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Hilti D-LP 32, Operating Instructions Manual

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Hilti D-LP 32 Operating Instructions Manual Download Page 8

8

2. Description

Parts and operating controls

D-LP 32 hydraulic unit

Transport handle, hinged

Lifting point for transport by crane

400 V 63 A socket, mains supply (Euro standard

socket as per EN CEE 63)

230 V socket

Socket for D-RC-LP 32 remote control unit

Oil level sight glass

 

Oil filter cover

Emergency off switch

Guidelines for use (sticker)

2.3

2.3.1

Wheels with puncture-proof tyres

PH

3

/

4

˝

coupling for pressure hose

PH

3

/

4

˝

coupling for return hose

FH

1

/

4

˝

couplings

for advance control hoses

FH

1

/

4

˝

couplings for

saw arm

Coupling for water supply from the site

Water supply to saw head (with water flow rate reg-
ulation)

D-RC-LP 32 remote control unit

On / off control switch

Cap / oil filler neck

230 V socket overload reset button

Front support

Hinged transport handle locking mechanism

2

8

17

1

7

6

8

12

10

15

21

16

14 11

13

9

8

20

3

19

18

4

5

22

Printed: 08.07.2013 | Doc-Nr: PUB / 5069667 / 000 / 01

Summary of Contents for D-LP 32

Page 1: ...Operating instructions en D LP 32 DS TS 32 Printed 08 07 2013 Doc Nr PUB 5069667 000 01 ...

Page 2: ...2 D LP32 DS TS32 Hydraulic unit Remote control unit Rail Saw blade Blade guard Hydraulic hoses End stop Rail support Printed 08 07 2013 Doc Nr PUB 5069667 000 01 ...

Page 3: ...nd accessories 13 4 Technical data 17 5 Safety precautions 21 6 Before use 27 7 Operation 35 8 Care and maintenance 43 9 Troubleshooting 45 10 Disposal 50 11 Manufacturer s warranty tools 51 12 EU declaration of conformity original 52 Printed 08 07 2013 Doc Nr PUB 5069667 000 01 ...

Page 4: ...ght personal injury or damage to the equipment or other property NOTE Draws attention to an instruction or other useful infor mation Explanation of the pictograms and other information 1 2 General warning Warning electricity Warning avoid hand injuries Warning signs Obligation signs Warning Risk of cutting injury Wear protective gloves Wear safety footwear Wear respiratory protection Wear eye prot...

Page 5: ...5 2 Description Description 2 1 Areas of application 6 2 2 D LP32 DS TS32 hydraulic saw system components 6 2 3 Parts and operating controls 8 Printed 08 07 2013 Doc Nr PUB 5069667 000 01 ...

Page 6: ...em Using the D RC LP32 digital remote control unit to adjust the infinitely variable oil flow rate the operator can select the optimum speed and most suitable rate of advance This feature ensures optimum efficiency for wall saw ing hydraulic coring plunge sawing or wire sawing 2 1 D LP32 DS TS32 hydraulic saw system components The basic diamond saw system consists of the follow ing components D LP...

Page 7: ...S WSRF 5 DS WSRP 4 DS WSWD 3 DS WSTA 2 DS WSW500 1 DS W11 7 6 5 7 4 1 2 3 D LP32 DD 750HY DS PS30 Hydraulic core drilling rig Plunge saw D LP32 DS TS32 DS WSS30 Wire saw D LP32 DS TS PS WSS and DD modular system 2 2 1 D R 150 L D S 150 D R 200 L DD BA6 DD BA3 70 DD AF HY D RC LP 32 DD CA L DD MF ML DD 750HY DD BU 202 DD R 100 M DD R 40 M D CO ML DS CA L M DD R 130 M DS PS 30 D LP32 DD FH DS B O 60...

Page 8: ...2 3 1 Wheels with puncture proof tyres PH 3 4 coupling for pressure hose PH 3 4 coupling for return hose FH 1 4 couplings for advance control hoses FH 1 4 couplings for saw arm Coupling for water supply from the site Water supply to saw head with water flow rate reg ulation D RC LP32 remote control unit On off control switch Cap oil filler neck 230 V socket overload reset button Front support Hing...

