COMPACT HYDRAULIC WIRE SAW

DSM‑101A
INSTRUCTION MANUAL◎ Thank you for purchasing our products.
◎ Before using, please read Instruction manual carefully, and use the machinesafety by following the instructions.
◎ After reading, please keep it where anyone can utilize.

ＭＥＡＮＩＮＧ ＯＦ ＳＩＧＮＡＬ ＷＡＲＤＳ ＷＡＲＮＩＮＧ , ＣＡＵＴＩＯＮ AND POINT
The instruction manual includes three signal words ； ＷＡＲＮＩＮＧ, ＣＡＵＴＩＯＮ and
POINT which mean as follows.

ＷＡＲＮＩＮＧ : It is assumed that if the user use the machine wrongly, it would be therisks that the user could be died or injured.
ＣＡＵＴＩＯＮ: It is assumed that if the user use the machine wrongly, it would be therisks that the user could remain the disabled or damage for thematerials.

ＰＯＩＮＴ: Important notices for the installation of machine, instructions, maintenanceand servicing.

"CAUTION" might cause the serious accidents depending on the situations. Since wemention the important notices, please strictly follow the instruction in order to avoid theaccidents.

Formal name is described as abbreviated name in the table. (But, formal name is described for thenecessary point in explanation.)
Formal name

Abbreviated name

Diamond Wire

Wire

Clamp Assy. with Main Motor

Clamp

Feed Assy. FW‑101A

Feed□50 Guide Bar 1350L

Guide Bar

Safety Net With Frame

Safety Net

Hydraulic Hose 5/8" Assy.

Hydraulic Hose

Feed Direction Transfer Switch

Feeding Switch

Tension Volume

Volume−2−

1．WARNING AND CAUTION【１】 Safety Notice for Hydraulic Machinery ･･････････････････････････････････････････････････

２【２】 Notice for Usage of Compact Hydraulic Wire Saw ･････････････････････････････････････････ ４
2. NAME OF COMPONENT UNIT AND PARTS ････････････････････････････････････････････････････ ６
3. SPECIFICATION ( MAIN BODY DSM‑101A ) ･･････････････････････････････････････････････････

８

4. STANDRD ACCESSORIES ･･･････････････････････････････････････････････････････････････････

８

5. APPLICATIONS ･････････････････････････････････････････････････････････････････････････････

９

6. OPTIONS ( SOLD SEPARATELLY )【１】 Hydraulic Unit ･････････････････････････････････････････････････････････････････････････

９【２】 Other Options ･････････････････････････････････････････････････････････････････････････ １０
7. GENERAL DRAWING IN USE【１】 Installation of DSM‑101A External Representation and Each Cover ････････････････････････１３【２】 Example of Installation for DSM‑101A・Hydraulic Unit・Safety Net・PC Protection Board ･････１４
8. OPERATING INSTRUCTIONS【１】 Moving Direction of Slide Block and Name of Control Panel and Parts ･･････････････････････１５【２】 Rotation and Stop of Main Pulley ･･･････････････････････････････････････････････････････ １５【３】 Moving and Stop of Slide Block ･･････････････････････････････････････････････････････････１６
9. USAGE【１】 Preparation for Hydraulic Unit E‑2002Ax ･････････････････････････････････････････････････１７【２】 Anchor Fixing ･････････････････････････････････････････････････････････････････････････ ２１【３】 Installation of DSM‑101A ･･････････････････････････････････････････････････････････････ ２１【４】 Connection of Control Panel ･･･････････････････････････････････････････････････････････ ２４【５】 Jointing of Diamond Wire ･･･････････････････････････････････････････････････････････････ ２５【６】 Mounting of Cover ･････････････････････････････････････････････････････････････････････ ２６【７】 Preparation for Feeding Water ( When using Option Water Supply Hose Assy. ) ･････････････ ２７【８】 Setup Safety Net and PC Protection Board (Sell separately)････････････････････････････････２７【９】 Cutting Operation ･････････････････････････････････････････････････････････････････････ ２８【10】 Dismantling ･･･････････････････････････････････････････････････････････････････････････ ３０
10. CHANGING THE POSITION OF Φ250 EASY ATTACHING RESIN GUIDE PULLEY ･･････････････ ３２
11. TROUBLESHOOTING DURING OPERATION ･････････････････････････････････････････････････ ３４
12. HOW TO JOINT DIAMOND WIRE ････････････････････････････････････････････････････････････ ３５
13. HOW TO USE WATER STOP PACKING ( OPTION ) ･･･････････････････････････････････････････ ３９
14. INSPECTION ･ MAINTENANCE ･ REPAIR【１】 Inspection Before Operation ････････････････････････････････････････････････････････････ ３９【２】 Regular Inspection ･････････････････････････････････････････････････････････････････････ ３９【３】 Maintenance ･･････････････････････････････････････････････････････････････････････････ ４０【４】 Repairs ･･･････････････････････････････････････････････････････････････････････････････ ４０
15. HOW TO STORAGE THE MACHINE ･････････････････････････････････････････････････････････ ４３
16. CHECK LIST
【１】 Before Operation Check List for Compact Hydraulic Wire Saw ･････････････････････････････４４【２】 Check List for Jointing Diamond Wire ････････････････････････････････････････････････････４５

１. WARNING AND CAUTION◎ Read 「WARNI‑‑‑‑‑‑NG AND CAUTION」 before use, and follow the instruction and use correctly.
◎ To avoid the risk of fire, electric shock and personal injury, follow 「Safety Notice for Hydraulic
Machinery」 and 「Notes for Usage of Compact Hydraulic Wire Saw」
◎ Save the instruction manual after read where users can read anytime.
◎ Read the instruction manual 「Dry Wire Sawing System」 for warning and caution of dry cutting with dry
wire sawing system of options.

【１】 Safety Notice for Hydraulic Machinery WARNING
1. Do not use for other than specified purposes.
2. Keep bystanders and children away.
◎ Never allow bystanders to contact hydraulic unit itself, other hydraulic equipment, control box orcord and hose.
3. Avoid dangerous environments.
◎ Do not use Hydraulic unit itself or control panel such as electric machines in the rain, damp or
wet places.
◎ Keep working area lightly.
◎ Do not use machine where there are flammable gas or flammable liquid.
◎ Cluttered work areas invite accidents.
4 .Wear appropriate work clothes.
◎ Do not wear the loose clothing or jewelries in order to avoid to being caught in the rotatingparts.
◎ When working outdoors, we recommend to wear the rubber gloves and insulated no‑skid footwear.
◎ Wear cap or hair cover in case that you have long hair.
5. Use safety protection tools.
◎ Wear safety glasses during working. If there are many dust, wear the dust mask.
6. Do not work with improperly posture.
◎ Fix the footing and maintain the balance at all times.
7. Work carefully without staying alert.
◎ When using the machines, operate carefully by considering

operation methods, how to use

and surrounding area.
◎ Do not come close to the rotating parts. It will be dangerous to being caught in or
injured.
◎ Be careful not to jam your hands or feet between moving parts or connecting parts.
◎ Do not use machine when you are tired or distracted.

−2− WARNING
8. Be careful for receiving electric shocks.
◎ Earth Hydraulic Unit for sure.
◎ Use power source equipped with earth leakage breaker.
◎ When working, wear rubber gloves and rubber shoes.
9. Do not treat the cord and horse roughly.
◎ Do not carry machines by holding the cord.
◎ Do not carry machines by pulling the cord from the power receptacle.
◎ Do not get close the cord or hose near the heat, oil and sharp objects.
10. Use CONSEC recommended accessories and options.
◎ When you use the accessories and options which are not listed in the manual or CONSEC's
catalogue, it might cause the accidents or personal injury. Do not use the accessories andoptions which CONSEC does not recommend.
11. Inspect for the damaged parts.
◎ Before using, inspect the protection cover and other parts damages carefully, and make surethat whether the machine operate properly and the designed functions work or not.
◎ Check for alignment, binding of moving parts, parts damages, mounting, and any otherconditions that may affect operation.
◎ Do not use machine if the switch does not turn on or of off.
◎ Regarding the exchange or the repair for the damaged parts, follw the instruction manual.
◎ In case that there are no instructions in the manual, contact to the distributors or CONSEC.
12. Stop Hydraulic unit as following cases.
◎ When connecting or removing Hydraulic hoses.
◎ When exchanging the options such as blades or core bits.
◎ Reparing◎ You hear the strange noise from Hydraulic unit.
◎ You can anticipate other hazardous situations.
13. Remove the key or the wrench for sure.
◎ Before turning on the switch, make sure that the key and the wrench which are used for theinspection and adjusting are removed.
14. Each machine should be maintained carefully.
◎ Regarding the supplying the oil or the exchange of options, follow the instruction manual.
◎ Keep the Grip dry and clean, and avoid the oil or grease.
15. When you do not use the machine, storage properly.
◎ Storage in the dry place, safe place where children can not reach and the place where you can lock.
16. Ask for repairing to CONSEC's sales (service) representative.
◎ Since this machine is manufactured in compliance with applicable safety standards, do not
remodel it.
◎ If the person who is a very little understanding of repairing, knowledge and technique, performance
can not operate enough. And, you will invite the accident or injury.
◎ Ask for repairing to the distributor or CONSEC's sales (service) representative.
−3−【２】 Notice for Usage of Compact Hydraulic Wire Saw
 WARNING
1. Use Hydraulic Unit which is manufactured as options by CONSEC.
◎ Read and understand instruction manual of each Hydraulic Unit carefully before using.
2. Be careful of such as conduit, gas pipe and water pipe.
◎ If you contact to the electric wire and conduit, you will receive the electric shock.
◎ When drilling or cutting wall and floor, check carefully the buried objects.
3. Use all covers.
◎ To prevent from flying of diamond wire due to breaking the wire andseparation of sleeve, use

