Hilti D-LP 15, DS-TS 22 Operating Instructions Manual
Operating instructions en
D-LP 15/
DS-TS 22
Printed: 13.01.2016 | Doc-Nr: PUB / 5139176 / 000 / 02
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D-LP15 / DS-TS22
D-LP15 hydraulic unit
D-RC22 remote control unit
DS-RF rail support
D-R200 L rail (length 200 cm)
DS-ES-L end stop
DS-TS22 saw head
DS-B saw blade
DS-BG blade guard
D-PH58-10 5/8ʺ hydraulic hoses
D-FH4/14-10 1/4ʺ hydraulic control hoses
Water supply hose
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Contents
1. General information 4
2. Safety precautions 5
3. The D-LP15 / DS-TS22 modular hydraulic saw system 11
4. General description and technical data D-LP15 / DS-TS22 12
5. Spindle speeds, gear selection, rules of thumb, sawing procedure, saw blades 13
6. Preparing the workplace and saw system 14
7. Setting up the saw system for various applications 15
8. D-LP15 hydraulic unit – setting up, operation, care and maintenance 22
9. Setting up, checking and operating the hydraulic saw system 23
10. Disassembly and fault finding 25
11. Care and maintenance 27
12. Manufacturer's warranty – tools 28
13. EU declaration of conformity (original) 29
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1. General information
The operating instructions must be read carefully
before the equipment is put into operation.
Always keep these operating instructions with the
equipment.
The wire saw system should be handed over to
other persons only complete with the operating
instructions.
Safety notices and their meaning
1.1
Explanation of the pictograms and other
information
1.2
DANGER
Draws attention to imminent danger that will lead to
serious bodily injury or fatality.
WARNING
Draws attention to a potentially dangerous situation
that could lead to serious personal injury or fatality.
CAUTION
Draws attention to a potentially dangerous situation
that could lead to slight personal injury or damage to
the equipment or other property.
NOTE
Draws attention to an instruction or other useful information.
General warning Warning:
electricity
Warning:
avoid hand injuries
Wear protective
gloves.
Wear safety
footwear.
Wear respiratory
protection.
Wear ear
protection.
Wear eye
protection.
Wear a hard hat.
Warning signs
Obligation signs
Warning:
Risk of cutting
injury
Read the operating
instructions before
use.
Symbols
A
Amps
V
Volts Alternating current
∅
Diameter
Hz
Hertz
n
o
Nominal speed
under no load
mm
Millimeters
/min
Revolutions
per minute
rpm
Revolutions
per minute
Always fit the blade
guard
Always fit the rail
end stops
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2. Safety precautions
Safety precautions 2.1 General safety information 6
2.2 Use of the equipment as directed 7
2.3 Electrical safety precautions 7
2.4 Safety precautions during transport 7
2.5 Safety measures at the working area 8
2.6 Preparations 8
2.7 Safety precautions to be observed when assembling,
securing and operating the wall saw 9
2.8 Securing the objects being cut and disposal of sawing slurry 10
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2. Safety precautions
General safety information
■ Sawing work influences the statics of the structure.
Approval must be obtained from the site engineer or
architect prior to carrying out drilling and sawing
work.
■ You must be fully aware that working with the
D-LP15/DS-TS 22 hydraulic saw system always
involves a certain element of risk due to wear or damage to parts. Check the condition of the entire system,
including accessories, each time before use to ensure
it functions correctly.
Wearing parts such as the blade guard holder rubber,
end stop, blade mounting screw, flush-cutting blade
mounting screws, etc., should be inspected particularly carefully. Check that all parts have been assembled
correctly and consider all other factors that could influence operation of the equipment.
Contact your Hilti representative or Hilti service centre
if faults or deficiencies are found.
■ Use the hydraulic saw system only when you have
read the operating instructions, when you are familiar
with the information contained therein and when you
have been trained to use the equipment safely by a Hilti
specialist. All warnings and safety information must be
observed.
■ The area in front of, behind or below the surface
where sawing work or drilling work is to be carried out
must be secured in such a way that persons or equipment cannot be injured or damaged by falling objects.
