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pulleys. Begin with the saw in an un-wired condition. Loosen the four 5/32” cap screws on each
pulley arm and move equally so that they both remain equidistant from the center. Tighten all eight
screws snug but not excessively. Observe carefully, and jog the yoke if necessary to ensure that the
pulleys and the bow sensor will clear the specimen and fixture during a complete cut program.
Verify that if the table indexes in the course of a cut program, the specimen and fixture remain
clear of the pulleys and bow sensor.
If it is necessary to adjust the pulley spacing with the saw already strung with cutting wire, the
procedure is more difficult but still possible.
1. Run the wire drive to one end of its travel and then stop.
2. Rotate the capstan by hand the last few remaining turns until the wire exits directly from its
retaining hole.
3. Affix a piece of masking tape over the wire on the capstan to prevent it from coming loose in
the next step.
4. Reduce the wire tension pressure regulator to about 10psi and switch the Tensioner
RUN/WIRE switch to WIRE. The tension pulleys move inward and the wire-cutting loop
becomes slack.
5. Move the guide pulleys to their desired position as described in the fist paragraph of this
section. If you are moving the guide pulleys outward a significant distance and there is not
enough slack in the cutting wire, remove the end of the wire from the capstan, pull about 6” of
wire from the capstan, and reinsert the wire end back into the next retaining hole and secure it.
6. Making sure that the wire is strung over all four pulleys, loosen the wire end in its capstan-
retaining hole, pull through any excess slack, and retighten.
7. Turn down the air regulator to 2 or 3psi and switch the Tensioner RUN/WIRE switch to RUN.
8. Rotate the capstan clockwise so that the wire continues to travel over the top of the capstan.
Look closely to see that the wire comes from the retaining hole exactly parallel to the groove.
9. Continue to rotate the capstan by hand one or two revolutions. Observe that the wire is tightly
seated in the capstan spiral; there are no crossovers, nor does the wire skip a groove. There
should be no more than two grooves of capstan showing between the windings.
10. Turn up the air regulator to between 15 and 30psi.
Mounting the Part Specimen
To avoid cutting into the dicing table, the saw is constructed to limit the downward travel of the
yoke so that the wire does not quite reach the table surface. In order to cut completely through the
specimen, you should first mount a 1 ½ inch sacrificial substrate to the table surface, and then
mount the specimen to this substrate. The substrate can be made from any suitable material that is
softer than the specimen. Typical materials are smooth particleboard or PVC. Affix the substrate to
the table using double-sided tape, wax, or glue.
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