Hilti DSW 1005E User manual

DSW 1005E English

DSW 1005E
en English ................................................. 1

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1 Information about the documentation
1.1 Explanation of signs used
1.1.1 Warnings
Warnings alert persons to hazards that occur when handling or using the product. The
following signal words are used in combination with a symbol:
DANGER! Draws attention to imminent danger that will lead to serious personal
injury or fatality.
WARNING! Draws attention to a potential hazard 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.
1.1.2 Symbols
The following symbols are used in this document:
Read the operating instructions before use.
General warning
Warning: hazardous electrical voltage
Warning: risk of cutting injury
Dealing with recyclable materials
Do not dispose of electric tools, machines or appliances together with house-
hold waste.
1.1.3 Symbols on the product
The following symbols are used on the type identification plate:
Revolutions per minute
Rated speed under no load
Diameter
1.1.4 Mandatory signs
The following obligation signs are used on the product:
Wear eye protection
Wear a hard hat and ear protection
Wear protective gloves
Wear safety shoes

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Lifting points
1.1.5 Illustrations
The illustrations in these operating instructions are intended to promote a better
understanding and may deviate from the actual version of the product.
These numbers refer to the corresponding illustrations found at the beginning of
these operating instructions.
The numbering reflects the order of the work steps in the illustration and may
deviate from the numbering of work steps in the text.
Item reference numbers are used in the overview illustration and refer to the
numbers used in the product overview section.
These characters are intended to specifically draw your attention to certain
points when handling the product.
1.2 Declaration of conformity
We declare, on our sole responsibility, that the product described here complies with
the applicable directives and standards. A copy of the declaration of conformity can be
found at the end of this documentation.
The technical documentation is filed and stored here:
Hilti Entwicklungsgesellschaft mbH | Tool Certification | Hiltistraße 6 | 86916 Kaufering, DE
2 Safety
2.1 Safety instructions
The safety instructions in the section below contain all general safety instructions for
power tools that the applicable standards require to be stated in the operating instructions.
Consequently, some of the instructions might not be relevant for this tool.
2.1.1 Proper arrangement of the workplace
▶Approval must be obtained from the site engineer or site management before beginning
drilling and sawing work. Drilling and sawing work on buildings and other structures
may influence the statics of the structure, especially when steel reinforcing bars and
load-bearing components are cut through.
▶Ensure that good lighting is in use.
▶Ensure that the workplace is well ventilated. Exposure to dust at a poorly ventilated
workplace may result in damage to the health.
▶Keep the workplace tidy. Objects which could cause injury should be removed from
the working area. Untidiness at the workplace can lead to accidents.
▶In order to avoid injuries and to prevent the diamond wire becoming trapped and
stuck, steel wedges and/or supports must be used to prevent uncontrolled movement
of objects that are being cut free.
▶Ensure that adequately-sized supports are correctly installed so that the remaining
structure maintains its stability after completion of the cutting work and removal of the
part cut away.
▶Never loiter in areas where loads are suspended by crane or lifting equipment.
▶The area of the cut or the opening created by the cutting process must be safely and
visibly cordoned off in order to avoid the risk of persons falling.