main pulley cover and auxiliary covers (right and left) during operation.
4. Do not operate upward. (Except using Dry Wire Sawing System)◎ This machine always use water. If Compact Hydraulic Wire Saw is used upward, water isaccumulated inside of Main Pulley Cover which is extremely dangerous. Do not operate
upward.
5. Do not cut in reverse position of feed direction selector switch which is equipped on the Control Box,
Feed Assy. might come off.
6. Operating at the high pace, follow the related laws.
◎ Mounting and dismounting of Slide Block on Pole Base. You must be close to the ground.
◎ If Slide Block drops, it is extremely dangerous. Take personnel safety measures.
◎ When operating at the high place, place the machine at the safe and stable place.
◎ When operating at the high place, set the machine at the safe and secured place.
◎ When operating at the high place, do not let bystanders come under cutting area.
◎ Please wear a security zone, a safety helmet by all means.
7. When installing or removing Guide Bar with leaving the Guide Clamp, Make sure to fix the Guide Bar
not to fall off. If the Guide Bar falls off, it is extremely dangerous.
8. When abnormality occurs, stop the rotation of Main Pulley.
◎ If the rotation of Diamond Wire stops or abnormal noise occurs, stop the rotation of Main Pulley
by pressing 「Cutting Stop」 Buttonon the remote control switch.
9.Check the Rubber Ring of Main Pulley and Guide Pulley which don't have abnormal wear.
10. Feed water when cutting (Except using Dry Wire Sawing System)◎ Always feed water. If Diamond Wire is heated up, operating life will shorten and cutting
efficiency will go down which will cause the breakage of wire and separation of sleeve.
11. When changing operation such as changing for feeding water position or Diamond Wire, stop HydraulicUnit, then operate carefully.
◎ If you do not stop Hydraulic Unit and continue to operate, then drive the pulley mistakenly, it isextremely dangerous that you will be caught in the machine or injured.

−4− WARNING
12. Use Diamond Wire recommended by CONSEC.
◎ Use Diamond Wire recommended by CONSEC and do not use other wire except Diamond Wire.
13. Joint Diamond Wire carefully.
◎ Follow 「HOW TO JOINT THE DIAMOND WIRE」 in this manual or method of designationby each manufacture for jointing Diamond Wire.
◎ Use Sleeve which fits to each Diamond Wire and specified by manufacture only.
14. Change Sleeve every one hour during cutting.
15. If Sleeve is worn out, change the new sleeve and joint the wire again.
◎ If sleeve is worn out, it will cause falling Sleeve off which is extremely dangerous.
Be careful for partial wearing which is extremely dangerous.
16．Diamond Wire may spark during cutting. Do not use in place where catching fire or explosion may beoccurred.
17．Switch off the Hydraulic Unit definitely when the Diamond Wire is set on a Main Pulley. There is a riskthat unexpected machine start causes injury.
18．Check the Diamond Wire doesn't contact with Safety Cover and also during cutting, there is no
possibility to contact each other. Machine or Safety Cover may be broken.
19. When you use Wire Saw machine, Safety Net and PC Protection Board have to be used for safety.
◎ Please set Safety Net by surrounding the Wire Saw and the objects which you cut. The workers
must operate from the outside of the construction area which is surrounded by Safety Net andplease also set PC Protection Board in front of the workers.
◎ In order to avoid being danger, please set Safety Net and PC Protection Board and ensure thezone of "Authorized Personnel Only" even if the wire flies in all direction by causing a breakageof the diamond wire and coming off the sleeve.
20. Do not hang and move the machine. If you hang completed machine with eyebolt and move it, thebalance can not be maintained and it swings like pendulum which is extremely dangerous.
21. Take safety measures for cutting object.
◎ If cutting objects break and fall during operation, it is extremely dangerous. Take safety measure
to prevent from falling by hanging the cutting object with heavy machinery. When hanging the
cutting object after cutting which might swing like pendulum. Take safety measure not to invite
the dangerous situation around working area.
◎ If cutting object breaks and wire is stuck in cutting surface, wire will be locked or will be
broken. Before breaking the cutting object, hammer the wedge on the cutting surface.
22. Make a copy and keep as a record for "Before operation check list for Compact Hydraulic Wire Saw"
and "Check list for jointing Diamond Wire" in this instruction manual page 44 and 45 for each
operation.W−5−

２. NAME OF COMPONENT UNIT AND PARTS
Component Unit (No. 1〜11) and configuration
１．Slide Block Assy. (Clamp Assy. with Main Motor + Feed Assy. FW‑101A)
Main Shaft

Set Plate

Hydraulic Motor
FF Coupler Socket(1/2 )(High Pressure Flow‑in)Connector(with cap)
Embedded bolt
30.0kgFF Coupler Plug (1/2 )(Low Pressure
Flow‑out)

Clamp Assy. with Main Motor
21.4kgSeparate‑Type Slide Block Assy.
Slide Block Assy. can be divided into

Ring

Clamp Assy. with Main Motor and Feed
Assy. FW‑101A.
When dividing it, rotate clockwise whilepulling the ring.

Feed Assy. FW‑101A
8.6kg

２．Pole Base Assy.
Eye Bolt M16×955L

Falling Prevention Plate
900

1877
Extension Pole

900

Leveling Bolt
Base
498

180

−6−

22.6kg

３．Main Pulley Assy.

４．Main Pulley Cover Assy.

１．Slide Block Assy.
（Refer page 6.）

9.8kg

6.3kg
６．Auxiliary Cover R

５．Auxiliary Cover L

２．Pole Base Assy.
（Refer page 6.）

7.0kg
7.0kg

７．φ250 Resin Guide Pulley Assy.
（3pce）
Control Box BW‑101A
Connecting Cord
（Standard Accessories
Refer page 8）
5.9kg
９．□50 Guide Bar 1350L
８．Guide Bar Clamp Assy.

10．Sub Pole Bracket
Assy.

９．□50 Guide Bar 1350L

3.3kg
5.2kg

8.2kg
11．φ250 Easy Attaching Resin Guide
Pulley Assy.

7.5kg

−7−

３. SPECIFICATION （ MAIN BODY DSM‑101A ）Model name

DSM‑101A

Clamp Assy. with
Slide Block Main Motor
Assy.

Feed Assy.
FW‑101A

Model

2‑060

Rated pressure

21MPaMax. discharge

54L/minMaximum rotation speed of Main Shaft

850min‑1

Feed

Rated Voltage

DC24V

Motor

Rated Power

54W

Hydraulic
Motor

Max. Feeding Speed

1634mm/min

Max. Tension

1786N

Main Pulley Assy. Outer Diameter

600mm

Assembling Gross Mass (Except control panel and connection cord)

133kg

Applicable Diamond Wire

10〜11mm

Applicable Hydraulic Unit

E‑2002Ax

４. STANDRD ACCESSORIES
Tension Volume

Feeding Switch

Hooked Waterproof Plug
Connector
Receptacle
Power Supply Cord 3cores 1.25mm2
Control Box BW‑101A
Power Supply
Power Supply Cord length

Tool bag・・・１pce

Connecting Cord

Single Phase A.C.100/200V

Cord length

20m

10m

Single‑ended Spanner
21・24mm・・・１pce each

Ratchet Wrench
17×21mm・・・１pce−8−Instruction Manual・・・１pce５. APPLICATIONS◎ Concrete construction, cutting for stone material, dismantlement, and making of opening part.
【EXAMPLE OF CONSTRUCTION】 Nuclear plant, bridge, bridge footing and subway structure.

６. OPTIONS （SOLD SEPARATELLY ）【１】 Hydraulic Unit CAUTION
Use it after reading the instruction manual of Hydraulic Unit.
Do not connect to the hook plug except control panel of standard accessory.

１） Ｅ−２００２Ａｘ

Remote Control Switch 20m

Power Cable 4cores 8 mm2 15m
High performance 20kW water‑cooled motor
helps to apply high load with maximum
discharge amount. Possible to cut large
Hydraulic Hoses 5/8 Assy. FF Plug‑Socket 20m

section with using DSM‑101A.

２） E‑１１１４Aｘ

Remote Control Switch 20m

Power Cable 4cores 8 mm2 15m

Mounted 11KW three‑phase induction
motor. Compact type 701mm wide andpossible to put on the general elevator.
Hydraulic Hoses 5/8 Assy. FF Plug‑Socket 20m−9−【２】 Other Options
Diamond Wire

SleeveManual HydraulicPressure Caulker
EP‑300N
Dies

Press Rest

Wire is covered by coated rubber
built in spring and installed diamond
bead.

Used to connect Diamond Wire.

Used when connecting Diamond
Wire with Sleeve and used to press
the Sleeve.

Wire Cutter

Guide Pulley Pole Base

φ200､φ220､φ250
Resin Guide Pulley Assy.

Used to cut Diamond Wire toadjust the length.

