Troubleshooting Diamond Saw Blade cutting problems

Loss of tension Undercutting Uneven Segment Wear Cracked Segments Excessive Wear Segment Loss Overheated Saw Blade Arbor Hole Out Of Round Eccentricity Saw Blade Won't Cut Cracked Core

Loss of tension Cause: Saw Blade being used on misaligned saw. Remedy: Check for proper saw alignment. Cause: Saw Blade is excessively hard for the material being cut, creating stress on the steel centre. Remedy: Make certain Saw Blade is correct for material being cut. (Consult manufacturer's recommendation chart or phone our technical helpline) Cause: Material slippage causing Saw Blade to twist and become kinked or bent. Remedy: Maintain tight grip on material while sawing. Cause: Utilizing Saw Blade flanges that are under size or not the same diameter, creating uneven pressure on the centre. Remedy: Make certain Saw Blade flanges are proper size and identical diameter. Cause: Saw Blade being used at incorrect RPM. Remedy: Make certain Saw Blade shaft is turning at the proper RPM by using a tachometer. This is especially important with concrete saws. Cause: Saw Blade improperly mounted on arbor shoulder hence becoming distorted when flanges are tightened. Remedy: Hold Saw Blade securely on arbor shoulder until outside flange and nut are firmly tightened.

Undercutting Cause: Undercutting is a condition in which the steel centre wears faster than the diamond segment, especially in the areas where the segment and core are joined. The condition is caused by a highly abrasive material grinding against the Saw Blade during the sawing operation. Usually materials containing sand are responsible for this condition (see section on SEGMENT LOSS). Remedy: The flow of slurry (abrasive cuttings) must be distributed over a wider area, away form the critical segment area. Many times this can be accomplished by using undercut protectors specially positioned around the steel centre to change the pattern of constant abrasion. Although successful in most cases, undercut protectors do not provide 100% protection. Use high water flow to wash out slurry.

Cause: With a floor saw, sawing all the way through the material, allowing the coolant water to escape from the kerf and thus overheating the Saw Blade. Remedy: Set the cutting depth several millimeters less than the total thickness of the slab, thus allowing water to stay in the kerf.

Uneven Segment Wear Cause: Segments worn on one side reducing side clearance, usually caused by misalignment of the saw or a lack of sufficient water on both sides of the Saw Blade. Remedy: Check saw alignment. Clean water system, making certain that water is properly applied to the leading edge of the Saw Blade flanges. Check to see if pump is supplying sufficient even water (See EXCESSIVE WEAR section). Cause: Saw Blade is worn out-of-round due to bad bearings, worn arbor, missing bushing, arbor hole larger than arbor, cleanliness of or damage to flange surfaces or excessive dulling condition. (See section of EXCESSIVE WEAR). Remedy: Replace bearing or worn arbor as required. Inspect flanges for damage and foreign materials; replace if necessary. Do not remove drive pins when supplied with Saw Blade flanges.

Cracked Segments Cause: Saw Blade bond is too hard for the material being cut. Remedy: Use Saw Blade with a softer bond. Cause: Cutting speed too fast. Remedy: Reduce speed of advance.

Excessive Wear Cause: Using too soft a bonded Saw Blade on highly abrasive material (for ex. using a concrete Saw Blade to cut asphalt or green concrete). Remedy: Consult one of our technical representatives for a Saw Blade recommendation for cutting abrasive materials. Cause: Lack of sufficient coolant to the Saw Blade. Often detected by excessive wear in the centre of the segment (Note: In both cases diamonds will usually be highly exposed) Remedy: Clean up water coolant system, Make sure water pump is functioning correctly. Cause: Wearing out-of-round accelerates wear. Usually caused by bad bearings, worn shaft or using a Saw Blade with too hard a bond for the material being cut. Remedy: Check bearings and arbor, if worn replace with new parts before installing another Saw Blade. Cause: Insufficient power caused by loose v-belts, inadequate voltage or improper RPM's. Remedy: Tighten belts (taut). Replace worn belts. Check supply voltages (use correct extension cords).

Cause: Cutting speed too fast. Remedy: Reduce rate of advance. Cause: Saw Blade not perpendicular to material being cut. Remedy: Check Saw Blade shaft flanges to ensure proper alignment of the Saw Blade and equipment. Cause: Saw Blade shaft RPM too low. Remedy: Check operating RPM of Saw Blade shaft. If necessary change equipment or modify' Saw Blade shaft speed.

Segment Loss Cause: The material slips during cutting which twists or jams the segments loose. Remedy: Hold the material securely while cutting. Cause: Saw Blade is too hard for the material being cut, causing excessive dullness, which causes the segment to pound off or fatigue. Remedy: Use a softer Saw Blade bond specification. Cause: Worn Saw Blade flanges fail to provide proper support causing the Saw Blade to deflect. REMEDY: Replace both Saw Blade flanges. Cause: Out of round Saw Blade rotation resulting in pounding caused by worn arbor or bad bearings in the shaft. Remedy: Replace worn arbor and/or bearings Cause: Overheating. Usually easily detected by bluish color on steel centre, generally confined to the area where the segment was lost. Remedy:: Check the water system for blocked water passages. Test pump to see if it is functioning correctly. For dry cutting it may be necessary to make shallower cuts and allow the Saw Blade to run free every few minutes to let the air cool it. Cause: Segment is subjected to sudden, sharp jolting whilst moving the machine or when contacting the material being cut. Remedy: Avoid jarring the Saw Blade when transporting the machine. Contact the material being cut with slow even, reciprocal movements.

