Ics Cws-200 User manual

CWS-200

CHAIN WALL SAW

OPERATOR’S MANUAL

TITLECWS-200 OPERATOR’S MANUAL

TABLE OF CONTENTS

PRIMARY COMPONENTS 4

SYMBOLS & LABELS 5

SAFETY 6

TECHNICAL SPECIFICATIONS 8

MACHINE REFERENCES & SET-UP 9

OPERATION 13

MAINTENANCE 17

TROUBLESHOOTING 19

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, track-

mounted 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.

TITLE CWS-200 OPERATOR’S MANUAL

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

• 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.

WARNING

F/N 541813

Valve Knob must be in

center “OFF” position

before powering on

hydraulic supply.

WARNING

F/N 541812

PRIMARY COMPONENTS

PRIMARY MACHINE COMPONENTS

WARNING LABEL LOCATIONS

WATER SUPPLY

HANDLE FRAME

GUARD CLAMP BRACKETS

GUARD ENCLOSURE

VALVE KNOB

TRAVERSE

CARRIAGE SIDE COVERSIDE COVER BASE

HYDRAULIC HOSE

CONNECTIONS

ROTATION CONTROLS

TRAVERSE CONTROLS

TITLECWS-200 OPERATOR’S MANUAL

SYMBOLS & LABELS

THE FOLLOWING SYMBOLS AND DEFINITIONS ARE FOUND THROUGHOUT THIS MANUAL AND

ARE DESIGNED TO MAKE YOU AWARE OF POTENTIAL HAZARDS OR UNSAFE PRACTICES

A potentially hazardous situation exists which, if not avoided,

could result in death or serious injury.

A potentially hazardous situation exists which, if not avoided,

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

WARNING

CAUTION

Valve Knob must be in

center “OFF” position

before powering on

hydraulic supply.

WARNING

F/N 541812

• 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.

WARNING

F/N 541813

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

1 2

TITLE CWS-200 OPERATOR’S MANUAL

SAFETY

WARNING

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

A potentially hazardous situation exists which, if not avoided,

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.

• 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.

TITLECWS-200 OPERATOR’S MANUAL

SAFETY

CAUTION

THE FOLLOWING SYMBOL APPLIES TO ALL ITEMS LISTED ON THIS PAGE

A potentially hazardous situation exists which, if not avoided,

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.

• 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.

TITLE CWS-200 OPERATOR’S MANUAL

TECHNICAL SPECIFICATIONS

CWS-200 SPECIFICATIONS

BASE MACHINE W/OUT

BAR, CHAIN, & GUARD 75 lbs (34 kg)

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 SUPPLY Minimum 20 psi (1.5 bar)

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

TITLECWS-200 OPERATOR’S MANUAL

REFERENCES & SET-UP

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 1

Loosen the side cover knob and

pivot the clamp stud forward to

disengage from the side cover base.

Remove the side cover.

STEP 4

Turn the tensioning knob counter

clockwise until the guide bar nearly

contacts the drive sprocket.

GUIDEBAR AND DIAMOND CHAIN INSTALLATION

STEP 2

Loosen the guide bar clamp nut a

couple of turns.

TITLE CWS-200 OPERATOR’S MANUAL

REFERENCES & SET-UP

STEP 5

Mount the chain on the guide bar

starting at the drive sprocket and

continuing over the guide bar nose.

STEP 7

Firmly tighten the guide bar clamp

nut using a 3/4" open-ended

wrench.

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 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.

GUIDEBAR AND DIAMOND CHAIN INSTALLATION

TITLECWS-200 OPERATOR’S MANUAL

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.

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.

REFERENCES & SET-UP

MACHINE FIT-UP TO 360 RAIL

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.

TITLE CWS-200 OPERATOR’S MANUAL

STEP 3

ALWAYS ensure the guard

enclosure is positioned and oriented

properly to the guide bar during

operation.

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.

REFERENCES & SET-UP

GUARD INSTALLATION

TITLECWS-200 OPERATOR’S MANUAL

OPERATION

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"

TITLE CWS-200 OPERATOR’S MANUAL

OPERATION

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.

OFF

PULSE

VALVE KNOB

MANUAL MACHINE CONTROLS

ROTATION

TRAVERSE

SLOW

FAST

TITLECWS-200 OPERATOR’S MANUAL

OPERATION

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 2

Rotate 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.

STEP 1

Mount to track.

STEP 3

Traverse in direction of cut

maintaining 45° angle.

Do not apply excessive feed load.

45°

TITLE CWS-200 OPERATOR’S MANUAL

OPERATION

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.

TITLECWS-200 OPERATOR’S MANUAL

MAINTENANCE

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.

• 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.

TITLE CWS-200 OPERATOR’S MANUAL

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.

MAINTENANCE

CWS-200 OPERATOR’S MANUAL

Further questions?

Call 800.321.1240 or visit our website at: icsbestway.com

PROBLEM Possible Cause

POOR CUTTING SPEED

Diamonds not exposed

Hydraulic flow rate too low

CHAIN STRETCH

Inadequate water pressure

Hydraulic flow rate > 25 gpm (95 lpm)

MACHINE DIFFICULT TO TRAVERSE

Guide rollers improperly adjusted or damaged

Slurry build-up on rail or machine gearing

WATER NOT FLOWING

Guide bar ports plugged with debris

Water hose kinked or damaged

MOTOR WON’T TURN

Hydraulic flow rate

Hydraulic flow in incorrect direction

STRAIGHTNESS OF CUT

Excessive feed load

GUIDEBAR RAIL CHIPPING

UNEVEN GUIDEBAR RAIL WEAR

UNEVEN SEGMENT WEAR

TROUBLESHOOTING

ICS, Blount Inc.

4909 SE International Way

Portland, OR 97222

Tel 800.321.1240 Fax 503.653.4393

icsbestway.com

CWS-200 OPERATOR’S MANUAL

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