Used with Resin Guide Pulley Assy.
When exceeding the cutting width as
standard cutting, use as an auxiliary
pulley.

Bear for hard use due to light andintensity by aluminum and resin pulleyof steel made hybrid design.

φ200､φ250 Resin Easy Attaching
Guide Pulley Assy.

Adjustable Stand Assy. 101A

Adjustable Bracket Assy. 101A

Easily changed installing due to lightand intensity by aluminum and resin
pulley of steel made hybrid design.

Setting is possible at the places suchas chimney, large diameter hume pipe
like curved surface and stairs likeuneven surface. Use to combine with
Adjustable Bracket Assy.

Setting is possible at the places suchas chimney, large diameter hume pipe
like curved surface and stairs likeuneven surface. Use to combine with
Adjustable Stand Assy.

Easy Attaching Sub Pole Bracket
Assy.

Electromagnetic Brake Assy.

Hydraulic hoses 5/8 ASSY.
FF Plug and Socket 20m

Easily changed installing.

By changing centrifugal brake toelectromagnetic brake, it can beelectromagnetic brake type. It is possible
to change at CONSEC service center.

−10−

Used when extending HydraulicHose of ・E‑2002Ax Need 2 pcs. (Itdoes not contain hydraulicactuation oil. )Exchange Adapter
B male ‑ F male 1/2

Exchange Adapter
B female ‑ F female 1/2

Pressure Relief Tool for Hydraulichoses

Used to change BS coupler plug
(Bridge Stone) and FF coupler plug
(Nitto Kouki).

Used to change BS coupler socket(Bridge Stone) and FF coupler socket(Nitto Kouki).

Used to release the pressure by
opening the increased innerpressure hose Assy. of coupler.
Exclusive use for FF coupler 1/2"( Nitto Koki )Water Stop Packing

Easy Attaching Water Supply Hose
101A

Safety Net With Frame
Connecting
Fitting

Stand

You can save the cutting water byinserting in the cutting groove
which prevents from flying the
cutting water and securing thewater way.

Possible to install □50 Guide Bar
and single‑lumen pipe and also
possible to fix by anchor.

Preventing from flying surroundingarea when breaking wire and flying
wire by separation of sleeve.

Dyneema Safety Net

PC Protection Board

Resin Wedge
Connecting

Stand(Sold separately)
There are two size of net, "2m x 3m"and "2m x 5m" for Safety Net with
Frame.

Transparent protection board makes
high level of visibility and easy tocarry due to the 2‑separable board.
This is dedicated for the protection in
front of worker.

Anchor Fixing Set

Construct such as concrete and fix the Pole Base Assy.

−11−

When cutting proceeds by Wire Saw
on some level, install the Resin
Wedge on the cutting surface of
cutting object which prevents fromtucking of Wire Saw caused bybreaking of cutting objects.

◎ Options for Dry Type Wire Sawing System
Read instruction Manual 「Dry Type Wire Sawing System」 for usage.
In‑Take Guide PulleyNozzle Pulley Assy.

Dust Cover Assy. for Flat Surface
use

Smoothly collect the cutting powder byfollowing‑up to the cut of Diamond
Wire.

Available to adjust the nozzle directionin positioning of Diamond Wire and comewith 20 m water supply hose.

Easily attached by one fitting.
After completing the cutting. Roller
can hold a Diamond Wire.

Dust Cover Assy. for R500
and Attachment set

Guide Bar 2 1600L

Water Supply Tank T‑38

Attachment for Dust Cover Assy.
for cutting R500 mm curved object
and changing with Flat Surface
Cover.

Guide Bar for Dry Wire Sawing
System. (DSM‑101A is used not only
installing by bolt but also inserting the
Guide Bar Clamp.)

Tank capacity is 38L. When usingwith fill water, it can feed the coolingwater through the nozzle of nozzle
pulley Assy. approximately 3.5 hours.

Cyclone Dust Collector CD‑35

Vacuum Machine

Dry Diamond Wire

Used to collect the cutting powder
into the sand bag.

Collect the cutting powder without
leaking during cutting.

Diamond Wire specially made for dry
cutting. Cooling fins are attached.
There are two kinds of Dry Diamond
Wire, the one is for more cutting
performance, the other is for more life.

Wire Guard
Sponge 1000

Wire Guide fitting
Pressing Plate forflat surface

Pressing Plate forcurved surface

Use with sponge and pressing plate. It plays as safety protection plate whenoccurring the troubles such as wire braking and dust control. (Use Safety Net foryour safety )−12−

Available to fix Wire Guard easily.

７. GENERAL DRAWING IN USE【１】 Installation of DSM‑101A External Representation and Each Cover◎ All cover must be used during cutting.
To prevent fling wire due to the coming off sleeve from wire and wire breakage, Main Pulley Coverand Auxiliary Cover R&L must be used during cutting for sure.

Pole Base

Auxiliary Cove L

DSM‑101A
Main Pulley
Main Pulley Cover□50 Guide Bar 1350L
Overall height
Stroke End
２０６８

Control Box
BW‑101A

Auxiliary Cove Ｒ

Effective
Stroke１２５５Connecting Cord

Sub Pole Bracket□50 Guide Bar 1350L
１３５７Guide Bar Clamp
４９８
φ250 Easy Attaching Resin Guide Pulley

φ250 Resin Guide Pulley WARNING
Main Pulley Cover and Auxiliary Cover R&L must be used during cutting for sure. Because if
they cannot be used, there is a possibility to get injured by hitting broken sleeve, wire,beads.

−13−

【２】 Example of Ｉnstallation for DSM‑101A・Hydraulic Unit・Safety Net・PC Protection
Board◎ When you use Wire Saw machine, Safety Net and PC Protection Board have to be used forsafety.
１） Please set Safety Net by surrounding the Wire Saw and the objects which you cut. The workers
must operate from the outside of the construction area which is surrounded by Safety Net andplease also set PC Protection Board in front of the workers.
２） In order to avoid being danger, please set Safety Net and PC Protection Board and ensure thezone of "Authorized Personnel Only" even if the wire flies in all direction by causing a breakageof the diamond wire and coming off the sleeve.
DSM‑101A
Cutting Object
Wire
Easy Attaching Water
Supply Horse Assy.

Feed Water Hose

Safety Net With
Transparent PC
Protection Board

Authorized Personnel Only
WorkerControl Box
BW‑101A
Hydraulic Unit
E‑2002Ax

 WARNING
1. If diamond wire breaks, there is a possibility being danger and injured by flying piece of wirematerial. Ensure the zone of "Authorized Personnel Only" in working area and keep out
except authorized person securely.
2. Assuming diamond wire breakage, implement the protection measures considering directionof wire flies.
◎ Wire Saw and cutting object must be surrounded by Safety Protection Board or Safety Net toensure the safety in case of wire flying due to the breakage. If the protection measures is notproper, it is caused fatal accident and quite danger.
Cutting Width

520〜1235mm

Max. thickness of object can be cut （one stroke） 2518mm （Cutting Width 1235mm）
Max. cutting area （one stroke）

Rectangle

Effective Stroke of Main PulleyMax. Rpm of Main Pulley

3.11m21255mm50Hz

748min‑1

60Hz

850min‑1

Max. Set Pressure

21MPa

Suitable Hydraulic Unit

E‑2002Ax−14−

８. OPERATING INSTRUCTIONS【１】 Moving Direction of Slide Block and Name of Control Panel and Parts「Cutting」「Reverse」

Slide BlockWhen turn feeding switch「Cutting」 or 「Reverse」, itmoves to arrow direction in the
figure.

Feeding Switch(Cutting・OFF・Reverse)

TensionVolume(Adjust manually「0」〜「10」)

 WARNING
Do not cut in reverse position, Feed Assy. might come off.

【２】 Rotation and Stop of Main Pulley◎ Explained operating instruction for Hydraulic Unit E‑2002Ax.
Use it after reading the instruction manual of Hydraulic Unit E‑2002Ax.
◎ The operation of Compact Hydraulic Unit Wire Saw DSM‑101A is used both Control Box(Standard Accessory) and remote control switch of Hydraulic Unit E‑2002Ax.
1) Start ･ Stop for Hydraulic Unit E‑2002Ax
 WARNING
1. Remote Control Switch must be operated by theoperator who use Compact Hydraulic Wire Saw.
2. When controlling the remote operation, make surethat surrounding area of Compact Hydraulic Wire
Saw is safe before operation.

Start

Stop

2) Rotation (Cutting) ･ Stop (Stop Cutting) of Main Pulley WARNING
Do not start Hydraulic Unit except rotating Main
Pulley Assy.
Cutting−15−

Cutting Stop

【３】 Moving and Stopping of Slide Block CAUTION
If Slide Block is fixed by L bolt, move it after loosing.

1) Moving / Stopping on the floor fixed position① Turn Feeding Switch 「Cutting」or 「Reverse」

Above② Turn the volume more than 「5」 and move it.
③ When stopping during operation, turn Feeding
Switch 「Cutting」 or 「Reverse」, then turn
tension volume 「5〜6」.

Below
Floor fixed position.

 CAUTION
When Slide Block moves with floor fixing, do not
move it less than the volume 「4」. Slide Block will
drop and it will cause the injury and breakdown of
the machine.

Feeding Switch「Cutting」or「Reverse」

Tension volume｢5｣ and above

2) Moving /Stopping on the wall fixed position① Turn Feeding Switch 「Cutting」or 「Reverse」

Above

wall fixed position.

