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.
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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.
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Make certain
blade shaft is turning at theproper RPM by using a tachometer.This
is especially important with concrete saws.
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6)Blade improperly
mounted on arbor shoulderhence becoming distorted when flanges
aretightened.
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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.
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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.
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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.
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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).
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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.
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Check bearings
and arbor, if wornreplace with new parts before installinganother
blade.
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4) Insufficient
power caused by loose v-belts, inadequate voltage or improper
RPM's.
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Tighten belts
. Replace worn belts.Check supply voltages.
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5) Cutting
speed too fast.
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Reduce rate
of advance.
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6)Blade not
perpendicular to material beingcut.
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Check blade
shaft flanges to ensure properalignment of the blade and
equipment.
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7) Blade shaft
RPM too low.
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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.
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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.
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Replace both
blade flanges.
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4)Out of round
blade rotation resulting in pounding caused by worn arbor
or bad bearings in the shaft.
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Replace worn
arbor and/or bearings
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5)Overheating. Usually easily detected by bluishcolor
on steel core, generally confined to the areawhere the segment
was lost.
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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.
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6)Segment is
subjected to sudden, sharp joltingWhilst moving the machine
or when contacting the material being cut.
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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.
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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.
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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.
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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
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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.
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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.
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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
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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.
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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.
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4) Blade becomes
glazed due to inadequate pressure against the material being
cut.
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Ensure adequate
but not excessivepressure to keep the blade sharpened.
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5) Blade segments
appear to still have plentyof life, but will not cut.
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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.
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6)Blade becomes
glazed due to excessive RPM.
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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.
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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.
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Use adequate
water to cool wet-cutting blades.Allow adequate airflow
around dry-cuttingblades to prevent overheating.
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4)RPM too high.
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Check operating
RPM of blade shaft.Change equipment or blades if necessary.
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