, flexible
쐆Water nozzle, long
쐊Water hose onne tor with regulating
valve
쐎1/2″square drive wren h
쐅Toolbox for tools and a essories
DS WS10-E electric wire saw
쐃Compa t wire saw with ele tri drive
쐇Control unit with air ompressor
Air hoses (2×7 m, 1×1 m)
쐏Positioning template
쐄Water hoses (2×10 m)
쐂Water nozzle, flexible
쐆Water nozzle, long
쐊Water hose onne tor with regulating
valve
쐎1/2″square drive wren h
쐅Toolbox for tools and a essories















쐅
쐅







3
Printed: 08.07.2013 | Doc-Nr: PUB / 5069736 / 000 / 01

1. General information
Explanation of the pictograms and other infor-
mation
1.2
Safety notices and their meaning
1.1
DANGER
Draws attention to imminent danger that ould lead to
serious bodily injury or fatality.
WARNING
Draws attention to a potentially dangerous situation that
ould lead to serious personal injury or fatality.
CAUTION
Draws attention to a potentially dangerous situation that
ould lead to slight personal injury or damage to the
equipment or other property.
NOTE
Draws attention to an instru tion or other useful infor-
mation.
Symbols
r1=l1x2
r
1
=l
1
x2
r2=l2x2
r
2
=l
2
x2
r3=l3x2
l2
l
3
l1l1
Store 1x = Start 1 bar Store 2x = Start 2 bar
min. 2.3m
max. 4.5 / 7.3m
358240 / 09.2008
min. 1.6m
max. 2.7 / 4.1m
l
2
STOP
STOP
STOP STOP
STOP
No persons may enter or remain within the danger area indicated while the equipment
is in operation.
On the control unit
Location of identification data on the machine
The type designation and serial number an be found on
the type identifi ation plate on the ma hine. Make a note
of this data in your operating instru tions and always
refer to it when making an enquiry to your Hilti repre-
sentative or servi e department.
Type:
Serial number:
4
General warning Warning:
electricity
Warning:
avoid hand injuries
Wear protective
gloves.
Wear safety
footwear.
Wear respiratory
protection.
Wear ear
prote tion.
Wear eye
protection.
Wear a hard hat.
Warning signs
Obligation signs
Return waste
material for
recycling.
Read the operating
instructions before
use.
< 4°C
358092
To avoid damage when there is a risk of freezing, the
cooling circuit of the system must be blown out with
compressed air after use.
water in
max 6bar
357824
To avoid damage, do not
exceed a water pressure
of 6 bar.
On the machine
A
Amps
V
Volts
kW
Kilowatts
Hz
Hertz
mm
Millimeters
/min
Revolutions
per minute
l/min
Liters per minute
rpm
Revolutions
per minute
Printed: 08.07.2013 | Doc-Nr: PUB / 5069736 / 000 / 01

2. Description
Description 2.1 Use of the equipment as dire ted 6
2.2 Components 6
2.3 Operating ontrols 7
2.4 Drive prin iple 11
2.5 Saw advan e and wire storage 11
2.6 Wire guidan e 11
5
Printed: 08.07.2013 | Doc-Nr: PUB / 5069736 / 000 / 01

