Hilti DSW 2005-TS User manual

DSW 2005-TS English

DSW 2005-TS
Original operating instructions

*2235115* 2235115 English 1
Original operating instructions
Contents
1 Information about the documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1 Aboutthisdocumentation ...................................... 3
1.2 Explanationofsymbolsused .................................... 3
1.2.1 Warnings ............................................. 3
1.2.2 Symbols in the documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.2.3 Symbols in the illustrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.3 Product-dependentsymbols .................................... 4
1.3.1 Symbolsontheproduct................................... 4
1.4 Stickers .................................................. 4
1.5 Productinformation .......................................... 5
2 Safety ................................................... 5
2.1 Generalsafetyinstructions ..................................... 5
2.2 Proper arrangement of the workplace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.3 Generalsafetyrules .......................................... 6
2.4 Protection against electric shock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.5 Requirementstobemetbyusers................................. 7
2.6 Safetyduringoperation........................................ 7
2.7 Danger zones and safety distances to be maintained . . . . . . . . . . . . . . . . . . . 9
2.8 Additional safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3 Description .............................................. 11
3.1 Product overview (saw system) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.2 Product overview DSW 2005-TS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.3 Intendeduse .............................................. 12
3.4 Itemssupplied ............................................. 13
3.5 Additionally required accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.6 Optionalaccessories ........................................ 13
3.6.1 Watersupply ......................................... 13
3.6.2 Single-pulley stand (DSW-SPP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.6.3 Release pulley (DS-WSRW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.6.4 Guard(DSW-WG) ...................................... 14
4 Technicaldata ............................................ 14
4.1 Weights of the individual components . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5 Typical examples of applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5.1 Verticalcut(default) ......................................... 15
5.2 Vertical cut with release pulley (DS-WSRW) . . . . . . . . . . . . . . . . . . . . . . . . . 16
5.3 Vertical cut with single-pulley stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5.4 Horizontal cut with 2 single-pulley stands . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5.5 Flushcutting .............................................. 17

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6 PreliminarySteps .......................................... 18
6.1 Installingguards ........................................... 18
6.2 Determininglengthofwire..................................... 18
6.3 Safety aspects to be clarified before work starts . . . . . . . . . . . . . . . . . . . . . 18
6.4 Markinglineofcut .......................................... 18
6.5 Planning wire guidance and sequence of cuts . . . . . . . . . . . . . . . . . . . . . . . 19
7 Assemblingthewiresaw .................................... 19
7.1 Drillingthrough-holes ........................................ 19
7.2 Installingbaseplate ......................................... 19
7.3 Installingguiderail .......................................... 21
7.4 Fittingtheendstop ......................................... 21
7.5 Installingwirespreader ....................................... 22
7.6 Installing holder for wire storage unit cover . . . . . . . . . . . . . . . . . . . . . . . . . 23
7.7 Installing wire storage pulleys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
7.8 Mountingthesawhead ...................................... 24
7.9 Installingdrivepulley ........................................ 25
7.10 Rounding off edges on object to be cut . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
7.11Installingdiamondwire ....................................... 25
7.12 Installing guard for drive pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
7.13 Installing guard for sawing wire loose side . . . . . . . . . . . . . . . . . . . . . . . . . 28
7.14 Installing wire storage unit cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
7.15 Connecting electricity supply and water supply . . . . . . . . . . . . . . . . . . . . . . 28
8 Beforeuse ............................................... 28
8.1 Homescreen.............................................. 28
8.2 Selectingoperatingmode ..................................... 29
9 Sawingoperations ......................................... 30
9.1 Operatingthewiresaw ....................................... 30
9.2 Enlargingwirestorageunit .................................... 32
9.3 Endingthesawingoperation ................................... 33
9.4 Removingwiresaw ......................................... 33
10 Careandmaintenance ...................................... 33
10.1Cleaningthewiresaw........................................ 34
11 Transportandstorage ...................................... 34
11.1Transportingthesystem ...................................... 34
12 Troubleshooting ........................................... 34
12.1Troubleshootingtable........................................ 35
13 Disposal................................................. 37
14 Manufacturer’swarranty .................................... 38