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▶Wear personal protective equipment. Wear safety footwear, protective gloves, a hard
hat and protective glasses.
▶Wear respiratory protection if the work causes dust.
▶Dress properly for the work. Do not wear loose clothing or jewelry as it can be caught
in moving parts. Contain long hair.
▶Keep children away. Keep other persons away from the working area.
▶Do not allow other persons to touch the equipment or the extension cable.
▶Avoid working in awkward body positions. Make sure you work from a safe stance
and stay in balance at all times.
▶To avoid presenting a tripping hazard, always ensure that cables and hoses leading
to the machine are laid flat on the floor.
▶Keep cables and hoses away from rotating parts.
▶In cooperation with the site engineer or architect, check to ensure that no gas, water,
electricity or other supply lines are located in the cutting area. Supply lines located
close to the cutting area which, for instance, could be damaged by falling parts, must
be specially protected and temporarily taken out of operation and switched off where
necessary.
▶Ensure that the cooling water used is drained or extracted in a suitably controlled
manner. Cooling water that is allowed to flow away or spray around in an uncontrolled
manner can lead to damage and accidents. The fact that water can drain away into
internal, hidden cavities must also be taken into account.
▶Don’t work from a ladder.
2.1.2 General safety rules
▶Use the machine only after you have read the operating instructions, after becoming
familiar with the content of the instructions and after receiving training by a Hilti
specialist. Observe all warnings and instructions.
▶Use the right tool or equipment for the job. Do not use the machine for purposes for
which it was not intended. Use it only as directed and when in faultless condition.
▶Use the machine and its accessories etc. in accordance with these instructions and in
the manner intended for the particular type of machine. Take the working conditions
and the work to be performed into account. Use of this machine in situations other
than those intended could result in hazardous situations.
▶Take influences of the surrounding area into account. Do not use the machine where
there is a risk of fire and explosion. Electric tools and machines generate sparks which
may ignite dust or gas.
▶Keep the grips clean, dry and free from oil and grease.
▶Do not overload the machine. It will work more efficiently and more safely within its
intended performance range.
▶Never leave the machine unattended.
▶Store machines in a secure place when not in use. When not in use, machines must
be stored in a dry, high place or locked away out of reach of children.
▶Always disconnect the supply cord from the electric supply when the machine is
not in use (e.g. during breaks between working), before making adjustments, before
cleaning and maintenance and before changing the sawing wire. This safety precaution
prevents the machine being switched on unintentionally.
▶Remove adjusting keys or wrenches before switching the machine on. A tool or a key
left attached to a rotating part of the machine may result in personal injury.
▶Before use, the machine, the sawing wire and accessories must be checked carefully
to ensure that all items function faultlessly and as intended. Check that moving parts
function faultlessly, without sticking, and that no parts are damaged. In order to ensure

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faultless operation of the machine, all parts must be fitted correctly and must meet
the necessary requirements. Damaged parts must be repaired or replaced properly
by an authorized service center.
▶Avoid skin contact with drilling and sawing slurry.
▶Wear a protective mask during work that generates dust, e.g. dry cutting. Connect a
dust removal system. Working on materials hazardous to the health (e.g. asbestos) is
not permissible.
▶Follow the instructions concerning care and maintenance.
▶Children are not permitted to play with the machine and must be instructed accordingly.
▶The machine is not intended for use by children, by debilitated persons or those who
have received no instruction or training.
2.1.3 Electrical safety
▶Take steps to avoid electric shock. Avoid body contact with earthed or grounded
surfaces such as pipes, radiators, ranges or refrigerators.
▶Check the machine’s power cables at regular intervals and have them replaced by
a qualified specialist if found to be damaged. Check the extension cables at regular
intervals and replace them if found to be damaged.
▶Check the condition of the machine and its accessories. Do not operate the machine
and its accessories if damage is found, if the machine is incomplete or if its controls
cannot be operated faultlessly.
▶If an electric cable is damaged while working, do not touch the cable – switch off at
the main switch and unplug the supply cord.
▶Damaged or faulty switches must be replaced at a Hilti service center. Do not use
a machine, power tool or appliance that cannot be switched on and off at the main
switch.
▶Have the machine, power tool or appliance repaired only by a trained electrical
specialist (Hilti Service) using genuine Hilti spare parts. Failure to observe this point
may result in risk of accident to the user.
▶Do not use the supply cords for purposes for which they are not intended. Never carry
the machine by the supply cord. Never pull the plug out of the power outlet by pulling
the supply cord.
▶Do not expose the supply cords to heat, oil or sharp edges.
▶Connect the machine and its ancillary equipment only to a power source equipped
with an earth/ground conductor and ground fault circuit interrupter (PRCD). Check
that these items are in perfect working order before operating the equipment. If a
generator is used, connect it to a grounding/earthing rod driven into the ground.
▶Make sure that the mains voltage corresponds to the specification given on the type
plate.
▶Electric cables and their plug connectors must be kept dry. When not in use, close
power outlets with the cover provided.
▶Use only extension cables of a type approved for the application and with conductors
of adequate gauge. Do not use rolled-up extension cables. A rolled-up cable may
cause a drop in power and may result in the cable overheating.
▶Disconnect the electric supply before beginning cleaning and maintenance work or in
the event of an interruption between periods of operation.
▶Please note that certain components of the power converter may retain an extremely
dangerous (potentially fatal) high voltage for up to 10 minutes after disconnection from
the electric supply.
▶Before beginning work, check the working area (e.g. using a metal detector) to ensure
that no concealed electric cables or gas and water pipes are present. External metal