3
5
4
1
2
5
6
7
6
Use of the equipment as directed
■The DS-WS10(-E) wire saw has been designed for
the te hni al demolition of steel, on rete, stone or
bri kwork stru tures in onstru tion and ivil engi-
neering appli ations. Use of the saw for other appli-
ations is onsidered to be “not as dire ted” and
requires prior approval by the manufa turer.
■The operator in harge must be aware of the possi-
ble dangers and of his responsibility for safety, both
with regard to himself and to others. The operator is
responsible for se uring the danger area by ordon-
ing the area off and installing the appropriate pro-
te tive equipment.
■The wire saw is designed for a maximum utting
length of 2 meters. The maximum distan e between
the pivoting pulleys at the ma hine and the wire entry
or exit point must not ex eed 3.5 meters.
■The wire saw may be operated only by spe ialists
trained in on rete utting te hniques, referred to in
the following as “operators”. These persons must be
familiar with the ontent of these operating instru -
tions and must have been trained in their safe appli-
ation by a Hilti spe ialist.
■National regulations and legislation as well as the
information in the operating instru tions and safety
pre autions on erning the saw and its a essories
(sawing wire, fastening a essories, lifting equip-
ment, ompressor, hydrauli power unit et .) must
be observed.
■Do not use the saw to ut loose obje ts or obje ts
held against the wire by hand.
■Use of the wire saw or its omponents for purposes
other than wire sawing is prohibited, i.e. use as a
transport or onveyan e devi e is not permissible.
■The ma hine is suitable for wet and dry utting. A
va uum dust removal system must be used when
dry wire sawing. Spe ial dust removal hoods are
available on request.
■The equipment may be lifted by rane only at the lift-
ing points provided.
■Do not ut materials whi h, as a result of the utting
pro ess, may produ e toxi , hazardous or explosive
dust or vapors.
■Do not ut easily ombustible aluminum or magne-
sium alloys.
2.1
2. Description
Components
2.2
Base plate
Guide rail and advan e unit
Pivoting pulley rossbar
Hydrauli drive unit (DS WS10) or ele tri drive unit
(DS WS10-E)
Guard
Wire storage extension
End stop
Printed: 08.07.2013 | Doc-Nr: PUB / 5069736 / 000 / 01

7
2. Description
Operating controls and parts
2.3 Guide rail and advance unit
Internal taper
E entri pin
Carriage lo king me hanism
Manual advan e me hanism
Piston rod se uring lamp
Return lo k
Compressed air onne tion
Drive unit interfa e and lo king me hanism
End stop
1
1
1
1
2
3
1
2
7
6
7
3
5
4
9
2
8
Base plate
Leveling s rews
An hor slot
Conne ting taper
Positioning template
Grip
Edge indi ating line of ut
Wire entry point
Pivotable drilling point indi ator
Optimum an hor position
Retaining magnet for atta hment to base plate
1
6
4
5
3
2
NOTE
The drilling point indi ator an be pivoted between the
positions of the through holes for the tension and sla k
sides of the wire.
Printed: 08.07.2013 | Doc-Nr: PUB / 5069736 / 000 / 01

2. Description
8
Guards
Guard mounting pin
Spring pin
1
DS WS10 hydraulic drive unit
Mounting interfa e
Hydrauli onne tion
Drive pulley
Return pulley
Carrying / holding bar
Guard guides
Tra tion pulley
37 4
6
26 25
1
2
Pivoting pulley crossbar
Atta hment point and lamp
Pivoting pulley lo king lever
Wire storage pulley
Guard mounting hole
Hollow axles
Guard
1
2
2
3 45 5
DS WS10-E electric drive unit
Mounting interfa e
Power able
Drive pulley
Return pulley
Carrying / holding bar
Guard guides
Tra tion pulley
Cooling water onne tion – feed/return
7 43
6
6 25 8
1
6
4
6
Printed: 08.07.2013 | Doc-Nr: PUB / 5069736 / 000 / 01

DS WS10 pneumatic system control unit
Advan e dire tion ontrol valve
Regulator for advan e pressure adjustment
(wire tension)
Advan e pressure indi ator
Se uring band
Safety and operating instru tions
Compressed air supply onne tion
Advan e ylinder onne tion
Air ompressor
DS WS10 water connection
Coupling (water outlet from hydrauli unit)
Flow regulation and shut-off valve
Water hose onne tion ( ooling water nozzles)
3
2
1
3
2
DS WS10-E water connection
Coupling (water outlet from motor ooling ir uit)
Flow regulation and shut-off valve
Water hose onne tion ( ooling water nozzles)
3
2
1
3
2
17
86
2 3 45
2. Description
9
Printed: 08.07.2013 | Doc-Nr: PUB / 5069736 / 000 / 01