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1 Information about the documentation
1.1 About this documentation
• Read this documentation before initial operation or use. This is a prerequisite for safe,
trouble-free handling and use of the product.
• Observe the safety instructions and warnings in this documentation and on the
product.
• Always keep the operating instructions with the product and make sure that the
operating instructions are with the product when it is given to other persons.
1.2 Explanation of symbols used
1.2.1 Warnings
Warnings alert persons to hazards that occur when handling or using the product. The
following signal words are used:
DANGER
DANGER !
▶Draws attention to imminent danger that will lead to serious personal injury or fatality.
WARNING
WARNING !
▶Draws attention to a potential threat of danger that can lead to serious injury or fatality.
CAUTION
CAUTION !
▶Draws attention to a potentially dangerous situation that could lead to personal injury
or damage to the equipment or other property.
1.2.2 Symbols in the documentation
The following symbols are used in this document:
Read the operating instructions before use.
Instructions for use and other useful information
Dealing with recyclable materials
Do not dispose of electric equipment and batteries as household waste
1.2.3 Symbols in the illustrations
The following symbols are used in illustrations:
These numbers refer to the corresponding illustrations found at the beginning of
these operating instructions
The numbering reflects the sequence of operations shown in the illustrations
and may deviate from the steps described in the text
Item reference numbers are used in the overview illustrations and refer to the
numbers used in the product overview section

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This symbol is intended to draw special attention to certain points when han-
dling the product.
1.3 Product-dependent symbols
1.3.1 Symbols on the product
The following symbols are used on the product:
Wear protective gloves
Wear eye protection
Wear a hard hat
Wear safety shoes
Wear breathing protection
Wear ear protection
General warning
Warning: hazardous electrical voltage
Risk of crushing parts of the body.
Warning: risk of injury by cutting.
Unauthorized access prohibited.
Recycle waste material.
1.4 Stickers
The following stickers are used on the product.
• Read the operating instructions before
use
• Wear a hard hat
• Wear ear protection
• Wear eye protection
• Wear protective gloves
• Wear safety shoes
• Make sure that the sawing wire is
correctly routed
• Comply with all requirements concerning
danger zones
• Do not enter the danger zone while the
product is in operation
• Do not extend the guide rail
• Do not work without an end stop
• Do not work without guards

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1.5 Product information
products are designed for professional users and only trained, authorized
personnel are permitted to operate, service and maintain the products. This personnel
must be specifically informed about the possible hazards. The product and its ancillary
equipment can present hazards if used incorrectly by untrained personnel or if used not
in accordance with the intended use.
The type designation and serial number are printed on the rating plate.
▶Write down the serial number in the table below. You will be required to state the
product details when contacting Hilti Service or your local Hilti organization to inquire
about the product.
Product information
Wire saw DSW 2005-TS
Generation 01
Serial no.
2 Safety
2.1 General safety instructions
Study all safety instructions and other instructions, images and technical data with
which this product is provided. Failure to comply with the instructions below can cause
serious injuries.
Keep all safety precautions and instructions for future reference.
2.2 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
can influence the statics, 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. Poorly ventilated workplaces can result
in damage to health because of exposure to dust.
▶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.
▶Wear personal protective equipment. Wear safety footwear, protective gloves, a hard
hat and protective glasses.
▶Wear respiratory protection if the work causes dust.
▶Wear suitable work clothes. Do not wear jewelry or loose clothing that could be
snagged by moving parts. If your hair is long, wear a hair net.
▶Do not allow other persons to touch the equipment or the extension cord.

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▶Keep children and other persons away from the working area.
▶Avoid awkward postures. Maintain firm footing and balance at all times.
▶Use only approved fasteners and lifting equipment of adequate load-bearing capacity
to secure, lift clear and transport from site the parts of the structure that are cut away.
▶Always run cables and hoses flat on the floor or ground away from the product to
prevent trip hazards.
▶Keep cables and hoses away from rotating parts.
▶Jointly with site management, make sure that no gas, water, electricity or other lines
are located in the cutting area. Lines in the vicinity of the cutting zone that could
be damaged by falling parts, for example, have to be specially protected and, if
necessary, temporarily taken out of service.
▶Ensure that the cooling water used is drained or extracted in a suitably controlled
manner. Cooling water allowed to drain away or spray around in an uncontrolled
manner can lead to damage and accidents. Also bear in mind that water can drain
away through hidden internal cavities.
2.3 General safety rules
▶Use the product 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 product for the job. Do not use the product for purposes for which it was
not intended. Use it only as directed and when in faultless condition.
▶Use the product and its accessories, accessory tools, etc. in accordance with these
instructions and in the manner intended for the particular type of product. Take the
working conditions and the work to be performed into account. Use of this product
for uses other than those intended could result in hazardous situations.
▶Take influences of the surrounding area into account. Do not use the product where
there is a risk of fire and explosion. Power tools create sparks which can ignite dust
or gases.
▶Keep the grips clean, dry and free from oil and grease.
▶Do not overload your product. It will work more efficiently and more safely within its
intended performance range.
▶Never leave the product unattended.
▶Store the product in a secure place when not in use. When not in use, products must
be stored in a dry, high place or locked away, out of reach of children.
▶Always disconnect the supply cord from the electricity supply when the product is
not in use (e.g. during breaks between working), before changing settings, before
cleaning and maintenance and before changing tools. This safety precaution prevents
the product from starting accidentally.
▶Remove adjusting tools or wrenches before switching on the product. A tool or a
wrench left attached to a rotating part of the product can cause injury.
▶Before use, the product, 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. All parts must be
fitted correctly and fulfill all conditions necessary for correct operation of the product.
Damaged parts must be repaired or replaced properly by an authorized service center.
▶Avoid skin contact with drilling and sawing slurry.
▶Follow the instructions concerning care and maintenance.
▶The product is not intended for use by children, by debilitated persons or by persons
who have received no instruction or training.