If necessary, concrete cores or blocks of concrete that
have been cut free should be secured to prevent them
falling.
■ The operator in charge must be aware of the possible dangers and of his responsibility for safety, both
with regard to himself and to others.
■ Read the operating instructions carefully before
operating the equipment for the first time and observe
all precautions and instructions contained therein.
■ The influences of the environment in which you
are working must be taken into account. Do not position the equipment where the hydraulic unit is liable
2.1
to become very wet. The hydraulic unit must be kept
level during operation, i.e. on a horizontal surface.
Secure the hydraulic unit at locations where there
may be a risk of it falling (e.g. on scaffolding). The
electric extension cable and its plugs and sockets
must not be allowed to lie in water. Do not use the
equipment in the vicinity of inflammable liquids or
gases. Make provision for water removal and disposal.
■ Always keep the operating instructions with the
equipment and pass them on to any subsequent user
who has been trained in its use.
■ When not in use, store the hydraulic saw system in
a locked, dry place out of reach of children.
■ Use the hydraulic saw system only for the applications for which it has been designed.
■ In addition to carrying out the specified care and
maintenance, careful cleaning is also a prerequisite for
safe, trouble-free operation of the equipment.
■ Always stay alert and carefully observe the
progress of your work. Proceed logically and do not
use the equipment when you are unable to concentrate
on your work.
■ Do not leave tools (e.g. open-end wrenches) in
place on the equipment. Check the drive unit to ensure
that all tools have been removed before switching on.
■ Keep the working area tidy and well lit. An untidy
workplace and inadequate lighting increases the risk
of accident.
■ Wear suitable, close-fitting work clothes including
a hard hat, protective goggles, protective gloves, safety footwear, ear protectors and a hair net, if you have
long hair.
■ Respiratory protection should be worn when working in enclosed or poorly ventilated areas and when
dry cutting is being carried out.
■ Keep children and other persons well away from
the workplace and allow no-one to touch the wall saw
or power cable.
■ Failure to comply with the warnings and safety
information may lead to severe or possibly fatal
injury as well as serious damage to the equipment
and other property.
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2. Safety precautions
■ Before beginning work, check the working area
(e.g. using a metal detector) to ensure that no concealed electric cables or gas and water pipes are
present. External metal parts of the machine may
become live, for example, when an electric cable is
damaged accidentally. This presents a serious risk of
electric shock.
■ The machine is not intended for use by children,
by debilitated persons or those who have received
no instruction or training.
■ Children must be instructed not to play with the
machine.
■ Dust from material such as paint containing lead,
some wood species, minerals and metal may be harmful. Contact with or inhalation of the dust may cause
allergic reactions and/or respiratory diseases to the
operator or bystanders.
Certain kinds of dust are classified as carcinogenic
such as oak and beech dust especially in conjunction
with additives for wood conditioning (chromate, wood
preservative). Material containing asbestos must only
be treated by specialists.
Where the use of a dust extraction device is possible
it shall be used. To achieve a high level of dust
collection, use a suitable vacuum cleaner of the type
recommended by Hilti for wood dust and/or mineral
dust together with this tool. Ensure that the workplace is well ventilated. The use of a dust mask of filter
class P2 is recommended. Follow national requirements for the materials you want to work with.
Use of the equipment as directed
■ The D-LP15/DS-TS 22 hydraulic saw system has
been developed for the technical demolition of steel,
concrete, stone or brickwork structures in construction and civil engineering applications. It can be used
for wet or dry sawing (the wet sawing technique is
normally used). Use extending beyond this is considered to be not as directed and requires to be clarified
in advance with the manufacturer.
■ The hydraulic saw system may be operated only
by specialists trained in concrete cutting techniques,
referred to in the following as “operators”. These persons must be familiar with the content of these operating instructions and must have been trained in their
safe application by a Hilti specialist.
■ National regulations and laws, as well as the oper-
2.2
ating instructions and the safety information applicable to the accessories employed (saw blade, fastening accessories etc.) must be observed.
■ Use only the accessories recommended in these
operating instructions. The use of other accessories
may result in damage or injury. Use only original Hilti
spare parts.