2. Description
 Ele tri supply onne tion 400 V~ / 32 A or 200 V~
/ 63 A
 230 V ele tri supply so ket (not fitted to 200 V~
version)
 Control abinet door lo k
 Main swit h
16 17
2224 26
15 18 19
DS WS10-E control unit
Transport and arrying handles
Lifting point for lifting by rane
Shelf for atta hing the ompressor
Air ompressor
(not supplied with the 200 V version)
Control panel ooling air exit
Power able so ket
Air hose onne tor – ompressor
Air hose onne tor – saw advan e unit
Wheel assembly
 Vi e for use when onne ting wire ends
1 2 10
4
 Green lamp – ready for operation
 Red lamp – lights when a fault o urs
 Yellow lamp – lights when servi ing is required
 Ele tri urrent indi ator (amps)
 Advan e pressure gauge (bar)
 Advan e speed adjusting knob (m/s)
 Advan e pressure adjusting knob (bar)
(pull out to unlo k)
 Advan e dire tion sele tion lever (up / neutral /
down)
 Green lamp – lights when drive is swit hed on
 Red lamp – lights when drive is swit hed off
 Power onverter error a knowledge button
 Emergen y stop button (pull out to release)
7
5
3
6
8
9
11
12
23
20
14
13
13
25
21
10
Printed: 08.07.2013 | Doc-Nr: PUB / 5069736 / 000 / 01

2. Description
Drive principle
The sawing wire is passed around the obje t to be ut,
over guide pulleys and the drive pulley before the ends
of the wire are joined to form an endless loop. The wire
loop is set in motion by rotation of the drive pulley and
pulled through the obje t to be ut by the linear advan e
movement of the drive unit.
Saw advance and wire storage
Wire advan e is by way of the “blo k and ta kle” prin i-
ple. The advan e movement, i.e. ausing the wire to be
drawn in, is effe ted by the pulleys being pushed apart
by a pneumati ylinder. In addition, the drive pulley is
mounted on a moving arriage. The length of wire that
an be stored on the pulleys depends whether a single
or double return system is used, i.e. with or without the
optional wire storage pulley. Please refer to the “Te h-
ni al data” se tion for further details.
Wire guidance
Alignment of the sawing wire between the pivoting pul-
ley on the ma hine and the pivoting pulley mounted on
the obje t being ut an be set pre isely by adjusting the
pulleys. In flush utting appli ations, the pivoting pul-
leys adjust automati ally to the de reasing distan e
between the wire entry and exit points by pivoting freely
as the ut progresses.
2.4
2.5
2.6
11
Printed: 08.07.2013 | Doc-Nr: PUB / 5069736 / 000 / 01

12
Printed: 08.07.2013 | Doc-Nr: PUB / 5069736 / 000 / 01

13
3. Accessories
Accessories 3.1 Hilti sawing wires and a essories 14
3.2 Wire storage extension (optional) 16
3.3 Pulley stand (optional) 16
3.4 Release pulley (optional) 16
3.5 Wire guard (optional) 16
3.6 A essories for setting up
and operating the wire saw and wire guides 17
3.7 A essories and wearing parts for Hilti wire saw systems 17
Printed: 08.07.2013 | Doc-Nr: PUB / 5069736 / 000 / 01

3. Accessories
Hilti sawing wires and accessories
Safety precautions and instructions for use
■Use only sawing wires that omply with the require-
ments of EN 13236.
■Conne ting together lengths of wires of different
diameters, from different manufa turers or of dif-
ferent types (e.g. ele troplated or sintered beads) or
use of badly worn or out-of-round wires is not per-
missible.
■Use of damaged wires (e.g. wires with kinks, loose
or shifted beads, broken strands, et .) is not per-
missible.
3.1 ■Observe the wire and wire onne tor manufa turer’s
instru tions when onne ting sawing wires and, as
far as possible, use only one wire onne tor in ea h
omplete wire loop.
■Use of flexible onne tors greatly redu es alternat-
ing bending stresses and thus redu es the probabil-
ity of wire breakage due to fatigue.
■Use only diamond wires with beads of a diameter
within the 8–12 mm range. Other diameters may
ause the wire to jump off the pulleys or result in
damage to the running surfa e of the pulleys.
Machine
DS WS10 DS WS10-E DS WS15 DS WSS30
Material
Reinforced concrete CS CM CS CM CM CH CM CH
Heavily-reinforced concrete 20 % steel 20 % steel 20 % steel 20 % steel
Reinforced concrete
dry cutting Dry Dry Dry Dry
Steel – 100 % steel 100 % steel 100 % steel
Specification Cutting characteristics Concrete type Reinforcement content
CS Fast-cutting S: soft, soft aggregates Normal to high
Good balance between cutting
CM speed and life M: medium, hard aggregates Normal
CH Specially for flint, long life H: hard, very hard aggregates Normal
20 % steel Fast-cutting Universal Normal to very high
100 % steel ––Only steel
Dry – Universal Normal to high
Guidelines for the use of diamond wires
14
Printed: 08.07.2013 | Doc-Nr: PUB / 5069736 / 000 / 01