② Turn the volume from 「0」 little by little, thenmove.
③ When stopping, turn the volume less than 「1」Below3) Stop at upper / at lower《 Stop at upper 》① Turn Feeding Switch 「Cutting」 and move up until
hitting to the falling prevention plate on the polebase.
② Turn the volume in neutral 「5〜6」.
《 Stop at lower 》

Stop at upper① Turn the switch「Reverse」 by volume more than「5」and move down by the motor.
② Turn「OFF」 the Feeding Switch just before thebottom and move down until hitting to Guide Bar.
−16−

Stop at lower

９. USAGE
 WARNING
Take safety measure during operation to avoid falling off the cutting objects.

◎ Explained operating instruction for Hydraulic Unit E‑2002Ax.
Use it after reading the instruction manual of Hydraulic Unit E‑2002Ax.

【１】 Preparation for Hydraulic Unit E‑2002Ax
Items to beprepared

Water Supply Hoses･･･necessary Quantity

Hose Band
･･･necessary Quantity

Three‑way Cock･･･necessary Quantity

Wheel Stopper… at least 2 pce

1. Connect to Power Supply◎ Connect Hydraulic Unit E‑2002Ax to Power Supply.
 WARNING
1. Be careful not to receive electric shock. Use Power Supply installed with Earth Leakage
Breaker.
2. When connecting Electric Cable to Power Supply, make sure to turn off the breakers ofengine and distribution panel. Also, connect to Earth (Green line).

2. Setting for Discharge Pressure (Max. Load Pressure)◎ Do not connect Hydraulic Unit to Hydraulic Hose 5/8".
◎ Pressure setting is 21MPa when factory shipment.

POINT
When staying connected Hydraulic hose, setting pressure will not be shown on Oil Pressure
Gauge.

1) Conduct running‑in operation of hydraulic actuation oil.
When oil temperature reaches more than 20℃,
running‑in operation is completed.
2) Press 『Start』 Button on Remote Control Switch tostart Hydraulic Unit.
3) Wait for approximately 6 seconds after starting
Hydraulic Unit, and press 『Cutting』 Button on
Remote Control Switch.
−17−

Start
Cutting

4) Loosen lock nut and adjust pressure adjustment knob.
5) When increasing pressure, tighten pressure adjustment
screw. When decreasing pressure, loosen pressureadjustment knob.
6) Set less than the range of 21MPa with looking at Oil
Pressure Gauge, and tighten lock nut and fix it.
Pressure Adjustment
Screw

 CAUTION
Max. rated pressure of Hydraulic Motor of Compact Hydraulic Wire Saw is 21MPa.
If using more than rated pressure, it will cause breakdown of Hydraulic Motor.

7) Press 『Cutting Stop』 Button on Remote Control
Switch.
8) Press 『Stop』 Button on Remote Control Switch tostop Hydraulic Unit.

Stop
Cutting
Stop

3. Connection of Hydraulic Hose and Water Supply Hose.
ValveＡ

1) Connect water supply hose from the tap water tocoupler (Male) of feed‑water inlet of Hydraulic Unit.

Drain Outlet（Left Side）

Shut
Open

2) Connect water supply hose in order to supply the

Leverwater for cutting surface to coupler (Male) of drain
outlet.

ValveＢ
Water supply mouth（Right Side）
Feed Water Hose(FF Coupler Socket (1/2 ) CAUTION
1. Explained double use of water supply for cooling of Hydraulic Unit and cutting. If theamount of water supply is not enough, separately prepare another source of cutting wateror supply the water by itself.
2. The amount of water supply is more than 10L/min and adjust the temperature of actuation
oil from 20℃〜60℃.
3. Use clean water as cooling water.
４．Check the Water Drain Valve A and B positioned on "CLOSE". (Water drains from Valve in"OPEN" position during supply water.)−18−3) Connect Hydraulic Hose Assy. to FF couplers of
Hydraulic Unit. Refer as following table of example
of connection of Hydraulic Hose.

FF Coupler
Socket (1/2 )FF Coupler
Plug(1/2 ) CAUTION
1. FF couplers should be connected until it clicks.
2. If there are dust or dirt on FF couplers, clean them up, then connect.
3. When using the new hydraulic hose (Option) to extend the length, the amount of oil decrease
due to no actuation oil in the hose. For this reason, connect Hydraulic Unit and discharge
and return of new extended hose like loop to Hydraulic Unit without connecting to Hydraulic
Machines, and feed the actuation oil with doing the inching by the remote control.
Use extended hose one by one and connect and feed the actuation oil. If you connect two
hoses, it will cause breakdown due to decreasing of oil amount rapidly.
(Approximately 6L feeding oil is necessary for per Hydraulic Hose Assy.)

Example of connection of Hydraulic Hose
◎ When connecting Hydraulic Hose from Hydraulic Unit 「E‑2002Ax」 「E‑1114Ax」 to Compact
Hydraulic Wire Saw.
FF Coupler
Hydraulic Unit

Plug

FF Coupler Hydraulic Hose

Extension Hose(FF Coupler Hydraulic Hose)

SocketSocketPlug

Conversion

FF Coupler

adapter

Hydraulic machinery

Plug

Socket―Discharge

SocketPlug

SocketPlug

SocketPlug―

Reverse−19−

Inflow

Outflow

4. Setting discharge amount (Rotation speed of Main Pulley)◎ Hydraulic Unit uses variable capacity piston pump.
By changing discharge, you can set RPM (Peripheral Speed of Diamond Wire) of HydraulicMotor arbitrarily.
Refer 「Indication of peripheral velocity of Diamond Wire」as following table.
◎ The discharge amount from factory setting is 41.7/50.2 L/min (50Hz/60Hz)
1) Press 『Start』 Button on remote control switch tostart Hydraulic Unit.

 CAUTION
When changing discharge amount, start Hydraulic
Unit before changing.

Start2) Loosen the lock bolt and set the discharge amount by
Increaturning the adjusting dial for the discharge amount.
① Set the discharge amount 「Maximum」.

Decre

Discharge Amountadjustment screw

The position of 「Maximum」 discharge amount is the
position where loosing the discharge adjustment volume
until you feel light, and tighten that the discharge
adjustment screw hits lightly.

Lock Nut② Set the discharge amount arbitrarily by referring asfollowing table.
If decreasing the discharge amount, turn to the direction of tightening the discharge amountadjustment screw. If increasing the discharge amount, turn to the direction of loosing thedischarge amount adjustment screw.
Indication of peripheral velocity of Diamond Wire.
0

1

2

3

4

5

Maximum

50Hz

23.0

21.1

19.1

17.1

15.1

13.1

11.3

Discharge
Amount (L)

47.9

43.8

39.7

35.5

31.4

27.3

23.5

60Hz

27.7

25.3

22.9

20.6

18.2

15.8

13.7

Discharge
Amount (L)(57.6)

52.7

47.7

42.8

37.8

32.9

28.3

 CAUTION
The maximum flow volume of Hydraulic Motor of Compact Hydraulic Wire Saw is 54L/min.
When using more than maximum flow volume, it will cause the breakdown of HydraulicMotor.
POINT
Appropriate peripheral velocity of Diamond Wire is 25 m/s in general.
Change the revolving speed according to the cutting object and situation.
We recommend 20 m/s for usage of peripheral velocity.
3) After setting, make sure to tighten lock bolt to fix the position.
4) Press 『Stop』 on Remote Control Switch to stop Hydraulic Unit.
−20−【２】 Anchor Fixing◎ Work following to instruction manual of each hammer drills.
Items to bepreparedHammer Drill…1 pceDrill Bitφ22…1 pceDriving Holder
W5/8…1 pceAnchor Bolt
W5/8
…1 pceHammer
…1 pceDust Blower…1 pce…1 pceScale1) Mark anchoring position.
2) Make an anchor hole (Dia.φ22mm ・ Depth 80mm) by
referring the drawing on the right.
3) Clean the hole by dust blower.
4) Insert Anchor (W5/8) into the hole.
5) Drive the Anchor securely by driving holder and byhitting Hammer.

In case the object is cut partially by winding
Diamond Wire through pilot holes(φ50).

 WARNING
1. Take care so that chips are completely blown out of the hole. Otherwise anchors could
come loose.
2. Use concrete anchors specified by CONSEC.

【３】 Installation of DSM‑101A
Items to beprepared

Stud Bolt
W5/8×160mm… 2 pceHex. Nut
W5/8… 2 pce

Square Washer
W5/8×□50×t6… 2 pce−21−

Level… 1 pce

Ratchet Wrench
21×26mm・・・１pce1) ① Screw the Stud Bolt into the anchor② Set the Pole Base and secure the Stud Bolt ・Square Washer ・Hex. Nut.
③ Set the base along the cut line.

１２６(Cut line is 126 mm from the tip of Pole Base.)④ Fix the Base by tightening the Hex. Nut.
If Pole Base rattles, adjust level adjustment by
Cut Lineleveling bolt.

Tip of Pole

 WARNING
1. Screw the Stud Bolt more than five screw threads. If you can not screw, the screw
thread might be damaged. Replace stud bolt or install another anchor.
2. Set along the cut line. If it is not along it, it will cause abnormality for wire and machines.

2) ① Insert Guide Bar Clamp into Pole Base.

①② Fix at the position of within 90mm in right figure.

