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Product Introduction





Fitting  Connectors

A. Fitting a Straight, Collared Steel Connector to a Sintered Bead Wire

A1 Cutting the Ends of the Diamond Wire:


1) Clamp or hold rigid the diamond wire.
2) Use sharp cutters or an angle grinder to cut the diamond wire at a distance of 15mm from the first bead. Ensure that the cut is clean and straight.


A2 Removing Spring:
Using a pair of pliers, unwind the exposed portion of the spring back as far as the plastic, and small 5mm portion of plastic covered spring left against the bead.)

A3 Removing the protective plastic coating:

Carefully remove the plastic coating using a sharp knife back to a distance of 5mm from the last bead, exposing spring.


A4 Fitting the Connector:
1) Push the hollow section of the connector onto the bare end of the wire as far as it will go. Ensure that it is tight up against the remaining portion of the plastic and spring. (No gap should be visible.)
2) Using hydraulic crimping pliers fitted with the correct crimping jaws, crimp the connector and crimp again.
NB. If in doubt check with your supplier that the crimping jaws being used are compatible with the connector, and do not use worn or deformed crimping jaws.


A5. Assembling and Crimping a Straight Connector, Second End:
1) Prepare the second end of the wire as above (A1-A3).
2) Twist the diamond wire as described :
Twisting the Diamond Wire

Before joining the ends of the loop, one end of the wire should be twisted a certain number of turns. It is important that the wire is only twisted in an anti-clockwise direction (as seen by the operator when looking at the cut end of the diamond wire). For the first cut, the wire should be twisted approximately one turn for each metre of diamond wire.
3) Assemble and crimp as above (A4).


General Instructions on the Use of Diamond Wire

A. Assembly Instructions


1) Twist the diamond wire in an anti-clockwise direction (as seen by the operator when looking straight at the cut end of the diamond wire) before joining the ends. Initial amount of twists: one turn for each metre of diamond wire.


2) To achieve even wear of the beads (i.e. to help avoid flat-spotting) the diamond wire should be re-twisted after each large cut is made (approx. 2m² for a 10m loop, 3m² for a 14m loop, 4m² for a 20m loop etc.) by applying a different number of turns to the wire, i.e. starting at 1.0 approximately 30% e.g. 1.3, 1.7, up to a maximum amount of 2.2 turns per metre and then if there is still life in the wire start decreasing the amount of twists after each large cut by 30%, and so on.


3) Observe the correct cutting direction (arrow on diamond wire). The cutting direction must not be changed. The beads are likely to become slightly tapered correspondingly (smaller diameter at the leading edge).

In the case of electroplated wire if there is no arrow in the plastic then go by the conical shape of the bead: the smaller diameter end of the bead is the leading edge.

4) Do not join up diamond wires where their bead diameters differ by more than 0.2mm.


5) Avoid kinks in the wire.

B. Instructions for Diamond Wire Sawing

Preparations for beginning the cut:
1) Round off the corners of the work piece to a radius of approximately 10cm (using a hammer and chisel) before beginning sawing and pull the diamond wire through by hand until it is rotating round sufficiently freely.
2) It is important, to prevent flat spotting, to ensure that the wire rolls continuously while going round the loop. To ensure this happens, if


there is no built-in roll-assistance in the system employed, the last guide pulley before the wire enters the work piece should be before, so the wire lands on the guide pulley slightly off-centre, i.e. by about 5mm. The wire should be central again by the time it leaves the pulley, having had to roll over slightly. (N.B. white polyamide pulleys and similar are no good for this – the wire just slides to the centre.) This ensures that each time a bead goes through the work piece, a different face of the bead is against the cut.

Feel for this rolling motion when pulling the wire through by hand before starting the cut. If in doubt, make a permanent mark near to the connector on the top of the wire, pull the complete loop through by hand, and check it has twisted over to one side next time the connector comes round.


3) To enable the wire to maintain its pressure against the work piece, as a rule of thumb the final guide pulleys are best 200mm away from the fact of the work piece for every metre between them.
4) Position the water supply at the point where the diamond wire enters the work piece. Depending on the length and configuration of the cut, it may be necessary to apply cooling water at several points. A properly functioning cooling water supply is of decisive importance if good cutting performance is to be achieved.
5) Use the advance/return movement to tension the diamond wire. Keep a safe distance and start the motor. The wire saw should be started smoothly and slowly and its speed increased gradually until the maximum permitted speed is reached.
While sawing:
The sawing procedure must be supervised constantly from a safe distance. Before adjusting the position of the cooling water supply, stop the advance movement and switch off the motor and hydraulic unit.
After sawing:
If the wire is to be used again at a later date, ensure it is allowed to dry thoroughly and stored in a dry area to prevent rusting of the strands which tends to lead to breakages.


Shijiazhuang LEILI Tools Co. Ltd

AddressDongDuZhuang Industry Zone, Changan District,Shijiazhuang,Hebei Province,China


Cell : +8615028103937 (24hours


E-mail: ll@leilitools.com


Facebook: https://www.facebook.com/jinlong.li.1426


ShiJiazhuang LEILI Tools Co.Ltd

address:13-1-401 ,Hongshanwan,Shijiazhuang,Hebei,China

+8615028103937 +8631189865438 derek@leilitools.com