Hilti D-LP 15 User manual

Operating instructions en
D-LP 15/
DS-TS 22
Printed: 13.01.2016 | Doc-Nr: PUB / 5139176 / 000 / 02

2
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 5/8ʺhydraulic hoses
D-FH4/14-10 1/4ʺhydraulic control hoses
Water supply hose











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Contents
1. General information 4
2. Safety precautions 5
3. The D-LP15 / DS-TS 22 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 infor-
mation.
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
no
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 dam-
age 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 particular-
ly carefully. Check that all parts have been assembled
correctly and consider all other factors that could influ-
ence 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 equip-
ment 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 possi-
ble 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 posi-
tion 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 dispos-
al.
■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 applica-
tions 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, safe-
ty footwear, ear protectors and a hair net, if you have
long hair.
■Respiratory protection should be worn when work-
ing 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 con-
cealed 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 harm-
ful. 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 workpla-
ce is well ventilated. The use of a dust mask of filter
class P2 is recommended. Follow national require-
ments 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 construc-
tion 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 consid-
ered 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 per-
sons must be familiar with the content of these oper-
ating 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 applica-
ble to the accessories employed (saw blade, fasten-
ing 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 con-
nections, in a dry condition. Close the electric sock-
ets 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 dam-
aged 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 work-
ing 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 trans-
ported by means of a crane, the lifting points provid-
ed 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 dama-
ged by debris that may fly off or fall down (broken-
off 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 permit-
ted. 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 dis-
played.
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 machi-
ne 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 spe-
cially 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 uncon-
trolled 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 materi-
als, fluids or gases. Flying sparks or electrostatic dis-
charge 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 mag-
nesium 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 suita-
ble 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 cut-
ting 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 environ-
ments 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 materi-
als to secure the saw (anchors, screws, etc.). Recom-
mendations can be found in our catalogues and bro-
chures.
■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 eccen-
tric rollers are engaged.
■When additional safety precautions are taken, over-
head 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 pre-
vent 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 result-
ing opening must be safely and visibly cordoned off to
prevent persons falling and to exclude the risk of dam-
age 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 sys-
tem.
■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
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3. D-LP15/DS-TS22 modular hydraulic saw system
D-LP 32
D-R 50-230L
DS-TS 32
DS-RF DS-RFP
D-EP-ML
DS-TS 22
D-CO-ML
DS-ES-L
DS-BG
∅600–1200 mm
DS-BGF
∅800–1200 mm
D-FH14/14-10
D-PH58-10 (2x) D-PH34-10 (2x)
D-FH4/14-10
3/4" - 5/8" (2x)
D-RC-LP 32
DS-ES-L
D-LP 15
D-RC 22
DS-TS 22C
Main components and safety-relevant spare parts
Item no. Designation Use
000000 D-LP 15 hydraulic unit
000000 D-TS 22 saw head
310220 D-RC 22 remote control unit Steuerung Sägekopf
284808 DS-R100-L rail Saw guidance
284809 DS-R200-L rail Saw guidance
284810 DS-R230-L rail Saw guidance
207137 DS-CP-ML rail clamp Fastening rails
284814 DS-RF-L rail support Fastening rails
284816 DS-RFP-L rail support Fastening rails for angled and stepped cuts
232241 D-CO-ML double taper Extending rails
232244 D-EP-ML eccentric pin Extending rails
371703 DS-ES-L end stop Safety stop for saw head
221130 DS-PH 58-10 hydraulic hose System hose
226393 DS-PH 58-1.6 hydraulic hose System hose
221129 DS-FH 4/14-10 hydraulic hose set System hose
221131 D-WH1 water hose Water supply
Item no. Designation Use
238000 DS-BG65 blade guard Blade guard for blades up to 650 mm dia.
238002 DS-BG80 center section Blade guard for 600 to 900 mm dia. saw blades *
238003 DS-BG80 side section Blade guard for 600 to 900 mm 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
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 guard for 600 to 900 mm dia. saw blades for flush cutting
238008 DS-BGF120 center section Blade guard for 1000 to 1200 mm dia. saw blades for flush cutting *
238009 DS-BGF120 side section Blade guard for 1000 to 1200 mm dia. saw blades for flush cutting
* Only to be used with the corresponding side sections!
