| Diamond
Tools ->
Trouble Shooting |
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DIAMOND BLADE TROUBLE SHOOTING
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| 1.Loss of tension |
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Cause
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Remedy
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| 1)Blade being used
on misalign saw. |
Check for proper saw alignment.
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2)Blade is excessively hard for
the material being cut, creating stress on the
steel core.
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Make certain blade is correct
for material being cut.
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3) Material slippage causing blade
to twistand become bent.
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Maintain tight grip on material
while sawing.
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4)Utilizing blade flanges that
are under size or not the same diameter, creating
unevenpressure on the core.
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Make certain blade flanges are
proper sizeand identical diameter.
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| 5)Blade being used at incorrect RPM. |
Make certain blade shaft is turning
at theproper RPM by using a tachometer.This is especially
important with concrete saws. |
| 6)Blade improperly mounted on arbor
shoulderhence becoming distorted when flanges aretightened. |
Hold blade securely on arbor shoulder
untiloutside flange and nut are firmly tightened. |
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| 2.Undercutting |
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Cause
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Remedy
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| 1) Undercutting
is a condition in which thesteel core wears faster
than the diamondsegment, especially in the areas
where the segment and core are joined. The condition
is caused by a highly abrasive materialgrinding
against the blade during the sawingoperation. |
Using undercut protectors specially
positionedaround the steel core to change the
patternof constant abrasion. Although successful
inmost cases, undercut protectors do not provide100%
protection. Use high water flow to wash out swan.
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2) With a floor saw, sawing all
the waythrough the material, allowing thecoolant
water to escape from the kerf andthus overheating
the blade.
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Set the cutting depth several
millimetres lessthan the total thickness of the
slab,thus allowing water to stay in the kerf.
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3.Uneven Segment Wear
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Cause
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Remedy
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| 1) Segments worn
on one side reducing sideclearance, usually caused
by misalignment ofthe saw or a lack of sufficient
water on both sidesof the blade. |
Check saw alignment. Clean water
system,making certain that water is properly appliedto
the leading edge of the blade flanges.Check to
see if pump is supplying sufficient even water
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2) Blade is worn out-of-round
due to badbearings, worn arbor, missing bushing,arbor
hole larger than arbor, cleanlinessof or damage
to flange surfaces or excessivedulling condition.
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Replace bearing or worn arbor
as required.Inspect flanges for damage and foreign
materials;replace if necessary. Do not removedrive
pins when supplied with blade flanges.
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| 4.Cracked Segments |
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Cause
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Remedy
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| 1) Blade bond is
too hard for the materialbeing cut. |
Use blade with a softer bond.
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2) Cutting speed too fast.
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Reduce speed of advance.
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| 5.Excessive Wear |
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Cause
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Remedy
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| 1) Using too soft
a bonded blade on highly abrasive material (e.g.
using a concrete blade to cut asphalt or green concrete). |
Use a blade for cutting abrasive
materials.
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2) Lack of sufficient coolant
to the blade.Often detected by excessive wear
in thecore of the segment
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Clean up water coolant system,
Makesure water pump is functioning correctly.
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| 3) Wearing out-of-round accelerates
wear.Usually caused by bad bearings, worn shaft
orusing a blade with too hard a bond for the material
being cut. |
Check bearings and arbor, if wornreplace
with new parts before installinganother blade. |
| 4) Insufficient power caused by loose
v-belts, inadequate voltage or improper RPM's. |
Tighten belts . Replace worn belts.Check
supply voltages. |
| 5) Cutting speed too fast. |
Reduce rate of advance. |
| 6)Blade not perpendicular to material
beingcut. |
Check blade shaft flanges to ensure
properalignment of the blade and equipment. |
| 7) Blade shaft RPM too low. |
Check operating RPM of blade shaft.If
necessary change equipment or modify'blade shaft
speed. |
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| 6.Segment Loss |
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Cause
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Remedy
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| 1) The material
slips during cutting which twists or jams the segments
loose. |
Hold the material securely while
cutting.
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2)Blade is too hard for the material
being cut, causing excessive dullness, which causes
thesegment to pound off or fatigue.
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Use a softer blade bond specification.