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parts of the machine may become live, for example, when an electrical cable is
damaged accidentally. This presents a serious risk of electric shock.
2.1.4 Requirements to be met by users
▶The wire saw may be operated only by specialists who have received training
in concrete cutting techniques. These persons must be completely familiar with the
content of these operating instructions and must have been trained by a Hilti specialist
on the safe application of these instructions.
▶Stay alert, watch what you are doing and use common sense when working. Do
not use the machine while you are tired or under the influence of drugs, alcohol or
medication. A moment of inattention may result in serious personal injury.
▶The user and any other persons in the vicinity must wear suitable eye protection, a
hard hat, ear protection, protective gloves and safety footwear while the machine is in
use.
▶Dust from material such as paint containing lead, some wood species, minerals and
metal may be harmful. Contact with or inhalation of the dust may cause allergic
reactions and/or respiratory diseases among operators or bystanders. Certain kinds
of dust such as oak and beech wood dust are classified as carcinogenic, especially
in conjunction with additives for wood conditioning (chromate, wood preservative).
Material containing asbestos may be worked on only by specialists. Where the use of
a dust-extraction device is possible it shall be used. To achieve a high level of dust
collection, use a suitable vacuum cleaner of the type recommended by Hilti for wood
dust and/or mineral dust together with this machine. Ensure that the workplace is well
ventilated. Use of a dust mask of the filter class P2 is recommended. Follow national
requirements for the materials you want to work with.
2.1.5 Safety during operation
▶Before use, check that the wire saw and its components, the wire and its connectors
as well as the accessories are in good condition and in perfect working order. Make
sure that any damage or malfunctions are rectified in a professional manner before
operation commences.
▶Position the control unit as far as possible outside the danger zone and remain in the
vicinity of the control panel during cutting operations.
▶Work with the saw may begin only when the wire saw and the pulley stands have
been securely and rigidly fastened to a solid supporting surface. A falling object could
result in serious personal injury or damage to property or equipment.
▶Connect the electric power and compressed air supply only once the wire saw has
been set up completely.
▶Operate the saw only when the wire guards / cover are correctly fitted and when the
sawing wire has been fed through the hollow axles of the pulley stands mounted right
at the wire entry and exit points.
▶Persons may enter the danger area (e.g. to adjust the pulleys or water nozzles,
hammer in wedges, etc.) only after the emergency stop button has been pressed and
the drive wheel has come to a standstill.
▶Adhere to the permissible drive unit parameters and recommended guide values for
wire speed and advance speed while sawing.
▶Use only sawing wires that comply with the requirements of EN 13236.
▶The number of wire breakages experienced can be reduced considerably by using
high-quality wires and wire connectors and the appropriate crimping tools for fitting
connectors.
▶The sawing wire may get hot. Don’t touch it unless you are wearing protective gloves.