②
Guide Bar Clamp

Rack(The lower is the position where lowering down at
the bottom, and the upper is the position where
Rack and Guide Bar are not interfered.)③ Insert Guide Bar from the side.
Guide Bar

 WARNING③

Regarding Guide Bar, install as shown ④, left islong and right is short by looking from the Base.
When operating the cutting work with installing
Guide Bar vice versa, use Sub Pole and fix Sub
Pole Bracket by anchor.

Guide Bar④
POINT
When using at narrow place, fix
the Guide Bar into the Guide Bar
Clamp and loose 4 pcs of backside Bolt of Guide Clamp, thenBack Side Bolt

install to the Pole.

3) Attach φ250 Easy Attaching Resin Guide Pulley and Sub
Pole Bracket to the Guide Bar. Fix and tighten φ250

φ250 Easy Attaching Resin Guide
Pulley Assy.

Easy Attaching Resin Guide Pulley.
 WARNING
Install φ250 Easy Attaching Resin Guide Pulleyafter securing safety measure like winding safety
wire to Guide Bar and hook by clamping ring.

Clamping
Ringsafety wire−22−4) Insert Clamp into Pole Base and slowly move it down
while holding until reaching to the bottom of Pole Base.

 CAUTION
When inserting Clamp into Pole Base, be careful not
to be caught on your hand.

5) Refer to the right figure. Install that engage part of feedshaft and clamp shaft are engaged.
POINT
It is possible to install clamp shaft and feed shaft
not to engage precisely due to pulling in the feedside shaft.

6) Turn counterclockwise until feed and clamp hook are engaged while pulling the ring.
Check the hooks are engaged securely and position pin is in the fixing hole.
Position Pin

Ring

Fixing HoleHook

 WARNING
If the position pin is not fixed securely, it is extremely dangerous that Feed can come off.

7) Refer to the right figure. Insert the Extension Pole into
the Pole Base and fix with safety plate by eye bolt.

Extension
Pole

Eye bolt

Safety plate

Pole Base−23−8) Connect Hydraulic Hose from Hydraulic Unit with
Hydraulic Motor.

 CAUTION
1. Connect FF coupler until it clicks.
2. If dirt and mud are on the FF coupler, wipe themby clean cloth before connecting.

9) Install Main Pulley to Main Shaft. Insert to Main Shaft
with matching on the position of key seat and screw by
Hex bolt and fix it securely.

 CAUTION
Pay attention to the front side and back side ofMain Pulley.

Embedded bolt

【４】 Connection of Control Box
 WARNING
Before operation, stop Hydraulic Unit completely to prevent from happening unexpected
accidents.
1) Turn the feeding switch ｢OFF｣ on the Control Box
and Turn the volume ｢0｣.

Feeding Switch「OFF」

Tension volume 「0」2) Connect Control Box and Feed by connection Cord.

Control Box
Feed

Connection Cord−24−3) Connect hook type waterproof plug to the socket of Control Box of Hydraulic.

 CAUTION
1. If plug is wet, connect after drying.
2. If dusts are attached on the plug, wipe it. Then connect.
3. If operating ｢Control Box BW‑101A｣ by applying the power source of 100V, you will need
the plug for 100V power source.

【５】 Jointing of Diamond Wire
1) Wind Diamond Wire to Main Pulley and φ250 Resin
Guide Pulley. Then, wind cutting objects.
When cutting the opening section and there are pilot
holes, make sure to wind Diamond Wire going through thepilot holes.

 CAUTION
1. If the corner of cutting object is sharp, Main
Pulley could not rotate or spins around due tolocking of Diamond Wire.
Before jointing Diamond Wire, round off thecorners.
2. Joint between cutting direction of Diamond
Wire which is indicated by allows and rotation
direction of Main Pulley which is clockwise
rotation by seeing Main Pulley side.)
POINT
Be careful for how to wind Diamond Wire for the cutting objects in order not to be bent
Diamond Wire. If winding of Diamond Wire is not proper, Diamond Wire could be locked or
could be worn out unevenly.
2) Measure the necessary length by Diamond Wire and cut a little bit longer.
POINT
When cutting with the pilot holes and cutting thesame objects several times, the length of
Diamond Wire is shortened due to changing
Diamond Wire after first cutting.
If taking the extra length of Diamond Wire foryour necessary, you can cut the cutting objects
several times by one Diamond Wire.

Cutting place

5

5

Cutting place

3) Joint Diamond Wire

 CAUTION
Regarding jointing Diamond Wire, follow the instruction manual or ｢HOW TO JOINTDIAMOND WIRE｣ in page 35,−25−4) Turn the volume of Control Box ｢0｣and turn
Feeding Switch ｢Cutting｣.
Turn the volume gradually from 「0」, and adjust that
the Slide Block starts just before moving (Notmoving the Slide Block).
◎ When Pole Base is fixed on the floor, the volume
should be around 「5〜6」.

Feeding Switch｢Cutting｣

Tension volume「5〜6」◎ Make sure that Main Pulley stops by moving Main
Pulley (Slide Block) up and down by hand.
 WARNING
Do not cut in reverse position, Feed Assy. mightcome off.

 CAUTION
When operating without connecting Hydraulic Hose, do not rotate Main Pulley (HydraulicMotor) by hand. It will cause the breakdown of Hydraulic Motor.
5) Make sure that Diamond Wire runs through the groove of Main Pulley and φ250 Easy Attaching
Resin Guide Pulley.
6) Set up Diamond Wire by uplifting Main Pulley (Slide Block) by hand.

 CAUTION
If setting up Diamond Wire by uplifting Main Pulley
by hand, hold the rib of Main Pulley. If you holdouter periphery, you will be caught in Diamond
Wire or will be injured.
Rib【６】 Mounting of Cover
1) Insert Main Pulley Cover into the Set Plate while pulling

Position Pin
Ring

the ring of Main Pulley Cover. (Refer right figure). Then,
fix the position pin on the hole of set plate.

Set PlateHole WARNING
Make sure that the position pin is in the hole of Set
Plate. If position pin is not fixed enough, Main
Pulley Cover could come off.

POINT
By opening Side Cover,
the range, which preventsfrom flying the water, will
spread.

Side Cover−26−

2) Attach Auxiliary Cover to the right and attach Guide
Bar to the left, and tighten by Hex. Bolt and fix.
 WARNING
Use all covers. To prevent from flying of diamondwire due to breaking the wire and separation ofsleeve, use main pulley cover and auxiliary covers(right and left) during operation.

【７】 Preparation for Feeding Water ( When using Option Water Supply Hose Assy. )1) Install Easy Attaching Water Supply Hose into Guide
Hex.Bolt（Dihedral Width２１）

Bar and tighten by Hex.Bolt and fix.
2) Close Water Cock. Then, connect Feed Water Coupler
or fix it by hose band.
3) Direct the nozzle of water supply hose Assy. to Diamond

Water Supply
Hose

Wire.
POINT
Water supply must go through all cutting place.

Nozzle【８】 Setup Safety Net and PC Protection Board (Sell separately)
Page 14 【2】 Same as "Example of installation for
DSM‑101A・Hydraulic Unit・Safety Net・PC Protection
Board", set Safety Net by surrounding the Wire Saw and theobjects which you cut. The workers must operate from theoutside of the construction area which is surrounded by
Safety Net and please also set PC Protection Board in frontof the workers.
Safety Net

PC Protection Board

 WARNING
1. Set Safety Net with Frame at the working area in order not to be danger in thesurrounding area by flying Diamond Wire such as breaking the wire, separation ofsleeve2. Set Hydraulic Unit and Control Box at the outside of working area where is surrounded by
Safety Net with Frame in order to operate at the safety area. Set Safety Net with Framein front of working staffs. Please also install PC Protection Board in front of the working
staff who is in the outside of the working area.
3. Take safety measure not to let people in the working area.
4. Take safety measure like over‑turning prevention in order not to fall Safety Plate or
Safety Net and PC Protection Board with Frame by fixing the scaffold by the wire or
the annealing wire.
−27−

【９】 Cutting Operation
 WARNING
1. When abnormality occurs during operation, stop the operation immediately.
2. Do not enter the working area where is surrounded by Safety Net during operation.
Also never allow strangers to come close to the area.
3. Control Box must be adjusted when starting the cutting operation which is indicated【５】Jointing of Diamond Wire 4) in page 26.

1) Start feeding water.
2) Press 「Start」 Button on Remote Control Switch of Hydraulic Unit to start Hydraulic Unit.
3) When Hydraulic Unit starts, wait for more than six
seconds. Then, press 「Cutting」 Buttonon Remote
Control Switch and rotate Main Pulley.
◎ If Slide Block moves down to Guide Bar, turn thevolume up slightly.
◎ If Main Pulley rotates without Diamond Wirerotation, turn the volume down slightly.

Start
Cutting◎ If Diamond Wire is locked, turn the volume downslightly.
 WARNING
Confirm that the rotation direction of Main Pulley must rotate clockwise by looking at
Main Pulley side.

 CAUTION
1. When Hydraulic Wire Saw is fixed on the floor, and turn the volume down too much, Slide
Block will fall. Be careful for adjusting the volume.
2. Be careful, if Main Pulley slips, rubber ring is worn out.

4) When Diamond Wire starts to rotate, turn the volume up
gradually.
POINT
Adjust the Oil Pressure Gauge of Hydraulic 14〜
16 MPa.