Item no. Designation Use
258436 DS-FCA-110 flush-cutting flange Saw blade mounting flange for flush cutting
307188 DS-FCA-110FF auxiliary flange Saw blade mounting flange for flush cutting
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4. General description and technical data D-LP15/DS-TS22
DS-TS22
Saw arm with built-in motor and 2-speed gearing
Blade guard
(follows movement of the saw arm)
Carriage with wear-resistant steel rollers
Grip with cam-action roller
5/8ʺcoupling for pressure hose
1/4ʺcoupling for control hose
Saw blade mounting flange with single M12×25
screw
The D-LP15 / DS-TS 22 wall saw system is a high per-
formance system for use with saw blades of up to
1200 mm dia. It is capable of cutting to a depth of 53
cm. The very compact DS-TS 22 / DS-TS22 saw is
equipped with a quick, easy cam-action roller mount-
ing system, 360° pivoting sawing arm with built-in
motor and 2-speed gear box that makes changing gear
very simple. The saw blade mount employs a single
screw and the drive spindle incorporates a central
blade cooling system. Power to the motor and system
control is hydraulic, making use of a semi-automatic
controllable advance system which operates indepen-
dently of the material being cut (once set, regulation is
automatic). In conjunction with the very rigid and
symmetrical D-R..L rail system, precise cuts and out-
standing cutting performance can be achieved in all
kinds of applications. Thanks to its oil-cooled electric
motor, the D-LP 15 hydraulic unit is very compact. The
DS-TS22 saw incorporates a pressure relief valve and
can therefore be powered by a number of different,
specified hydraulic units. The D-LP15, the standard
hydraulic unit for use with this system, has a nominal
power of 15 kW at 32 amps. It is also suitable for use
with 16 amp mains supplies. This saw system is
extremely convenient, can be assembled and operated
quickly and easily by one man and provides optimal
cutting performance at all times
Technical data for the DS-TS 22
Blade diameter range 600–1200 mm
1st gear 800–1200 mm
2nd gear: 600– 800 mm
Cutting performance in moderately
abrasive reinforced concrete using
Hilti blades (guide): approx. 2 m2/h
Weight DS-TS22: 27 kg
Hilti motor: 30 cm3
Max. oil flow rate: 45 I/min
Max. operating press.: 190 bar
Hydraulic couplings
Pressure hoses (PH): 5/8ʺ(Holmbury type 4)
Control hoses (FH): 1/4ʺ(Holmbury type 2)
TS22 operation: D-RC22 remote control
➀
➂
➁➆
➄
➅
➃
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13
Rule of thumb for peripheral speed / cutting
speed
– Reduce the peripheral speed when hard aggregates
are encountered (silex, flint etc.).
– The peripheral speed can be increased when the
concrete cuts easily.
– Use the normal, recommended peripheral speed
when the steel reinforcement content is high.
The sawing procedure
– Always mount the saw blade in
the correct direction of rotation.
The direction of rotation of the
motor is engraved on the saw
head. The cutting edge of the diamond grit must
face the direction of rotation.
– Use a small saw blade (600 mm dia.) to cut an
approx. 5 cm deep guide kerf (in London flint, maxi-
mum 2 cm) at approx.70% power output (approx.
100 bar operating pressure).
– Depending on conditions, subsequent cuts can be
made to a depth of approx. 10–15 cm at full power,
i.e. at 32 amps and an operating pressure of 160–
180 bar (guide value).
– When reinforcing bars are cut lengthways, or when
a large are of steel must be cut, position the saw
blade so that concrete above and below the steel is
also cut. This prevents polishing of the segments.
– Do not attempt to work with a
blade if its segments have
become polished. A blade with
polished segments can be
resharpened by making a shal-
low cut (2–3 cm) in unreinforced concrete or in an
abrasive material using little water. Alternatively, the
segments can be resharpened by making a dry cut
in the Hilti sharpening plate.