Accessories for connecting Hilti diamond wires
3. Accessories
Sintered Electroplated
Spezification CS CM CH Concrete, 20 % steel 100 % steel
dry cutting
No. of beads / m 40 44 40 40*) 40 48*)
Beads dia. (mm) 10.5 10.5 10.5 10.2 10.2 10.8
*) each bead is crimped additionaly.
DS-WS10.5 diamond wires
Designation Designation Designation Designation Designation Designation
Wire length DS-W 10.5 DS-W 10.5 DS-W 10.5 DS-W 10.2 DS-W 10.8 DS-W 10.2
(m) CS CM CH 20% steel 100% steel dry
4,6 햲384 528* 햳376 816* 햴376 818* 햵384 540* --
7,8 햲384 529* 햳376 817* 햴376 819* 햵384 541* --
10 햲384 530* 햳235 835* 햴235 834* 햵384 542* --
14 햲384 531* 햳235 836* 햴235 838* 햵371 982* 햶371 987* -
18 햲384 532* 햳315 019* 햴315 020* 햵371 983* 햶371 988* -
22 햲384 533* 햳315 022* 햴315 023* 햵371 984* 햶371 989* -
26 햲384 534* 햳315 025* 햴315 026* ---
30 햲384 535* 햳315 028* 햴315 029* ---
50 햲384 536 햳370 500 햴376 630 햵371 985 햶371 990 -
100 햲384 537 햳370 426 햴376 631 햵371 986 햶371 991 -
per/m 햲384 539 햳376 635 햴376 634 햵377 830 햶377 781 햷377 782
* with factory-fitted flexible connectors
햳
햲
햴
햵
햶
햷
햽
햸
햹
햻
햺
햿
헀
Designation ackage Ordering designation Item no.
contents
Crimping pliers 1DS-WSTHY 햸235845
For crimping connectors / repair sleeves
Flexible connectors 1DS-WCMV 햹340427
Quick-release type
Set of flexible connectors 5DS-WCSet 햺371383
Quick-release type with pin and O-ring
in 10 DS-W 235842
Replacement pin for quick-release connectors
Sleeve 5DS-WS 햻235841
Repair sleeve
O-ring 10 O-Ring 10/4,7×2,5 235844
Fitted between connector and bead
Crimping jaws 2DS-WJ 햽340426
Replacement jaws for crimping pliers
Assembly tool connector 1DS-WMT 295161
For pin removal
Angle grinder 1AG 125-S 햿000000
For cutting diamond wire
Cutting disc 1AC-D 125 1mm 헀304623
For cutting diamond wire
15
Printed: 08.07.2013 | Doc-Nr: PUB / 5069736 / 000 / 01

Pulley stand (optional)
In appli ations where, due to restri ted a ess, it is
impossible to mount the ompa t wire saw dire tly on
the obje t to be ut or where longer uts of up to a max-
imum of 2 meters are to be made, the sawing wire is
guided to the utting fa e by the pulley stand.
3.3
Release pulley
The release pulley is used to redu e the length of wire
in onta t or to in rease the radius of the ar followed
by the wire (avoiding a tight radius) at the rear of the
obje t to be ut.
3.4
Wire storage extension (optional)
The wire storage extension an be used to in rease wire
storage apa ity from 250 m to 500 m.
3.2
Wire guards (optional)
3.5
Wire guards must be fitted in situations where it an-
not be ensured that persons do not enter the danger
area while the equipment is in operation, i.e. the area
in whi h flying fragments et . present a risk of injury,
or in situations where there is a risk of damage to prop-
erty or other equipment within this area. When wire
guards are used, he k to ensure they are fitted or-
re tly.
3. Accessories
16
Printed: 08.07.2013 | Doc-Nr: PUB / 5069736 / 000 / 01