Page 9: ...re 100 l min D LP 32 DD 750 HY 32 45 Ampere 40 60 l min 32 63 Ampere 80 100 l min D RC LP 32 Start Ampere II I 32 63 45 100 1600 1200 1000 900 800mm D RC LP 32 Start Ampere II I 32 63 45 100 1600 1200 1000 900 800mm 220 kg D RC LP 32 Start Ampere II I 32 63 45 100 1600 1200 1000 900 800mm 60 40 80 60 40 80 60 40 80 Printed 08 07 2013 Doc Nr PUB 5069667 000 01 ...

Page 10: ...imum blade diameter sequence Plunge depth for initial guide cut Plunge depth for subsequent cuts Cut no I saw arm trailing Cut no II saw arm leading Cut no III saw arm trailing Direction of blade rotation counterclockwise as seen from side where blade is fitted Recommended oil flow rate in l min speed for corresponding blade dia mm 2 3 4 1 2 7 4 5 6 3 2 l ll lll lll ll l 1515 15 l ll lll cm Hard G...

Page 11: ...ndicator lights briefly before cut out on overheating Water cooling lights when unit is inadequately cooled Zero position lights when one of the control knobs is not in the zero or neutral position Mains supply warning lamp Oil level lights when oil level is too low Emergency OFF lights when button is pressed in Service indicator lights when service is due Operating hours indicator working pressur...

Page 12: ... 1 4 saw arm pivot Water supply Water control valve may be fitted at blade guard or at hydraulic unit Saw blade mounting flange with special M12 25 10 9 grade steel screw Grips Cam action rollers Clamping screw for positioning blade guard holder and blade guards Cam action roller lockbutton 2 3 7 5A 9A 11 8 7 17 9A 9 11 13 12 8 7 12 11 15 4 4 14 2 1 6 5 5A 15 3 12 16 2 10 18 11 12 Rating plate Gre...

Page 13: ...e set 14 tools and accessories 3 2 D R L rails DS ES L end stops DS RF rail supports and DS RFP angular cutting plate 14 3 3 DS BG BGF blade guard 14 3 4 DS FCA 110 flush cutting flange 15 3 5 Diamond saw blades 15 3 6 Accessories D LP32 DS TS32 tool set 16 Printed 08 07 2013 Doc Nr PUB 5069667 000 01 ...

Page 14: ...m dia saw blades 238004 DS BG120 center section Blade guard for 1000 to 1200 mm dia saw blades 238005 DS BG120 side section Blade guard for 1000 to 1200 mm dia saw blades 333883 DS BG16 blade guard Blade guard for 1200 to 1600 mm dia saw blades Item no Designation Use 238006 DS BGF80 center section Blade guard for 600 to 900 mm dia saw blades for flush cutting 238007 DS BGF80 side section Blade gu...

Page 15: ...antageous when difficult conditions such as high steel content or hard aggregates etc are encountered Safety precaution Keep to the recommended settings in order to ensure that blade peripheral speed remains within the safe range for the saw blade used DS FCA 110 flush cutting flange 3 4 Specification Cutting characteristics Type of concrete Reinforcement CS H UP Fast cutting Soft aggregates Norma...

Page 16: ...e guard holder Grip nut 1 Fastening blade guard Hex key 4 mm 2 Eccentric rollers covers Hex key 10 mm 1 Fastening blade guard holder DS hex key with T grip 1 Eccentric rollers D PRT pressure release valve FH1 4 1 Pressure release FH1 4 D PRT pressure release valve PH3 4 1 Pressure release PH3 4 D steel wedge 130 70 20 6 Securing concrete block Copper ring 5 Core bit extension Special M10 countersu...

Page 17: ...er supply 18 4 2 Dimensions and weights 18 4 3 IP enclosure protection code 18 4 4 Climatic conditions for operation and storage 18 4 5 Technical data 19 4 6 Noise information 19 4 7 Rating plates 20 Printed 08 07 2013 Doc Nr PUB 5069667 000 01 ...