−28−

5) When Diamond Wire cuts continually, feeding water will be hard to reach for the cutting surface.
Change the position of feeding water. You can also use Water Stop Packing for feeding water.
Refer in page 39.
① Press 「Cutting Stop」 Button on Remote Control
Switch and stop the rotation of Main Pulley. Then,press 「Stop」 Button to stop Hydraulic Unit.
② Turn the volume of Control Box down until Slide
Block does not come down. If Pole Base is fixed on
the floor, the volume should be around 「5〜6」.
③ Reset Easy Attaching Water Hose to supply the

Stop
Cutting Stop

water evenly for cutting places.
④ Continue working by repeating the procedure from
2) in page 28.
6) When Slide Block reaches to the tip of Pole Base,move down Slide Block until at the lower of stop
position. Rewind Diamond Wire and start cutting
again. Refer the right figure.
① Press 「Cutting Stop」 Button on Remote Control
Switch and stop the rotation of Main Pulley. Then,press 「Stop Button」to stop Hydraulic Unit.
② Stop feeding water and Stop Slide Block at thelower position. Refer 【３】 「Moving andStopping of Slide Block」 in page 16.
③ Wind Diamond Wire to φ250 Resin Guide Pulley which is installed in Sub Pole. Refer the
figure.
④ Adjust Slide Block just before start moving (Not moving). Same procedure 4) in page 26,⑤ Tense Diamond Wire. Same procedure 6) in page 26.
⑥ Continue to work by repeating the procedures 2) in page 28.
7) Take safety measures by wedge. When the rest of cutting object comes to the end, cutting will
be interfered due to tucking of cutting objects by Diamond Wire. And, it will break due to its
own weight.
① Press 「Cutting Stop」 Button on Remote Control Switch and stop the rotation of Main
Pulley. Then, press 「Stop」 Button to stop Hydraulic Unit.
② Stop feeding water and drive the wedge on the cutting surface.
③ Adjust the volume of Control Box in order not to coming down Slide Block.
When Pole Base is fixed on the floor, the volume should be around 「5〜6」.
④ Continue working by repeating the procedure from 2) in page 28.

−29−8) Before finishing cutting, change the position of φ250 Easy Attaching Resin Guide Pulley.
◎ Changing the position of φ250 Easy Attaching Resin Guide Pulley, refer to 「CHANGINGTHE POSITION OF φ250 EASY ATTACHING RESIN GUIDE PULLEY」 in page 32.
 WARNING
Be careful for the danger of coming Diamond Wire off when finishing cutting work.

9) If cutting object can not be cut by one stroke, shorten Diamond Wire by cutting or change to theshort Diamond Wire, then rejoin Diamond Wire and start cutting again.
◎ When using special Diamond Wire, use the one which is smaller diameter than first one.
◎ When rejoining Diamond Wire, stop Slide Block at the lower position and remove Diamond
Wire. Refer to 【３】「Moving and Stop of Slide Block」in page 16.
◎ For rejoining Diamond Wire, refer 「HOW TO JOINT DIAMOND WIRE」 in page 3510) After finishing cutting, press 「Cutting Stop」 Button on Remote Control Switch to stop therotation of Main Pulley, and press 「Stop」 Button to stop Hydraulic Unit.
11) Stop Slide Block at the lower position.
(Refer to 「Moving and Stopping of Slide Block」in page 16.)
12) Turning Feeding Switch of Control Box 「OFF」.

【10】 Dismantling◎ Read as following warnings before dismantling Compact Hydraulic Wire Saw.
 WARNING
1. Slide Block must stop at the lower position.
2. Feeding Switch of Control Box is ｢OFF｣.
3. Motor of Hydraulic Unit must be stopped.
4. Before dismantling, do not remove the anchor fixing, It is extremely dangerous that themachine will fall down. After dismantling Slide Block and so on, remove the anchor fixing.

1) Remove φ250 Easy Attaching Resin Guide Pulley and Diamond Wire by lowering Slide Block.
2) Remove Easy Attaching Water Supply Hose.
3) Remove Auxiliary Cover right and left.
4) Remove Main Pulley Cover.
5) Remove φ250 Resin Guide Pulley, Sub Pole Bracket and Guide Bar.

−30−

6) Remove Main Pulley by loosening embedded bolt.
 WARNING
Be careful for not to drop Main Pulley.

7) Remove Hydraulic Hose from Clamp.

 CAUTION
After removing Hydraulic Hose, clean the coupler and install the coupler cap.

POINT
Compact Hydraulic Wire Saw is positioned at the higher than Hydraulic Unit and if
remove Hydraulic Hose from Hydraulic Wire Saw at the start, the air will go into theinside of Hydraulic Hose. As a result, Hydraulic actuation oil will overflow from the tank.
Remove Hydraulic Hose from Hydraulic Unit at the start.

8) Loosen the eye bolt on the tip of Extension Pole, then remove the eye bolt, Falling Prevention
Plate and Extension Pole.

9) Remove Connecting Cord from Control Box and Feed.
POINT
1. Remove Connecting Cord after wiping the water on Connecting Cord.
2. When removing Connecting Cord, do not tug it.
3. Install the cap on Connecting Cord of Feed.

10) Remove Feed first, remove Clamp from Pole Base,then remove Pole Base in order.

11) Work is completed after cleaning the surroundingarea and turn off the power.

−31−

10 . CHANGING THE POSITION OF φ250 EASY ATTACHING RESIN GUIDEPULLEY
1) Press 「Cutting Stop」 Button on Remote Control Switch to stop the rotation of Main Pulley andpress 「Stop」 Button to stop Hydraulic Unit.

 CAUTION
Stop φ250 Easy Attaching Resin Pulley with taking Diamond Wire up.

2) Stop feeding water.
3) Stop Slide Block at the lower position (Refer to 【３】「Moving and Stop of Slide Block」 in page 16) andRemove φ250 Easy Attaching Resin Guide Pulley byloosening Diamond Wire.L

 CAUTION
Be careful for not to drop Slide Block rapidly.

4) Change the position of φ250 Resin Guide Pulley.
◎ After finishing cutting, reverse the direction of
installation of φ250 Easy Attaching Guide Pulleyon the center of Guide Bar in order not to contact
each Diamond Wire−32−5) Turn the volume on Control Box 「0」 and Turning
Feeding Switch ｢Cutting｣.
Turn the volume gradually from 「0」, and adjust that the
Slide Block starts just before moving (Not moving the
Slide Block).
◎ When Compact Hydraulic Wire Saw is fixed on thefloor, the volume should be around 「5〜6」.
◎ Confirm that Main Pulley stops by moving Main

Feeding Switch「Cutting」

Tension volume「5〜6」

Pulley (Slide Block) up and down by hand.

 CAUTION
When operating without connecting HydraulicHose, do not rotate Main Pulley (Hydraulic Motor)
by hand. It will cause the breakdown of HydraulicMotor.

6) Make sure that Diamond Wire runs through the groove of Main Pulley and φ250 Easy Attaching
Resin Guide Pulley.
7) Set up Diamond Wire by uplifting Main Pulley (Slide
Block) by hand.

8) After finishing above works, continue working by repeating the procedure from 2) in page 28.
 WARNING
Change Sleeve every one hour which connects with Diamond Wire. If sleeve is worn out,
it will cause falling Sleeve off which is extremely dangerous. Be careful for partial wearing
which is extremely dangerous.

−33−

11 . TROUBLESHOOTING DURING OPERATION CAUTION
1. Explained troubleshooting during operation for 「Hydraulic Unit E‑2002Ax」.
2. Read the instruction manual carefully for 「TROUBLESHOOTING DURING OPERTION」of
Hydraulic Unit.
◎ If you feel abnormality during operation, stop the rotation of Main Pulley immediately.
Investigate the troubles as following table under the safe condition.
TroubleCause

Troubleshooting

Volume of Control Box is too low.
Feeding Switch is off.

Turn Feeding Switch to 「Cutting」 or 「Reverse」.

Connector of Cord is unplugged.

Plug Connector of Cord.

Plug of Control Box isn't connected or is broken.

Repair for disconnecting.

Iron powder or sludge is adhered on Rack Gear or
Pole.

Slide Block does not
move.

Do not use temperature of Control Box become under

the output power is shut down.

75℃.

Connection failure of Pole Base and Extension

Replace new Rack Gear.

Pinion Gear is damaged.

Replace new Pinion Gear.

Pole has cracks or deformations.

Repair, replace.

Connecting Cord is broken.

Replace new Connecting Cord.
RepairFailure of Control Box.
Connection failure of Hydraulic Hose.

Reconnect Hydraulic Hose.

Volume of Control Box is too high.

Turn volume down.

Diamond Wire jams on the corner of cutting object.
Wiring of Hydraulic Unit and Power Supply Cableis wrong.

Remove the edge of cutting object for smoothrotating.
Reconnect Power Supply Cable of Hydraulic Unit.

Adjustment failure of discharge amount ofRefer to 「Setting discharge」 of 「Hydraulic Unit

Hydraulic.

E‑2002Ax」 instruction manual.

Failure of 「Start」 「Cutting」 Button of
Hydraulic Unit.
Failure of Hydraulic Motor.

RepairRepairRotation speed is not proper.
Cutting thick reinforcing steel.

Refer to 「Indication for peripheral speed of Diamond
Wire」 in this Instruction Manual.
Wait until finishing thick reinforcing steel cut.