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2.4 Protection against electric shock
▶Always check the product before use. In particular, check that all electricity cables,
connectors and hoses are in good condition. Do not operate the product and its
accessories if damage is found, if the system is incomplete or if its controls cannot be
operated faultlessly. Have the product repaired by Hilti Service.
▶Connect the product and its accessories only to a power source equipped with an
earth/ground conductor and ground fault circuit interrupter (portable residual current
device, 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 to
ground the system.
▶Make sure that the electricity supply corresponds to the specification given on the
type plate.
▶Protect yourself against electric shock. Avoid body contact with grounded parts such
as pipes, radiators, cooking stoves or refrigerators.
▶Keep electric cables and especially their plug connectors dry. Close power outlets
with the covers provided when not in use.
▶Disconnect the power cable before beginning cleaning and maintenance work or in
the event of an interruption between periods of operation.
2.5 Requirements to be met by users
▶Only specialists who have received training in concrete cutting techniques are
permitted to operate the product. 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 product while you are tired or under the influence of drugs, alcohol or
medication. A moment of inattention while operating the product can result in serious
injury.
▶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 exclusion zone by cordoning it off and taking protective measures
(guards, etc.) as necessary.
▶Dust from materials such as paint containing lead, some types of wood, minerals and
metal can be harmful to health. Contact with or inhalation of the dust can cause allergic
reactions and/or respiratory or other diseases to the operator or bystanders. Certain
kinds of dust such as oakwood and beechwood dust are classified as carcinogenic,
especially in conjunction with additives for wood conditioning (chromate, wood
preservative). Only specialists are permitted to work on material containing asbestos.
Ensure that the workplace is well ventilated. It is advisable to wear a filter class P2
dust mask. Comply with national regulations applicable to the materials you will be
working with. To help prevent the product of dust in large quantities, position the
water lances at the through-holes.
▶Observe the national regulations and laws, as well as the operating instructions and
the safety information applicable to the accessories used (e.g. diamond sawing wire,
fastening accessories, lifting equipment, etc.).
2.6 Safety during operation
▶Before use, check that the product and its components, the diamond sawing wire and
its connectors as well as the accessories are in good condition and in perfect working

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order. Make sure that any damage or malfunctions are rectified in a professional
manner before operation commences.
▶While the product is operating, remain in a location far outside the danger area with
the remote control unit. Make sure that you have the entire working area in clear view
at all times.
▶Work only when the product and also the wire guides have been securely and firmly
secured to a solid sub-base. A toppling or dropped part can result in serious damage
or injury.
▶Do not connect the electricity supply until the wire saw has been set up completely.
▶Entry into the danger zone (e.g. to adjust the pulleys or water supply, hammer in
wedges, etc.) is permissible only after the Emergency Stop button has been pressed
and the drive pulley 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 diamond sawing wires that comply with the requirements of EN 13236. Use
only diamond sawing wires approved for a cutting speed of at least 30 m/sec, with
rubberized or plastic-coated spaces between the beads.
▶The number of wire breakages experienced can be reduced considerably by using
high-quality diamond sawing wires and wire connectors and the appropriate crimping
tools for fitting connectors.
▶The diamond sawing wire can become hot, so do not touch it unless you are wearing
protective gloves.
▶Use only fasteners (anchors, bolts, etc.) of adequate size to secure the wire guides
and 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 the
cooling water system and the area surrounding the workplace under observation. Do
not operate the product if your full attention is not on the job.
▶Modifications to the saw system are prohibited. Operate the product only with the
sawing wire mode active.

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2.7 Danger zones and safety distances to be maintained
▶The exclusion zone extends to at least twice the radius of the length of wire that would
be unleashed in the event of the wire breaking (L1) (L2) and the areas in the extended
axes of the directions in which the wire is running. This exclusion zone 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 whiplash of the diamond sawing wire and safely and reliably stop
flying fragments or debris.
▶Always keep a minimum distance of 1.5 m away from all movable parts during
operation.