Page 18: ...220 kg remote control unit D RC LP32 L B H 390 180 120 mm Weight 2 2 kg DS TS32 saw head L B H 510 380 400 mm Weight 36 kg IP protection code D LP32 hydraulic unit IP 44 D RC LP32 remote control unit IP 65 4 1 4 2 4 3 Climatic conditions for operation and storage The nominal values given in the data for the D LP32 DS TS32 hydraulic saw system are applic able at ambient temperatures within the 15 C...

Page 19: ...e length 10 m Cable length with extension 20 m DS TS32 saw head Drive 54 ccm hydraulic motor Dimensions L B H 510 380 400 mm Gearing 1 gear Max oil flow rate 100 l min Max operating pressure 200 bar Hydraulic couplings Pressure hose PH 3 4 Control hose FH 1 4 Operation With D RC LP32 digital electronic remote control Saw blade diameter range 800 1600 mm dia Wire sawing 500 dia drive wheel Weight 3...

Page 20: ...20 4 Technical data Rating plates 4 7 Printed 08 07 2013 Doc Nr PUB 5069667 000 01 ...

Page 21: ... safety precautions 23 5 4 Safety precautions during transport 23 5 5 Safety measures at the danger area 24 5 6 Preparations 24 5 7 Safety precautions to be observed when assembling securing and operating the wall saw 25 5 8 Securing the objects being cut and disposal of sawing slurry 25 Printed 08 07 2013 Doc Nr PUB 5069667 000 01 ...

Page 22: ...use all 22 5 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 LP 32 DS TS 32 hydraulic saw system always involves a certain element of risk due to wear or damage to parts Check the condition of ...

Page 23: ...owing as operators These persons must be familiar with the content of these operating instruc tions and must have been trained in their safe applica tion by a Hilti specialist National regulations and laws as well as the operat ing instructions and the safety information applicable to the accessories employed saw blade fastening acces sories etc must be observed 5 2 Use only the accessories recomm...

Page 24: ...uring 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 ...

Page 25: ...re necessary Never attempt to connect or disconnect hydraulic hoses while the hydraulic unit is running and while the hoses are under pressure 5 7 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 5 5 Unless special safety precautions are taken the D LP32 DS TS32 ...

Page 26: ...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 author ity responsible about existing regulations We recom mend the following pre treatment Collect the sawing slurry e g using an industrial vac uum cleaner Allow the slurry to settle and dispose of t...

Page 27: ...efore use 6 1 Preparations at the workplace and preparing the saw system 28 6 2 Setting up the saw system 29 6 3 D LP32 hydraulic unit Connections and preparation for use 34 Printed 08 07 2013 Doc Nr PUB 5069667 000 01 ...

Page 28: ... cooling water Check the electric supply fuse rating 63 amps is best and 32 amps is the minimum and check functionality of the earth connection this is the responsibility of the site manager Use an electric extension cable with standard Euro plug as per EN CEE 63 Select the cable cross section accord ing to the load it is to carry amps and the cable length Please refer to the following table Cable...

Page 29: ...e a minimum distance of 20 cm to the near est edge must be observed The dust must be blown out of the holes and the anchors set approx 5 mm below the surface of the concrete On masonry etc for example Hilti HIT adhesive anchors or through rods may be used On extremely uneven surfaces suitable shims or pack ing pieces must be positioned beneath the rail supports where necessary or the rail support ...

Page 30: ...L rails can be extended to form a rigid unit by using a D C O ML double taper and D EP ML eccen tric pin The recommended distance between rail supports is approx 1 5 m When a double taper is not available for use rails can be extended by mounting a rail support at the joint between two rails In this case use a DS ES L end stop to set the correct distance between rail sections 6 2 3 D R L rails are...

Page 31: ...m Fit the special blade flange and the special screw M12 25 10 9 grade Rotate the blade slightly so that the countersunk holes for fastening the blade for flush cutting are positioned BESIDE the 6 water grooves Use the 19 mm AF ring wrench to tighten the special M12 screw securely Instructions for handling hydraulic hoses and hydraulic couplings Always clean the couplings with a cloth before con n...

Page 32: ... depth is reduced The blade is also subjected to additional bending loads Please refer to the following table for setting up dimen sions and cutting depths IMPORTANT When making angular cuts make a shal low guide cut and begin cutting gently 6 2 7 6 2 6 Angle of cut 10 20 30 40 45 Diameter mm 900 900 900 900 900 C cm 30 24 18 8 3 A cm 24 26 29 34 38 Flush cutting using the DS FCA 110 flush cutting...