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| 3)Worn blade flanges fail to provide
propersupport causing the blade to deflect. |
Replace both blade flanges. |
| 4)Out of round blade rotation resulting
in pounding caused by worn arbor or bad bearings
in the shaft. |
Replace worn arbor and/or bearings |
| 5)Overheating. Usually easily detected
by bluishcolor on steel core, generally confined
to the areawhere the segment was lost. |
Check the water system for blocked
waterpassages. Test pump to see if it isfunctioning
correctly. For dry cutting it may benecessary to
make shallower cuts and allow theblade to run free
every few minutes tolet the air cool it. |
| 6)Segment is subjected to sudden,
sharp joltingWhilst moving the machine or when contacting
the material being cut. |
Avoid jarring the blade when transporting
themachine. Contact the material being cut withslow
even, reciprocal movements. |
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| 7.Overheated Blade |
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Cause
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Remedy
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| 1)Adequate coolant
was not provided. |
Check water supply for adequate
volumeand for obstructions through water system.Use
dry blades ONLY for shallow cutting(2-5cm deep)
or step cutting. Allow bladeto run free every
10-15 seconds to increaseairflow cooling.
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2)Using improper bond specification
forthe material being cut.
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Contact our technical help linefor
an accurate bond specification recommendation.
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| 3)Cutting speed too fast. |
Reduce speed of advance. |
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| 8.Arbor Hole Out Of
Round |
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Cause
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Remedy
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| 1)Saw arbor badly
worn due to blade beingimproperly seated. |
Be certain the blade is properly
seatedon the arbor before tightening the flange.
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2)Blade flanges not properly tightenedpermitting
blade to rotate or shaft.
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Always wrench tighten arbor nut;
neverhand tighten. Always use hex nuts,not wing
nuts.
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| 3)Blade flanges or arbor shaft worn
and not providing blade suppo |
Check blade flanges or arbor shaft
for wear,foreign matter and proper tightness. Bothflanges
should be tightened no less than themanufacturers
recommended figure.Replace any worn machine parts. |
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| 9.Eccentricity |
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Cause
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Remedy
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| 1)The blade bond
is too hard for the materialbeing cut. The harder
bond retains thediamonds and they begin to round
off, causing the blade to become dull. Instead of
cutting the blade begins to pound', causing the
blade to wear out of round. |
Change to a softer bond of blade
which will wearaway more readily allowing new,
sharp diamondsand hence a new cutting edge to
be exposed.
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2)The saw blade shaft may have
a groovescored in it, caused by the blade spinning
between the flanges. A new blade installed on
the arbor shaft will seat into the groove andimmediately
run eccentrically when the saw starts.
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Replace the worn shaft.
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| 3)If the blade shaft bearings are
worn, the shaftand mandrel will run eccentrically,
causing theblade to wear out of round. This happens
mostoften with concrete saws when proper lubrication
of the bearings is neglected. |
Install new blade shaft bearings.
In somecases it may also be necessary to replace
the bladeshaft if it is worn or out of alignment. |
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| 10.Blade Won't Cut |
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Cause
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Remedy
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| 1) Blade bond too
hard for the materialsbeing cut |
Choose a softer bond.
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2) Insufficient power to permit
blade to cutproperly. (Loose v-belts, low voltage,
insufficient horsepower motor).
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Check belts, voltage and motor
output.
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| 3) Blade has become dull due to continuoususe
on fairly hard or vitrified material. |
Redress blade on an abrasive material
untildiamonds become exposed again. Thismay be necessary
occasionally, however ifdullness occurs too often,
the blade bond islikely to be too hard for the material
being cut. |
| 4) Blade becomes glazed due to inadequate
pressure against the material being cut. |
Ensure adequate but not excessivepressure
to keep the blade sharpened. |
| 5) Blade segments appear to still
have plentyof life, but will not cut. |
Some harder bonded blades designed
forabrasive materials require a non-diamond bearingsection
or 'free-back' at the base of the segment,for better
adherence to the steel core.A blade used to this
stage has worn out inthe normal manner and should
be replaced. |
| 6)Blade becomes glazed due to excessive
RPM. |
Match blade diameter and specification
to machine |
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| 11.Cracked Core |
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Cause
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Remedy
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| 1)Blade bond too
hard for the material being cut. |
Use correct blade with a softer
bond.
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2)Excessive cutting pressure,
or jamming and twisting of the blade in the cut
can cause the bladecore to bend or flex. When
subjected to extremestress and metal fatigue,
the blades steel core will eventually crack.
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The saw operator should use steady
reciprocal infeed pressure and be careful not
to twistor jam the blade in the cut.
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| 3)Overheating through inadequate water
supplyor improper use of dry cutting blades. |
Use adequate water to cool wet-cutting
blades.Allow adequate airflow around dry-cuttingblades
to prevent overheating. |
| 4)RPM too high. |
Check operating RPM of blade shaft.Change
equipment or blades if necessary. |
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