Overheated Saw Blade Cause: Adequate coolant was not provided. Remedy: Check water supply for adequate volume and for obstructions through water system. Use dry Saw Blades ONLY for shallow cutting (2-5cm deep) or step cutting. Allow Saw Blade to run free every 10-15 seconds to increase airflow cooling. Cause: Using improper bond specification for the material being cut. Remedy: Contact Diamond Tec for an accurate bond specification recommendation. Cause: Cutting speed too fast. Remedy: Reduce speed of advance.

Arbor Hole Out Of Round

Cause: Saw arbor badly worn due to Saw Blade being improperly seated. Remedy: Be certain the Saw Blade is properly seated on the arbor before tightening the flange. Cause: Saw Blade flanges not properly tightened permitting Saw Blade to rotate or shaft. Remedy: Always wrench tighten arbor nut; never hand tighten. Always use hex nuts, not wing nuts. Cause: Saw Blade flanges or arbor shaft worn and not providing Saw Blade support. Remedy: Check Saw Blade flanges or arbor shaft for wear, foreign matter and proper tightness. Both flanges should be tightened no less than the manufacturers recommended figure. Replace any worn machine parts. Eccentricity Cause: The Saw Blade bond is too hard for the material being cut. The harder bond retains the diamonds and they begin to round off, causing the Saw Blade to become dull. Instead of cutting the Saw Blade begins to pound', causing the Saw Blade to wear out of round. Remedy: Change to a softer bond of Saw Blade which will wear away more readily allowing new, sharp diamonds and hence a new cutting edge to be exposed. Cause: The saw Saw Blade shaft may have a groove scored in it, caused by the Saw Blade spinning between the flanges. A new Saw Blade installed on the arbor shaft will seat into the groove and immediately run eccentrically when the saw starts. Remedy: Replace the worn shaft. Cause: If the Saw Blade shaft bearings are worn, the shaft and mandrel will run eccentrically, causing the Saw Blade to wear out of round. This happens most often with concrete saws when proper lubrication of the bearings is neglected. Remedy: Install new Saw Blade shaft bearings. In some cases it may also be necessary to replace the Saw Blade shaft if it is worn or out of alignment.

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Saw Blade Won't Cut Cause: Saw Blade bond too hard for the materials being cut (for ex. abrasive material or asphalt Saw Blade being used to cut concrete) Remedy: Contact Diamond Discs International technical helpline for an accurate bond specification recommendation. Cause: Insufficient power to permit Saw Blade to cut properly. (Loose vbelts, low voltage, insufficient horsepower motor). Remedy: Check belts, voltage and motor output. Cause: Saw Blade has become dull due to continuous use on fairly hard or vitrified material. Remedy: Redress Saw Blade on an abrasive material until diamonds become exposed again for ex. run the Saw Blade through a 'breeze block'. This may be necessary occasionally, however if dullness occurs too often, the Saw Blade bond is likely to be too hard for the material being cut. Cause: Saw Blade becomes glazed due to inadequate pressure against the material being cut. Remedy: Ensure adequate but not excessive pressure to keep the Saw Blade sharpened. Cause: Saw Blade segments appear to still have plenty of life, but will not cut.

Remedy:: Some harder bonded Saw Blades designed for abrasive materials require a non-diamond bearing section or 'free-back' at the base of the segment, for better adherence to the steel centre. A Saw Blade used to this stage has worn out in the normal manner and should be replaced. Cause: Saw Blade becomes glazed due to excessive RPM. Remedy: Match Saw Blade diameter and specification to machine

Cracked Core
Cause: Saw Blade bond too hard for the material being cut. Remedy: Use correct Saw Blade with a softer bond. Cause: Excessive cutting pressure, or jamming and twisting of the Saw Blade in the cut can cause the Saw Blade core to bend or flex. When subjected to extreme stress and metal fatigue, the Saw Blades steel core will eventually crack. Remedy: The saw operator should use steady reciprocal infeed pressure and be careful not to twist or jam the Saw Blade in the cut. Cause: Overheating through inadequate water supply or improper use of dry cutting Saw Blades. Remedy: Use adequate water to cool wet-cutting Saw Blades (for ex. 7-18 liters per minute for concrete saws). Allow adequate airflow around dry-cutting Saw Blades to prevent overheating. Cause: RPM too high. Remedy: Check operating RPM of Saw Blade shaft. Change equipment or Saw Blades if necessary. NEVER USE A SAW BLADE WITH A CRACKED CORE!