■ Use only saw blades approved for a cutting speed
of 63 m/sec.
Electrical safety precautions
■ Connect the unit only to a power source equipped
with an earth conductor and ground fault circuit
breaker (PRCD). Check that these items are in perfect
working order before operating the equipment.
■ Make sure that the mains voltage corresponds to
the specification given on the rating plate.
■ Protect yourself against electric shock, i.e. avoid
contact with earthed components such as pipes,
radiators and the like.
■ Check the condition of all cables and plugs each
time before use.
■ Keep all electric cables, especially their plug connections, in a dry condition. Close the electric sockets by means of the covers supplied when not in use.
■ Use of extension cables: Use only extension
cables with adequate conductor cross-section which
are approved for the intended field of use. Do not
work with extension cables when they are rolled up.
This can result in a drop in output at the equipment
and may cause the cable to overheat. Replace damaged extension cables.
■ Disconnect the power cable before beginning
cleaning and maintenance work or in the event of a
lengthy interruption between periods of operation.
■ Any generator used must be earthed when in
operation.
Safety precautions during transport
■ Make sure that the hydraulic saw system cannot
move about during transportation.
2.4
2.3
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2. Safety precautions
■ Always avoid adopting a bent-over body position
when carrying heavy items, i.e. keep your back
straight when lifting and carrying. Maintain a secure
stance, especially when using ladders or when working from scaffolding.
■ Use the handles provided for transportation of the
drive unit and control unit. Ensure that the handles
are always kept clean and free of grease.
■ If the drive unit and control unit are to be transported by means of a crane, the lifting points provided must be used.
■ Only suitable, conventional site cranes or mobile
cranes may be used for lifting.
Safety measures at the danger areas
■ Safety measures must be implemented in the area
where sawing is taking place to ensure that operators
and bystanders cannot be injured or property damaged by debris that may fly off or fall down (brokenoff diamond segments, small stones, sawing slurry,
etc.) while sawing is in progress. Safety measures
must also be implemented in the area not directly
visible to the operator, i.e. behind where sawing is
taking place.
■ Persons must NEVER enter the danger area (3
meters in all directions from the line of the cut to be
made) while the blade drive is switched on.
3m
3m ∞m
3m3m
STOP
STOP
STOP
STOP
2.5
3m 3m
3m
1m ∞m
STOP
STOP
STOPSTOP
CAUTION
Secure the working area. Ensure that no persons can
be injured or property / equipment damaged by falling
objects or debris that may fly off during the sawing
operation.
1. Approval must be obtained from the site engineer or
site management before beginning the sawing
work.
2. Find out whether overcutting at corners is permitted. If not, the corresponding corner holes must be
planned and drilled first.
3. Check that the area is cordoned off, that supports
are in place and warnings to third parties are displayed.
When setting up and operating the saw system and
when removing parts that have been cut away,
always ensure that no persons are below the area in
which you are working. Falling objects could cause
serious injury.
The danger area may be entered only when the machine is switched off at the main switch (emergency-off
button pressed).
Preparations
■ Keep the working area tidy and always unroll the
full length of hoses and cables. Untidiness and bad
organisation of the working area can lead to accidents.
■ Make sure that no gas, water, electricity or other
supply lines are located in the cutting area. Supply
lines located close to the cutting area which could be
damaged by falling parts, for instance, must be specially protected and, if necessary, temporarily switched
off etc.
■ Ensure that the cooling water used is drained or
extracted in a suitably controlled manner. Water that is
allowed to drain away or spray around in an uncontrolled manner can lead to damage or accidents. The
fact that water could drain away into internal, hidden
cavities, e.g. in brickwork or masonry, must also be
taken into account.
■ Make a careful note of any influence the immediate
surroundings may have on operations. Do not use the
hydraulic saw system in areas where there is a risk of
2.6
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2. Safety precautions
explosion or in close proximity to combustible materials, fluids or gases. Flying sparks or electrostatic discharge can lead to fires or explosions.
■ Do not cut materials which may produce toxic or
explosive dust or vapours when cut.
■ Do not cut easily combustible aluminium or magnesium alloys.