Page 33: ...of 10 metres This length can be extended but a drop in performance must then be expected Using other hydraulic units to power the DS TS32 saw Damage to the DS TS 32 resulting from use of a hydraulic unit other than the D LP 32 or D LP 30 to power the system is not covered by the warranty provided by the Hilti Corporation Should you decide to operate the saw at your own risk with a hydraulic unit o...

Page 34: ...rane 34 6 Before use D LP32 hydraulic unit Connections and preparation for use 6 3 3 phase 400 V mains supply with appropriate fuse rat ing The switching control sets the correct direction of motor rotation automatically Standard plug as per EN CEE 63 The unit employs a star delta switching system Y Starting up takes only a few seconds max 5 sec Use an extension cable with adequate cross section T...

Page 35: ...tion Operation 7 1 Checks before beginning sawing 36 7 2 The sawing procedure and saw operation 37 7 3 Guidelines and guide values 38 7 4 Dismantling the saw system 41 Printed 08 07 2013 Doc Nr PUB 5069667 000 01 ...

Page 36: ...ust be mounted without play and the cam action rollers engaged The hydraulic hoses and water hoses must be laid out connected correctly and the locking sleeves engaged The saw blade must be mounted in the correct direc tion of rotation and the central screw at the saw blade flange or six M10 countersunk screws tightened securely The blade guard and end stop must be fitted secure ly The remote cont...

Page 37: ...pth is reached and then return the knobs to the neutral 0 position Guideline Please refer to the sticker on the rear of the D RC LP32 remote control unit for cutting depths guide cuts and cutting sequence 8 Use knob to select sawing direction and set the speed control knob to maximum Optimise power output by adjusting the current control knob Make the guide cut with a pressure of max 110 bar 9 Rep...

Page 38: ...ompletion of the guide cut subsequent cuts can be made with the saw arm in the trailing or leading posi tion The depth of cut on the other hand depends great ly on the material and can be between 10 and 15 cm see illustration Sawing guidelines steps II III and sub sequent steps These cuts should be made at full pow er 110 190 bar Ending the sawing procedure When the concrete has been cut through t...

Page 39: ...S30 plunge saw 600 750 mm 2 Wire sawing D LP32 DS TS32 WSS30 Drive wheel Oil flow Pressure Effective Advance Effective cutting Amps dia mm l min bar speed speed speed A r p m m sec 500 100 120 140 820 Maximum 21 5 45 50 3 Drilling D LP32 DD 750HY Motor 20 cm3 Oil flow Pressure Effective Advance Effective cutting Amps 4 gears l min bar speed speed speed A maximum r p m m sec 60 120 480 Manual autom...

Page 40: ...2 40 49 56 66 69 50 59 71 74 60 73 77 70 79 7 Operation Saw blade diameters and cutting depths for the DS TS32 DS TS30 and DS TS22 C saw heads Cutting depths T cm Saw blade diameter DS TS22 C T DS TS30 T DS TS32 T 2 gears cm 2 gears cm 1 gear cm 500 mm dia m 600 mm dia 23 23 700 mm dia 28 28 750 mm dia 31 31 800 mm dia 33 33 33 900 mm dia 38 38 38 1000 mm dia 43 43 43 1200 mm dia 53 53 53 1500 mm ...

Page 41: ...rs including Hilti Depending on the situation concrete quality aggregates steel content etc speeds of between 30 and 50 m sec can be used Guidelines for D LP32 with 2 speed gear DS TS 30 D LP32 DS TS 30 in 1st gear 1st gear 800 1600 dia 356749 2 D LP32 DS TS30 in 2nd gear D LP32 DS TS30 WSS30 in 1st gear 32 63 Ampere 80 100 l min D RC LP 32 Start Ampere II I 32 63 45 100 1600 1200 1000 900 800mm 6...

Page 42: ...42 Printed 08 07 2013 Doc Nr PUB 5069667 000 01 ...