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▶Use only fastening materials of adequate size (anchors, bolts, etc.) to fasten the pulley
stands for the wire saw and to secure the object being cut.
▶If equipment such as scaffolding, platforms or ladders is used, check that this
equipment complies with regulations, that it is undamaged and set up in accordance
with regulations.
▶At all times while the saw is in operation, the operator must ensure that no persons
are present in the danger area. This also applies to the area not immediately visible to
the operator, i.e. the area behind or below the object in which the cut is being made.
If necessary, a large area must be cordoned off or security personnel posted.
▶Stay alert at all times. Monitor the progress of the sawing operation and keep an eye
on the cooling water system and the area surrounding the workplace. Do not operate
the machine if your full attention is not on the job.
▶No modifications may be made to the saw system. Modification of the factory-set
frequency converter parameters is strictly prohibited.
2.1.6 Additional safety instructions for wire saws
Safety measures at the danger area
Note
The danger area extends to at least twice the radius of the length of wire that would
be unleashed in the event of the wire breaking and also includes the area in the
extended axis of the directions in which the wire is running.
The scope of this danger area is not limited unless suitable protective devices are
installed (protective barriers or curtains, wire guards, etc.). The protective devices
must be designed and installed in such as way that they prevent wire whiplash and
safely and reliably stop any flying fragments or debris.
▶The operator is responsible for ensuring that the correct safety measures are taken at
the workplace. It may be necessary to cordon off a large area and position security
personnel accordingly.
▶Make sure that adequate safety precautions are taken at the sawing area so that
neither the operator nor other persons can be injured and no damage can be caused
to equipment or other property in the event of wire breakage or due to flying fragments
or debris. Safety measures must also be implemented in the area behind the object in
which the cut is being made.
◁Persons may NEVER enter the danger area while the wire drive unit is switched on.
▶Use only fastening materials of adequate dimensions to fasten the pulley stands for
the wire saw and to secure the object being cut.
◁Work with the saw may begin only when the wire saw and the pulley stands have
been securely and rigidly fastened to a solid supporting surface. A falling object
could result in serious personal injury or damage to property or equipment.
▶Check that the wire saw and its components function correctly before use.
▶Connect the electric power and compressed air supply only once the wire saw has
been set up completely.
▶Position the control unit as far as possible outside the danger zone and make sure
that you remain close to the control panel during cutting operations.
▶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.
▶Keep any free (unsupported) lengths of sawing wire as short as possible (max. 3.5 m).

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▶Mount pulley stands at the wire entry and exit points in order to reduce the risk of wire
whiplash.
◁The whiplash effect results in rapid acceleration of the sawing wire, possibly
causing parts of the wire to fly off with great force.
▶Make sure there are no objects (e.g. scaffold bars) within the areas in which whiplash
may occur.
◁In the event of wire breakage, the free end of the sawing wire could be deflected in
an unforeseen direction by an object of this kind.
▶Operate the saw only when the wire guards / covers are correctly fitted and when the
sawing wire has been fed through the hollow axles of the pulley stands mounted right
at the wire entry and exit points.
▶Always wear protective gloves.
◁The wire gets hot and may cause injury such as cuts or burns.
2.1.7 Safety instructions applicable to transporting the wire saw
▶Avoid lifting and carrying heavy objects. Use suitable lifting equipment and means of
transport and share heavy loads between several people.
▶Use the grips provided for transportation. Keep the grips clean and free from oil and
grease.
▶Bear in mind that the machine could fall over. Stand the machine only on a solid, level
surface. Use the forward-facing pivoting pulleys to help steady the wire saw against a
suitable surface.
▶Secure the machine and its components to prevent movement or falling over during
transportation.
▶The machine may be lifted by crane only using tested and approved lifting gear at the
lifting points provided. Before lifting, check that all removable items of equipment are
securely attached to the drive unit and that the end stop is fitted. Never loiter beneath
a load suspended by a crane or lifting equipment.
3 Description
3.1 Symbols on the control unit
While the equipment is in operation, nobody may enter or remain within the danger zones
shown.

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3.2 Safety distance
Always maintain the safety distance.
It is absolutely essential that the safety instructions regarding the safety distance are
observed.