Safety precautions to be observed when
assembling, securing and operating the wall
saw
WARNING
Use an anchor suitable for the material on which you
are working and observe the anchor manufacturer’s
instructions.
NOTE
Hilti M12 metal expansion anchors are usually suitable for fastening diamond core drilling equipment to
uncracked concrete. Under certain conditions it may
be necessary to use an alternative fastening method.
Please contact Hilti Technical Service if you have any
questions about secure fastening.
■ Use metal anchors (size M12) for fastening DS-RF
rail supports and DS-RFP angular cutting plates.
Secure fastenings of a type suitable for the material
being cut must be installed, e.g. Hilti HKD-D, HSA-A,
Hilti HIT, HEA / HAS anchors.
■ Use only ISO 8.8 grade fastening screws for the rail
supports.
■ An end stop must always be fitted at the end of the
rail to prevent unintentional advance beyond this point
(prevents saw coming off the end of the rail).
■ The blade guard must always be in place when the
saw is in use. NEVER stand in the direction of radial
flight of a running saw blade. Special precautions must
be taken to secure the danger area when special cutting applications are in progress.
■ Always operate the machine from the closed side
of the blade guard when corner cuts are made with the
2.7
blade guard in the partly open position. The operator
must take additional precautions (fit a cover, plank of
wood, boards etc.) where necessary.
■ Never attempt to connect or disconnect hydraulic
hoses while the hydraulic unit is running and while the
hoses are under pressure.
■ Handle the DS-RFP angular cutting plate carefully.
There is a risk of pinching your fingers.
■ It is essential that the prescribed checks are carried
out before beginning sawing (see section 9.1)
■ Unless special safety precautions are taken, the
D-LP 15/DS-TS 22 must NOT be operated in environments where there is a risk of explosion.
■ The hydraulic unit and the operator with the remote
control unit should be positioned as far as possible
outside the danger zone. The operator with the remote
control unit should remain at a safe location while the
saw is in operation.
■ Use only adequately dimensioned fastening materials to secure the saw (anchors, screws, etc.). Recommendations can be found in our catalogues and brochures.
■ Operate the saw only when the blade guard and
rail-end stops have been fitted and secured.
■ Observe the recommended cutting speeds and
advance pressures while sawing.
■ Protective gloves should be worn as the oil and
parts of the equipment can become very hot.
■ Wear the protective clothing and other items of
protective equipment listed in section 2.1.
■ Before each cut, check that there is no play
between the saw head and the rail and that the eccentric rollers are engaged.
■ When additional safety precautions are taken, overhead sawing is also possible. In this case, the blade
guard must be equipped with a means of water
drainage. Do not stand beneath the saw.
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2. Safety precautions
Securing the objects being cut and disposal
of sawing slurry
■ Steel wedges and/or supports must be used to prevent uncontrolled movement of parts being cut free in
order to avoid injuries and to prevent the saw blade
becoming trapped or jammed.
■ Use only approved and appropriately dimensioned
means of securing and lifting for the removal and
transportation of parts that have been cut free. Such
parts may have a weight of many tons.
■ Never loiter in the vicinity of loads suspended by
cranes.
■ The point at which the cut is made and any resulting opening must be safely and visibly cordoned off to
prevent persons falling and to exclude the risk of damage or injury.
■ Introducing sawing slurry into the drains or sewage
system without suitable pre-treatment is problematic
from an environmental point of view. Ask the local
authority responsible about existing regulations. We
recommend the following pre-treatment:
– Collect the sawing slurry (e.g. using an industrial
vacuum cleaner)
– Allow the slurry to settle and dispose of the solid
portion of the waste at a building waste disposal
location (the separation process can be accelerated
by adding a flocculent).
– Neutralise the residual water by adding a neutralis-
ing agent or dilute it by adding a large quantity of
water before allowing it to enter the drainage system.
■ Always switch off the hydraulic power unit before
setting up or dismantling the saw or before carrying
out any other manipulation of the saw head or blade,
etc.
2.8
Printed: 13.01.2016 | Doc-Nr: PUB / 5139176 / 000 / 02
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