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▶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.
2.8 Additional safety instructions
▶Do not cut easily flammable materials.
▶National regulations and laws, as well as the operating instructions and the safety
information applicable to the accessories used (e.g. diamond sawing wire, fastening
accessories, etc.), must be taken into account.
▶Do not work without the end stop fitted in order not to overrun the end of the rail with
the saw head.
▶Do not attempt to install the product on the ceiling.
▶Do not hold objects against the diamond sawing wire by hand, e.g. with a view to
using it as an improvised saw.
▶Always work with fully fitted and a fully functional guards.
▶Always install the holder for the wire storage cover so that the cover can be correctly
secured.
▶Install the wire saw only when the base plate is securely mounted on the sub-base. If
the base plate is not securely installed, the wire saw can topple.

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3 Description
3.1 Product overview (saw system)
@Wire saw DSW 2005-TS
;Saw head DST 20-CA
=Remote control unit DST WRC-CA
(in sawing wire mode)
%Sawing wire

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3.2 Product overview DSW 2005-TS
@Guard for sawing wire loose side
(black)
;Guard for drive pulley
=Holder for guard (red)
%Wire storage unit cover (red)
&Wire storage pulley (top)
(Wire storage pulley (bottom)
)Base plate
+Wire spreader
§Drive pulley
3.3 Intended use
The DSW 2005-TS (01) is a modular wire-sawing system to be used only in combination
with the DST 20-CA (01) wall saw as drive unit and the DST WRC-CA (01) as control unit.
Operation of the saw head in combination with the wire saw system is permitted only in

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the wire sawing operating mode. For information on safety and operation of the saw
head, read the operating instructions of the DST 20-CA (01) wall saw. For information on
safety and operation of the control unit, read the operating instructions of the DST WRC-
CA (01) remote control unit.
The product is designed for the technical demolition of steel, concrete, stone or brickwork
structures in construction and civil engineering applications.
The product is suitable for wet and dry cutting. A dust removal system must be used for
dry cutting.
Only specialists who have received training in concrete cutting techniques are permitted
to operate the product.
Changes or modifications not expressly approved by Hilti may restrict the user’s right to
operate the product.
3.4 Items supplied
DSW 2005-TS, operating instructions
Other system products approved for use with this product can be found at your local
Hilti Store or at: www.hilti.group
3.5 Additionally required accessories
DST 20-CA saw head, DST WRC-CA remote control unit, DSR200L or DSR230L rail,
DSESL end stop, diamond sawing wire.
3.6 Optional accessories
3.6.1 Water supply
@Water supply, long
;Water supply, short
=Water hose
The following accessories can be used to bind
the dust produced during sawing and to cool
the diamond sawing wire.

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3.6.2 Single-pulley stand (DSW-SPP)
The diamond sawing wire can be redirected
over a single-pulley stand.
3.6.3 Release pulley (DS-WSRW)
A release pulley can be used for cutting thick
walls, for example, or for long cuts. This is
a way of optimizing wire contact length and
increasing cutting speed.
3.6.4 Guard (DSW-WG)
Guards must be fitted if it cannot be ensured
that persons do not enter the danger zones
where they would be at risk from flying frag-
ments, or where there is a risk of damage to
property, while work is in progress.
4 Technical data
Dimensions (W x D x H) 860 mm x 700 mm x
2,350 mm
Drive wheel diameter 500 mm
Cutting speed 13.3 m/s … 24.1 m/s
Capacity, wire storage 5.6 m
Rail DS-R200-L or DS-R230-L
Wire diameter 8 mm … 12 mm
Recommended wire length 11.5 m
4.1 Weights of the individual components
Total weight without saw head 105.0 kg
Base plate 20.5 kg

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Wire spreader 31.0 kg
Wire storage pulley (bottom) 9.5 kg
Wire storage pulley (top) 11.5 kg
Holder for guard (top) 3.2 kg
Drive pulley 8.0 kg
Guard for drive pulley 5.2 kg
Guard (red) 10.2 kg
Guard (black) 4.0 kg
5 Typical examples of applications
The following examples illustrate the most common applications.
5.1 Vertical cut (default)
• At the start of the cut, pass the sawing wire as shown through the object to be cut.
• Swivel the pulley at the wire infeed down as soon as the sawing wire approximately
reaches the position shown. This prevents the sawing wire from damaging the wire
guide.
• To prevent damage, do not exceed the maximum wire engagement length (B) of
1.5 meters.

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5.2 Vertical cut with release pulley (DS-WSRW)
• At the start of the cut, pass the diamond wire over the release pulley.
• As soon as the cut comes level with the pulley, swing the pulley down and swivel the
release pulley clear, to avoid damage to the wire guide.
5.3 Vertical cut with single-pulley stand
• At the start of the cut, pass the diamond wire over the single-pulley stand
• Swivel the guide pulley on the pulley stand down as soon as the diamond sawing wire
reaches the position shown.
This keeps the diamond wire from damaging the wire guide.