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3.3 Designations of controls
3.3.1 Layout of components
@Base plate
;Guidance and advance unit
=Pivoting pulley bearer
%Drive wheel
&Guards
(Wire storage extension (optional)
)End stop
3.3.2 Positioning template
@Grip
;Edge of cut
=Wire feedthrough hole
%Pivoting hole-center indicator

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&Optimum anchor position (Holding magnets for fastening to
the base plate
3.3.3 Base plate
@Leveling screws
;Anchor slot
=Connecting taper
3.3.4 Wire guidance and advance unit
@Internally tapered connectors
;Eccentric pins
=Carriage lock
%Manual advance drive unit
&Piston rod lock
(Return stop

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)Compressed air connection
+Drive interface and locking mecha-
nism
§End stop
3.3.5 Pivoting pulley bearer
@Mounting interface and clamping
lever
;Pivoting pulley locking lever
=Wire storage pulley
%Guard mounting hole
&Hollow axles
(Guard
3.3.6 Electric drive unit
@Fastening interface
;Drive wheel
=Wire storage pulley
%Carrying handle and grip
&Guides for side guard
(Traction pulley
)Cooling water connections, inlet /
outlet
+Motor

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3.3.7 Guard
@Cotter pin ;Stud for holding wire storage unit
3.3.8 Control unit connections and attached parts
@Transport handles
;Lifting point
=Air compressor mounting shelf
%Air compressor
&Control unit cooling air exit
(Power cable socket
)Compressed air connection, com-
pressor
+Compressed air connection, wire
advance unit
§Transport wheels
/Vice for fitting wire connectors
:400 V / 32 A supply socket
∙230 V power outlets
$Control unit door lock
£Control cable

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3.3.9 Control unit operating controls
@“Ready for operation” indicator
(lights green)
;Fault indicator (lights red)
=Gauge showing current input in
amps
%Gauge showing advance pressure
in bar
&Advance pressure regulator (lift
knob to unlock)
(Advance direction selector lever
(up/neutral/down)
)Emergency off button
+Main switch
§Drive “Off” (red)
/Wire speed adjustment in m/s
:Drive “On” (green)
∙Clear button
3.4 Intended use
This equipment complies with IEC 61000-3-12 provided that the short-circuit power SSC
at the interface point between the user’s supply and the public supply network is greater
than or equal to 350. It is the responsibility of the installer or user of the equipment to
ensure, by consultation with the public supply network operator, that the equipment is
connected only to a supply with a short-circuit power SSC of greater than or equal to 350.
The wire saw is designed for the technical demolition of steel, concrete, stone or
brickwork structures in construction and civil engineering applications. Use extending
beyond this is considered to be not as directed and requires to be clarified in advance
with the manufacturer.
The operator in charge must be aware of the possible dangers and of his responsibility
for safety, both with regard to himself and to others. The operator is responsible for
securing the danger area by cordoning it off and taking protective measures (guards,
etc.) as necessary.
The wire saw is designed for a maximum cutting length of 2 m. The maximum distance
between the pivoting pulleys at the machine and the wire entry or exits points must not
exceed 3.5 m.
The wire saw may be operated only by specialists who have received training in concrete
cutting techniques. These persons must be completely familiar with the content of
these operating instructions and must have been trained by a Hilti specialist on the safe
application of these instructions.
National regulations and laws, as well as the operating instructions and the safety
information applicable to the accessories used (e.g. sawing wire, fastening accessories,
lifting equipment, compressor, etc.) must be observed.
Do not use the saw to cut loose objects or objects held by hand against the sawing wire.

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Use of the wire saw for purposes other than wire sawing is strictly prohibited, e.g. the
saw may not be used a means of transport or as an improvised lifting winch.
The machine is suitable for wet and dry cutting. A dust removal system must be used for
dry cutting. Special dust hoods are available on request.
The equipment may be lifted by crane only at the lifting points provided.
Do not cut materials in which the cutting process may produce hazardous or explosive
dust or vapors.
Do not cut easily flammable materials.
3.5 Drive principle
The sawing wire is passed round the object to be cut, over guide pulleys and round the
drive wheel, forming an endless loop when the ends of the wire are connected together.
Rotation of the drive wheel sets the endless loop in motion and linear movement of the
drive unit causes the sawing wire to be drawn through the object as cutting progresses.
3.6 Saw advance and wire storage
Wire advance works according to the block and tackle principle. The advance movement,
causing the wire to be drawn in, is achieved by the wire storage pulleys being pushed apart
by a pneumatic cylinder. Accordingly, the drive unit is mounted on a moving carriage.
The length of wire that can be stored in the machine depends on whether the wire is rigged
around one or two sets of pulleys and whether the optional wire store extension is used.
3.7 The functions of the wire guidance system
With the aid of the adjustable pivoting pulleys, the line of the sawing wire between the
machine and the pivoting pulley mounted on the object to be cut can be brought exactly
into alignment. In flush cutting applications, the pivoting pulleys can be allowed to pivot
freely with the wire as the distance between the wire entry and exit points decreases
while the cut progresses.
3.8 Guards or protective covers
Guards must be fitted before the wire saw is operated and the guards must remain fitted
during the entire period the machine is in operation. Check that the guards or covers are
fitted correctly before beginning the work.
If fitting guards is not possible, it is essential to ensure that no one enters or remains in
the danger area during operation of the equipment.