Feeding water is low flow.

Increase the amount of feeding water

Diamond Wire is worn out.

Replace new Diamond Wire.

Temperature of Hydraulic actuation oil is high.

Refer to 「TROUBLESHOOTING DURING

Hydraulic Motor has no power.
Volume of Control Box is too low

Main Pulley is slipping.

Reconnect Pole Base and Extension Pole.

Rack Gear is damaged.

Feed is failure.

Cutting speed is slow.

Remove iron powder or sludge.

Temperature of Control Box is over 75℃ so that

Pole.

Main Pulley does not
rotate. (HydraulicMotor does not
rotate)Turn Volume up.

Diamond Wire jams on the corner of cutting object

OPERATION」 in Instruction Manual of 「Hydraulic
Unit E‑2002Ax」.
Turn the volume up on Control Box.
Remove the edge of cutting object for smoothrotating

Diamond Wire is sandwiched between separated

Make a clearance on the cutting surface by driving

cutting object and cutting object.

the wedge on the cutting surface.

−34−

12 . HOW TO JOINT DIAMOND WIRE
1. Preparation for Diamond Wire
Items to be prepared

Wire Cutter…1pce

Manual HydraulicPressure Caulker
EP‑300N…1pce

Sleeve…1pce

Pliers…1pce

Cutter Knife…1pce

2. Proper Sleeve to joint Diamond Wire
○ Applicable Sleeves to joint by Manual Hydraulic Pressure Caulker EP‑300N are as follows.
Outer Diameter

φ9〜φ9.5

Length20〜23mmMaterial

The equivalent of SS400

RemarkUse only those specified by the manufacturer of Diamond Wire.

3. Cautions for jointing Diamond Wire
 WARNING
1. Read instruction manual carefully for Diamond Wire and Sleeve and start working.
2. The sleeve which is complied with diamond wire must be used.
3. Arrow mark of sleeve and diamond wire traveling direction have to be same direction. Otherwise sleeve
could not be fixed properly, furthermore the sleeve could be flied away and quite dangerous. The
sleeve has to be used properly with understanding the instruction manual of sleeve.
4. Replace the sleeve every one hour cutting time. If the sleeve is worn out, there is a possibility thatsleeve comes away from diamond wire. In particular, uneven wear is more dangerous.
5. Do not joint several Diamond Wires. (Do not joint more than two places by Sleeve.)
Check the joint part regularly during operation. If abnormality occurs, rejoin again.
6. When adjusting the pressure of Hand Hydraulic Caulker, read carefully instruction manual of Hand
Hydraulic Caulker EP‑300N. Adjust the pressure from 8〜8.5 tons. (Adjust by CONSEC service center)
If the pressure is correct, pressed sleeve becomes even hexagonal shape. If low pressure during
jointing, sleeve easily comes out from wire. In this case, beads and sleeve fly away and fatal accident
would be caused.
7. If the Hand Hydraulic Caulker has any abnormality, it must not be used and contact dealer or COSEC's
distributor.
8. Please use specified dies. Do not use worn out dies. As a indication for replacement timing of dies,pressed sleeve becomes uneven hexagonal shape. Worn out dies cannot be pressed sleeve properly,
as a result, sleeve easily comes out from wire. In this case, beads and sleeve fly away and fatal
accident would be caused.

 CAUTION
When using Diamond Wire, use the glove to avoid the injury.
−35−

4. How to Joint Diamond Wire
1) Install Press Rest to 「Hand Hydraulic Caulker EP‑300N」.
2) Cut the position about 5 mm from the end of diamondlayer of Diamond Wire by wire cutter.
POINT
Cutting Diamond Wire must be vertical and flat
toward the length direction of Diamond Wire.

553) Pull the end of spring out by pliers from cutting
surface of Diamond Wire.

4) Remove the coating material by cutter knife. Remove
the coating material by going Diamond Wire into Sleevesmoothly.
 WARNING
The length of removing coating material must be
10mm. If the length is less than 10mm, joint
strength will be lower due to the shortness
between Sleeve and Sleeve of contact. If thelength is more than 10mm, there is a space
between Sleeve and coating material and Diamond
Wire rasps with Sleeve which will cause thebreaking down of Diamond Wire.

10

 CAUTION
1. When removing coating material, be careful for not to separate the element wire.
If the element wires are separated, it will not go into Sleeve.
2. Be careful for not to be injured when removing the coating material.

5) Arrow of sleeve and diamond wire traveling direction have to be same direction.
 WARNING
If the sleeve has direction requirement for connecting, follow the sleeve instruction manual.
If connected wrong direction, sleeve easily comes out from wire. In this case, beads andsleeve fly away and fatal accident would be caused.

−36−6) Twist Diamond Wire based on one rotation per 2m to the
Sleeveallow direction and put it into Sleeve.
 WARNING
If Sleeve has a direction, follow the instruction
manual of Sleeve.

Twist to twisting directionof Diamond Wire.

 CAUTION
Twist Diamond Wire to prevent from wearing out of Diamond Wire during cutting the cutting
objects.
7) Twist slightly by putting both ends of Diamond Wire
into Sleeve and confirm that both ends are contacted.
And, confirm that the one side space between Sleeve andcoating material must be less than 0.5mm.

Less than
0.5mm

Less than
0.5mm

 WARNING
When inserting Diamond Wire into Sleeve, there are dusts or excrescences both of surfaceof Diamond Wire and inside of Sleeve which is extremely dangerous because joint strength
will be not enough. Do it again from 2).
8) Set Sleeve on the dies of Hand Hydraulic Caulker, andpressure Sleeve by controlling Pressure Handle
Pressure Handle

reciprocating motion. When the dies move byreciprocating motion and the dies click, it is completed.

Dies

 CAUTION
When pressing Sleeve, be careful for not catching
your fingers.

Manual HydraulicPressure Caulker

Dies9) Open Pressure Handle and turn to the right again. Then,dies will open.

−37−10) Press the rest of Sleeve in the same way of 7).
Position that Sleeve of hexagon surface is same planeboth of right and left.
And, press that left side and right side are
overlapped.

11) Turn Sleeve 60°and press it by the procedure 7) 〜
9). After repeating twice (total pressing is three times),

６０

pressing is completed.
 WARNING
1. Rotate to match with hexagon surface and diessurface. If the surfaces are not matched,Diamond Wire will be easily to come off due tocracking of Sleeve and not enough pulling out
strength. If Diamond Wire comes off, Sleeve will
fly which will cause serious accident.
2. When caulking Sleeve, be careful for the sound.
When cracking is occurred, snapping sound will
be generated. When cracking is occurred, do
not use.

12) I turn a wire and a sleeve 60 degrees once again, and, please carry out work of 8) ‑ 10)
again. By for each three times perform crimp in turn in before and after and arecompletion.
 WARNING
Totally, 6 times presses have to be done. (Each 3 times for front and rear position) If pressing
number of times is lower, sleeve easily come off from wire.

13） Replace the sleeve every one hour cutting time.
 WARNING
It is quite dangerous that if the sleeve wear out, it would become root cause that sleevecomes off from wire. In addition, uneven wear is more dangerous.

14） Prior to set wire on the machine, please check with using "Check list for jointing Diamond
Wire". If everything is OK, it can be used. If there is any abnormality, correct it and use.

−38−

13 . HOW TO USE WATER STOP PACKING ( OPTION ) WARNING
Before setting Water Stop Packing, make sure that cutting operation is stopped andHydraulic Unit is stopped.
1) Cut until cutting reaches to the depth where Water Stop Packing can be pushed in.
2) Stop cutting operation and make the water way in the
cutting place in order to press Water Stop Packing inFeeding Water

around cutting place as right figure.

Water Stop
Packing

Feed the water toward the direction of movement of
Diamond Wire.
POINT
When cutting operation proceeds and drive thewedge, press Water Stop Packing into all theway inside.
3) When cutting operation proceeds and drive the wedge,press Water Stop Packing into all the way inside.

Drain

wedge

Feeding Water

Drain
Water Stop Packing

14 . INSPECTION ･ MAINTENANCE ･ REPAIR【１】 Inspection Before Operation◎ Make a copy for ｢CHECK LIST FOR COMPACT HYDRAULIC WIRE SAW BEFOREOPERATION｣ and fill it out. Keep it with caution.
When abnormality occurs, contact your dealers or CONSEC's distributor.

【２】 Regular Inspection
1. Inspection for attachment screw and wearing out.
1) Inspect the looseness of attachment screw and retighten the loosen place.
2) Inspect Rubber Ring, wearing out and swinging of φ250 Resin Pulley.

2. Inspection and maintenance for rotation of φ250 Resin Pulley.
1) Rotate Pulley by hand. When rotation is heavy or not smooth, change Ball Bearing.

−39−

【３】 Maintenance◎ Clean and maintenance after the operation.
1) Cleaning Slide Block (Clamp and Feed)
Remove Feed from Clamp and clean them individually.
① ClampHydraulic Motor is extremely high temperature after operation. If pouring the water abruptly,
the water might flow inside from the clearance. Wash it by water after the temperature
decreases.
Wash out the sludge on Main Shaft (Attached Main Pulley) and Roller. After cleaning, apply
the rustproof.
② FeedAfter the operation, temperature is extremely high.