3. Accessories
Accessories for setting up and operating wire saws and wire guides
3.6
Accessories and wearing parts for Hilti wire saw systems
3.7
Ordering designation Quantity Item no. Use
DS-WS tool set 339300 Wire saws
comprising:
Hilti plastic toolbox 1311869 Storage
Accessories, list of contents and uses 1339295 Overview of contents
Open-end / ring wrench, 19 mm 1221189 Fastening
Hammer 11/2kg1339303 Fastening
Screwdriver, 6 mm 1339304 Fastening
BB blow-out pump 햲159725 Blowing out anchor holes
Folding rule, 2-metre 12731 Marking
Spirit level 1310306 Marking
Wooden pencil 2335500 Marking
Cleaning cloth 1334211 Cleaning
Hilti spray 1308976 Lubrication
Hilti grease dispenser 1203086 Lubrication
Flat brush 13206 Cleaning
Protective goggles 15205 Eye protection
Clamping spindle, short, M12S 햳3251830 Fastening
DD-CN-SML clamping nut 햴3251834 Fastening
HSD-G M12 setting tool 햵1243743 Fastening
Water connection nipple 햺1356700 Water supply
GK seal 5356701 Water seal for 356700
Steel wedge 햶441910 Securing concrete blocks
Ordering designation Quantity Item no. Use
M12L clamping spindle, long 햳1251831 Fastening
HKD-D M12×50 flush anchor * 햷50 252961 Fastening
Water supply, long 햸1339307 Water supply
Water supply, flexible 햹1339379 Water supply
* Hole diameter 16 mm
햲
햵
햶
햷
햸
햹
햴
햳
햺
17
Printed: 08.07.2013 | Doc-Nr: PUB / 5069736 / 000 / 01

18
Printed: 08.07.2013 | Doc-Nr: PUB / 5069736 / 000 / 01

19
4. Technical data
Technical data 4.1 Te hni al data for the DS WS10 hydrauli drive 20
4.2 Te hni al data for the DS WS10-E ontrol unit 20
4.3 Dimensions and weights 21
4.4 Te hni al data for the DS WS 10 and DS WS10-E 22
4.5 Compressed air supply 23
4.6 Wire storage apa ity and length requirements 23
4.7 Type plates 24
4.8 Noise levels 24
Printed: 08.07.2013 | Doc-Nr: PUB / 5069736 / 000 / 01

4. Technical data
Technical data for the DS WS10 hydraulic unit
The DS-WS 10 ompa t wire saw is designed for oper-
ation with the Hilti D-LP 15 and D-LP 32 or D-LP 30
hydrauli power units. Use of other hydrauli units for
powering the saw is permissible only when su h units
are of a suitable spe ifi ation and type approved for use
as a power sour e for hydrauli drilling or sawing equip-
ment.
Flow rate: max. 50 l/min
Optimum operating range: 36 to 50 l/min
Pressure: max. 210 bar
Optimum operating range: 80 to 120 bar
4.1
20
A built-in safety devi e limits the oil flow rate to the
hydrauli motor to a maximum of 50 l/min., thus limit-
ing the wire speed to a maximum of 27 m/se .
The operator will noti e when the flow rate limiting devi e
is a tivated as the drive unit then no longer runs smooth-
ly (audible and visual indi ation).
CAUTION
Do not, under any ir umstan es, operate the saw at a
flow rate in ex ess of 50 l/min.
Technical data for the DS WS10-E control unit
DS EB-WS10 3x400 V DS EB-WS10 3x200 V
Rated voltage 400 V~ 200 V~
Rated frequen y 50 / 60 Hz 50 / 60 Hz
Pin assignment 3P+N+PE / 3P+PE 3P+PE
Rated urrent 22 A 44 A
Fuse rating 32 A 63 A
Power input, max. 11 kW 11 kW
Generator output, min. 40 kVA @ 32 A 40 kVA @ 63 A
Ground fault ir uit breaker in supply 30 mA (type A) 30 mA (type A)
Prote tion lass IP 54 IP 54
Power outlet 230 V / 10 A none
Ambient temperature range – storage –15 to +50°C –15 to +50°C
Ambient temperature range – operation –15 to +45°C –15 to +45°C
Leakage urrent ≤10 mA ≤10 mA
Insulation resistan e at least 300 kΩat least 300 kΩ
4.2
Printed: 08.07.2013 | Doc-Nr: PUB / 5069736 / 000 / 01