10. Troubleshooting
The sawing wire was not pushed far enough into the
connector
– Push the wire into the connector as far as it will go.
– Cut the wire exactly at right angles and remove an
adequate length of the plastic coating.
The connector was crimped too close to one of its ends
– Crimp the connector exactly at the position specified
by the connector manufacturer.
The wire breaks immediately before or after
the connector
Wire breakage due to fatigue
– Reduce bending stress on the wire by using flexible
connectors.
– As far as possible, use only one connector for each
wire loop (one continuous length of wire).
– Fit a new wire if breakage occurs several times in quick
succession.
The wire begins to vibrate strongly during
sawing
Wire tension is too high or too low
– Optimize the wire tension by adjusting the pressure.
The guide pulleys are not exactly in alignment with
each other
– Adjust the pulleys to bring them into alignment.
The guide pulleys are too far apart (unguided wire
length too long)
– Reduce the unguided length by mounting additional
pulley stands.
– Set up the saw closer to the point at which the cut is
being made.
A guide pulley is worn and out of round or a small stone
is stuck in the groove
– Check the pulleys for true running and renew them if
necessary.
– Check the pulley grooves and clean them out if nec-
essary.
10.10
10.9
Too little cooling / flushing water (dust is created)
– Direct the flow of water exactly toward the wire and
in to the kerf.
– Increase the water flow.
Tension on the wire is too high relative to length of
wire in contact at the cutting face
– Increase the length of cut and / or reduce wire ten-
sion.
Cutting through very abrasive material
– Use a diamond wire of a different specification.
The sawing wire wears unevenly / one-sided
The wire was not twisted before joining the ends together
– Twist the wire approx. 0.5 turn per meter length in a
counterclockwise direction (as seen from the wire
end) before joining the ends.
The diamond wire collapses / beads are
pushed together
Inadequate cooling of the diamond wire
– Ensure that sufficient water reaches the cutting face.
– Stop cutting at regular intervals to allow the wire to
cool.
The diamond wire suddenly sticks in the kerf while
sawing
– Secure the object being cut to prevent movement.
– Reconsider the sequence in which the cuts are made.
– Remove loose material from the kerf.
The diamond wire is pulled out of the
crimped connector
Use of the wrong crimping pliers (inadequate crimp-
ing force)
– Use the crimping pliers recommended by the manu-
facturer of the connector.
The jaws of the crimping pliers are worn
– Replace the jaws.
10.7
10.6
10.8
61
Printed: 08.07.2013 | Doc-Nr: PUB / 5069736 / 000 / 01
Summary of Contents for DS WS10
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