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4 Technical data
4.1 Technical data – control unit
Rated voltage 400 V
AC frequency 50 / 60 Hz
Mains connection (phase requirements) 3P+N+PE / 3P+PE
Rated current 17 A
Mains fuse rating 32 A
Maximum input power 11 kW
Minimum generator output 40 kVA (32 A)
Ground fault circuit interrupter in supply 30 mA (type A)
Control unit protection class IP 54
Power outlet 230 V / 10 A
Ambient temperature (storage) −15 ℃ … 50 ℃
Ambient temperature (operation) 0 ℃ … 45 ℃
Leakage current ≤ 10 mA
Insulation resistance at least 300 kΩ
Weight of the control unit 68.5 kg
4.2 Technical data – drive unit
Motor power 9.4 kW
Engine speed 0 /min … 2,060 /min
Cutting speed 0 m/s … 29 m/s
Drive wheel diameter 280 mm
Cooling water flow rate (30 °C) 4 ℓ/min
Cooling water temperature 4 ℃ … 30 ℃
Minimum / maximum cooling water pressure 4 bar … 6 bar
Ambient temperature (storage) −15 ℃ … 50 ℃
Ambient temperature (operation) 0 ℃ … 45 ℃
Weight of the drive and wire storage unit 81.2 kg
Protection class IP 65
4.3 Compressed air supply
Minimum / maximum pressure (compressed air sup-
ply)
6 bar … 8 bar
Air flow rate (compressed air supply) 205 ℓ/min
4.4 Length of the internal supply lines
Length of compressed air line (short) 1 m
Length of compressed air line (long) 7 m
Length of cooling water supply line 10 m
Length of power cable 7 m

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4.5 Noise information
Noise values
Typical A-weighted sound power level to ISO 3744 103.7 dB (A)
Typical A-weighted emission sound pressure level to ISO 11202
(at a distance of 3 meters)
80.2 dB (A)
4.6 Dimensions
4.6.1 Dimensions of the drive and wire storage unit
The dimensions of the drive and wire storage unit are shown in the diagram.
4.6.2 Dimensions of the control unit
The dimensions of the control unit are shown in the diagram.

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4.6.3 Dimensions of the pulley stand
The dimensions of the pulley stand are shown in the diagram.
5 Operation
5.1 Preparations at the workplace
5.1.1 Marking the cuts to be made
The parts to be cut out are usually marked by the client.
If necessary, make dividing cuts to adjust the maximum size and weight of the concrete
blocks to the prevailing conditions (i.e. the lifting capacity of the crane or the maximum
permissible floor loading capacity and size of doors).
5.1.2 Planning the wire guidance system and cutting configuration
Thorough training and experience are the most important prerequisites for optimum
planning of the cutting configuration and wire guidance system.
Long lengths of wire in contact with the object to be cut or cutting in a very flat arc reduce
sawing performance.
The rule of thumb is: Pulley distance H = cutting length L x 0.2.
For a cutting length of 1.5 meters the pulley distance should thus be 0.3 meters
(1.5 m x 0.2 = 0.3 m).
When planning the wire guidance system, make sure that the wire contact length does
not exceed 2 meters.

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Arrange the cutting sequence so that the wire cannot become trapped by parts that are
cut away.
5.1.3 Examples of applications
The following examples illustrate the most common applications.
Horizontal and vertical cuts, cutting length 20 to 40 cm