Bent Filter

After the temperature decreases, wash out the sludge
by brush. Have a great effect for waterproof and dust
proof with securing the air blow by adopting the bent
filter, but do not pour the water on the bent filter
directly. The effectiveness of air blow will not function
due to blocking by water and dust. (Change the bent

Coupling

filter when it is blocked by dust and so on.)Apply the rustproof on coupling after cleaning.
 WARNING
Do not wash by high pressure cleaning machine. Do not dip Feed in the water and pourthe water directly to the coupling and cable, because the water will flow inside.

 CAUTION
When cleaning, attach the cap on the connector of Feed.

2) Cleaning for Main Pulley, Pole Base, Sub Pole Bracket, Guide Cover, Resin Guide Pulley.
○ Wash out the dirt by water. After cleaning, apply the rustproof on the rotation part ofResin Guide Pulley.
3) Cleaning for Main Pulley Cover and Auxiliary Cover R・L○ Wash out the sludge on the cover.

−40−【４】 Repairs
1) Replacement for Resin Pulley Main Body of Guide Pulley.
Pulley Bracket

Hex. Nut 20

Easy Attaching
BracketSpring Washer 20

Spacerφ50

Resin Pulley Main Body Assy.

Hex. Head. Bolt
M20×120Ｌ◎ The Resin Pulley Main Body for φ250 Resin Guide Pulley and φ250 Easy Attaching Resin
Guide Pulley is common.
2) Replacement for Rubber Ring of Main Pulley.
 WARNING
Do not remove the balance weight on Main Pulley, because the balance weight is installed
when assembling in order not to vibrate by high speed rotation. If removing the balance
weight, Main Pulley will vibrate by loosing the balance during rotation and Main Pulley will
breakdown. And, Diamond Wire will come off or Rubber Ring will be worn out.

Balance Weight
Wire Retainer Rubber
Ａ

Flat Washer 8
Spring Washer

Wheel
Hex. Bolt M8×40

Wheel Cover
Fig.1

−41−

Fig.2 The procedure oftightening of Hex. Bolt.

◎ Replacement Procedure① Clean it before dismounting. And, mark the position adjustment on Wheel Cover and Wheel bymagic marker. If not assembling the same position before dismounting, the balance will loose
and vibration will occur during the rotation.
(If Balance Weight come off, contact to CONSEC service)② Loose the Hex Bolt, remove Wheel Cover and remove Rubber Ring.

 CAUTION
If removing Wheel Cover by force, it will break up.
③ Clean Wheel Cover and Rubber Ring of Wheel, and confirm that there are no dirt, scuff,
dent, burr and cracking. Then, install Rubber Ring into Wheel.
④ Press Wheel Cover and Wheel evenly along the circle by matching with mark of position
adjustment. Confirm that Rubber Ring does not run over and the inner circumference
engages with outer circumference of A (Fig 1).
⑤ Tighten Hex. Bolt on diagonal line temporary by tightening torque 10 N・m(１０２ｋｇｆ・ｃｍ).
After confirming that Rubber Ring does not run over, tighten Hex. Bolt on diagonal line
evenly by tightening 17.2〜27N･m（175〜275kgf･cm).

 CAUTION
If tightening each Hex. Bolt, such as tightening by force, it will cause the cracks. Tighten Hex.
Bolt several times by following Fig.2.

⑥ After tightening Hex.Bolt, use it after confirming that there are no cracks of Wheel Coverand Wheel, running over of Rubber Ring and not forgetting of tightening Hex.Bolt.
◎ This machine is manufactured by proper accuracy.
If the machine does not operate normally, do not repair by yourself. Contact to thedealers or CONSEC's distributor.
◎ If you have any questions for use, please feel free to contact CONSEC corporation.

−42−

15 . HOW TO STORAGE THE MACHINE
Storage for products and accessories.
Storage for products and accessories at safety and dry place when the products and theaccessories are not in use. And, avoid to storage them as following.

◇Out of reach of children◇Unlocked place◇Rain and humidity

Do not store such places.

◇Sudden change the temperature◇Direct sunlight◇Placed volatile substances such as flammable and explosive

The product information such as appearance in this
instruction manual could be changed without
informing advance notice.

−43−

16 . CHECK LIST
【１】 Before Operation Check List for Compact Hydraulic Wire Saw
Rank (Difference of judgment)

SituationａInspection in range.

Doesn't need immediate improvement, but better to take proper action at proper time.

ｂ

Need early taking action.

Needs corrective action at the earliest possible time. Or needs maintenance by owner level.

ｃ

Need immediate taking action.

Immediately needs proper action, or needs repair by service professional.

Check list for Compact Hydraulic Wire saw before operation.
Project name
Check point

SerialnumberName of Inspector
Check item

Check methods

Defect item
Looseness of screw

Hydraulic

Visual check of

Coupler

appearance

Motor

Connect Hydraulic Hoseand Hydraulic Unit by hoseand start no‑load running.

RollerRotate by hand

Slide Block
Receptacle

Visual check of

Rank

Tightenｃ

Replace Hydraulic
Coupler 【CAUTION】
Put seal tape on thescrew part.

ｂ

Repairｃ□: Never rotate due to sticking of concrete waste.

Repairｃ□: Possible to rotate but foreign material is in

Spray rustproof□: Oil leakage

Hydraulic

ActionCenter of coupler frontedge□: Abnormal noise can be confirmed. Hydraulicgauge of hydraulic unit indicates over 10MPa.
（100kg/cm２）

inside because of abnormal noise.

lubricant□: Receptacle burns and become black.

Repairａｃappearance
Iron powder, etc
Operation check of

accumulate on Rack

Remove the

Feeding Switch

Gear of Pole Base. They

accumulated materials

Feeding(Feeding ・Reverse) after

operationassemble with Pole Baseand connecting with□: Possible to move

Pole BaseDo actual feeding
operation with assembling
Slide Block.
Check whether level bolt

Level Bolt

can naturally rotate byusing the tools.

interfere with operation.

but motion is notstable.

Control Box.

Rack Gearｂ

Failure of Feed

Repairｃ

Failure of Control Box

Repairｃ□: Iron powder, etc accumulate on a rack gear.
They interfere with feed operation.

□: Level bolt cannot rotate easily due toaccumulated concrete waste on a screw.

Remove theaccumulated materialsｂ

Remove theaccumulated materials
like concrete waste
and spray rustproof
lubricant.

ｂ

Fixing check

Check bolt tightening
condition by using thetools.

□: Balance weight doesn't fixed completely.

Tightenｂ

Rubber Ring

Visual inspection□: Rubber ring is worn out extraordinarily.

Replace rubber ringｃ

Check whether pulley can□: Rotation is heavy or foreign material is in siderotate smoothly by hand.

because of abnormal noise during rotation.

Replace bearingｂ

Main Pulley

Rotation
Each Pulley
Resin Pulley

Visual inspection□: Resin pulley is worn out extraordinarily.

Replace resin pulleyｃVisual inspection□: Check breakage, deformation, crack

RepairｃControl Box

Control Box

connecting cord

Cord

Visual inspection□: Cord and Receptacle have damage or not.

Repairｃ

Safety Net

Safety Net

Visual inspection□: Check breakage and crack

Replace safety netｃ

PC Protection
Board

PC Protection
Board□: Check breakage and crack

Replace PC Protection
Board

ｃ

Visual inspection−44−

【２】 Check List for Jointing Diamond Wire
Before start working, make a copy of "Check list for jointing Diamond Wire" and check the jointing
part in accordance with check list. It must be checked and kept. If any fault is found, required
correction by check list is necessary.
Check list for jointing wire
Project nameDate of jointing
Name of person jointing wire

Name of inspector
Serial number of hydraulic caulker

Inspection
timingCheck item

Condition

Check item

Removal length of coating material

Dimensional

10.0mmcheck

Judgment

Remarks

Acceptance・
Rejection

Removal condition of coating material

Rubber coating on a wire isproperly removed or not.
Acceptance・
Rejection

Condition of rubber coating material

BeforeCondition of resin coating material

Remove coating

Resin coating material is almost
removed and the wire surface
is white.

caulking
VisualCondition of sleeve

A designated sleeve

inspection
Dust or oil remain inside of thesurface or not.
Hydraulic Caulker
Dies

Acceptance・
Rejection

Store in a plastic
bag, after
removing dust
and oilDo you use Hand Hydraulic
Caulker EP‑300N.
Pressure 8‑8.5 ton

Acceptance・
Rejection

Adjust by
CONSEC service
centerNo crack and breakage on thesurface of CONSEC originaldies.
State of the appearance
Sleevecoating material

No breakage, chipping,looseness and lack of beads
Beads

Shape of cross‑section
After

Visualcaulking

inspection

No wear, bend and breakage on
the jointing partNo exposed wire cable due tothe wearing and lack of coveredrubberAcceptance・
Rejection

Each hexagonal plane is almost
even or not.

Acceptance・
RejectionLess than 0.5mm on each side

Acceptance・
Rejection

23.5mm or more

Acceptance・
Rejection

Clearance between sleeveand coating material

length of sleeve※Change Sleeve every one hour during cutting.
−45−

Element Wire
must not comeout from Sleeve.

Main office: 4‑6‑8 Shoko Center Nishi‑ku Hiroshima 733‑0833 Japan

International Department : 1‑7‑5‑1, Sakaimachi, Naka‑ku, Hiroshima, 730‑0853 Japan
Phone : 81‑82‑297‑3231
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