Page 43: ...enance 8 1 Cleaning the equipment 44 8 2 Maintenance of the D LP32 hydraulic unit 44 8 3 Maintenance of the DS TS32 saw head 44 8 4 Maintenance of the other saw modules 44 8 5 Service and repair 44 Printed 08 07 2013 Doc Nr PUB 5069667 000 01 ...

Page 44: ...ut cooling water 8 1 8 2 connected Always keep the water running when oper ating at temperatures below zero Disconnect the water supply to the hydraulic unit and the water system hose when work is finished The hydraulic unit then drains itself automatically Use only water hose couplings of the free flow type for the water supply to the hydraulic unit If an electric generator is used to power the D...

Page 45: ...Faults indicated by the D RC LP32 remote control unit 46 9 2 Error messages ER 47 9 3 Other malfunctions faults in the hydraulic unit 48 9 4 The hydraulic unit or saw system overheats lacks power 49 Printed 08 07 2013 Doc Nr PUB 5069667 000 01 ...

Page 46: ...i e Increase cooling water flow rate warning lamp lights too little water or water too warm see cooling page 39 1st advance warning Cooling water temperature 20 C Use Y piece with water valves more water at the hydraulic unit less at the saw head Water cooling Machine is too warm The operator must react quickly taking warning lamp blinks Inadequate cooling the action described above otherwise slow...

Page 47: ...use Action to be taken Er11 Processor error Contact Hilti service Er12 Processor error Contact Hilti service Er13 Error from left contactor Contact Hilti service Er14 Error from right contactor Contact Hilti service Er15 Error from star contactor Contact Hilti service Er16 Error from delta contactor Contact Hilti service Er17 Processor error Contact Hilti service Er18 Processor error Contact Hilti...

Page 48: ...level too high or LP 32 standing or hanging at an angle Reduce blade motor speed r p m slowly and switch off Water in oil visible Oil seals in saw head Check at the vent or by when oil at sight glass defective opening the oil drainage screw has milky white Oil cooler defective Oil clear OK appearance Hydraulic unit not drained at Oil white DANGER unit temperatures below zero must be servised immed...

Page 49: ...ead causes blade See page 29 drops to wander Do not overload the saw blade Saw blade wanders Saw blade overloaded too soft Saw at a reasonable cutting depth off course blade takes on blue color When cutting at great depth Signs of friction scoring on 60 cm blade diameters 1500 sides of blade 1600 mm make guide cut using Cutting too deep 800 mm dia blade with 5 mm wide segments Select the correct s...

Page 50: ...lease ask your Hilti customer service department or Hilti repre sentative for further information Only for EU countries Disposal of electric tools together with household waste is not permissible In observance of European Directive on waste electrical and electronic equipment and its imple mentation in accordance with national law electric tools that have reached the end of their life must be coll...

Page 51: ...r and tear are not covered by this warranty Additional claims are excluded unless stringent national rules prohibit such exclusion In particular Hilti is not obligated for direct indirect incidental or consequential damages losses or expenses in connection with or by reason of the use of or inabil ity to use the tool for any purpose Implied warranties of merchantability or fitness for a particular...

Page 52: ...ards 2006 42 EC 2004 108 EC EN 60204 1 EN 55014 1 EN ISO 12100 2011 65 EU Technical documentation filed at Hilti Entwicklungsgesellschaft mbH Zulassung Elektrowerkzeuge Hiltistrasse 6 86916 Kaufering Deutschland Hilti Corporation Feldkircherstrasse 100 FL 9494 Schaan Paolo Luccini Johannes Wilfried Huber Head of BA Quality and Process Management Senior Vice President Business Area Electric Tools A...

Page 53: ...53 Printed 08 07 2013 Doc Nr PUB 5069667 000 01 ...

Page 54: ...54 Printed 08 07 2013 Doc Nr PUB 5069667 000 01 ...

Page 55: ...55 Printed 08 07 2013 Doc Nr PUB 5069667 000 01 ...

Page 56: ...l 423 2342111 Fax 423 2342965 www hilti com Hilti registered trademark of Hilti Corp Schaan W 2580 1212 1 en 1 Printed in Liechtenstein 2012 Right of technical and programme changes reserved S E O 370696 A2 Printed 08 07 2013 Doc Nr PUB 5069667 000 01 ...

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