Saw blades – the Hilti DS-B saw blade
programme
– The quality of the saw blade and selection of the cor-
rect type of blade is decisive. The Hilti DS-B blades
types CS-M and CM-M have been designed for use
with the DS-TS22. They achieve optimum cutting
performance while reducing the load on the saw
system to a minimum.
5.4
5.5
5.6
5. Spindle speeds, gear selection, rules of thumb, sawing prodecure, saw blades
Optimum cutting speed (blade peripheral
speed): As a guide, most saw blade manufacturers,
including Hilti, recommend a speed of approx. 40
m/sec. Depending on the situation (concrete quality,
aggregates, reinforcement etc.) speeds of 30–50
m/sec. may be used.
Recommended speed and gear (r.p.m. under
load) – guide values
High (2nd) gear – 1200 r.p.m.
DS-B saw blade dia. (mm) 600 700 750 800
Peripheral speed m/s 38 43 47 50
Low (1st) gear – 700 r.p.m.
DS-B saw blade dia. (mm) 800 900 1000 1200
Peripheral speed m/s 30 33 36 44
Changing gear with the DS-TS 22
Use the hex. wrench with T-grip to select the gear
before mounting the saw blade. Insert the wrench in
the bore in the blade mounting flange and turn it in the
direction indicated by the marks engraved on the saw
head.
– High (2nd) gear = turn the wrench to the left as far as
it will go
– Low (1st) gear = turn the wrench to the right as far
as it will go.
– If an intermediate position is selected by mistake,
the spindle will NOT rotate.
– The gear change mechanism should be kept clean
and lubricated with Hilti spray at weekly intervals.
5.1
5.2
5.3
12
TK 110 mm
Ø 60 mm
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14
6. Preparing the workplace and the saw system
The warnings and safety precautions listed in
sections 1 and 2 must be observed.
Power requirements and cooling water
– Ensure that the electric supply has a fuse rating of
32 amps (minimum 16 amps) and that the earth /
ground connection is functional (this is the respon-
sibility of the site manager).
– Use an electric extension cable with standard Euro
plug as per EN CEE 32. Select the cable cross sec-
tion according to the load it is to carry (amps) and
the cable length. Please refer to the following table:
Cross sectional area of individual cable cores (F
Current Hydraulic F mm2Fmm2Fmm2F mm2F mm2
Amps (A) unit 2.5 4 6 10 16
16 LP15/400V 49 78 117 195 m*
20 LP15/400V 39 63 94 156 250
32 LP15/400V 24 39 59 98 156
* maximum cable length in meters
Electric cable
CEE 32 plug (male) on the D-LP 15 400 V – pin
assignment
PE = earth / ground
N = neutral (not used)
L1 = phase
L2 = phase
L3 = phase
– Ensure that the water supply has a pressure of 4–6
bar. The normal cooling water flow rate is 10 I/min.
For technical reasons, the flow rate must be not less
than 5 I/min.
– Make suitable arrangements for water removal,
depending on the job and situation, e.g. water barri-
ers, wet-type vacuum cleaner, cover with plastic
sheets etc.
Clarify the situation and secure the workplace
– Obtain approval from the site engineer or site man-
agement before beginning sawing. Find out
whether overcutting at corners is permitted. If not,
the corresponding corner holes must be planned
and drilled first.
6.1
6.2
F mm2
L2
L1
N
PE
L3
6.3
– Check that the area is cordoned off, that supports
are in place and warnings to third parties are dis-
played.
Planning the cutting sequence and marking
the cuts and fastening points
– The parts to be cut out are usually marked by the
client. A rational cutting sequence can be followed
when the rail supports are well positioned.
– If necessary, adjust the maximum size and weight
of the concrete blocks to the prevailing conditions
by making dividing cuts, e.g. in accordance with the
work order, the means of handling the blocks, the
capacity of the crane or the maximum floor loading
capacity.
The cutting sequence
1st cut 2nd cut 3rd cut 4th cut 5th cut
Steel wedges can be used as necessary to secure the
cut-out concrete blocks.
Designation: Steel wedge
6.4
6.5
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15
7. Setting up the saw system for various applications
12
730
595
329
177
139
230 5
94
243
66
324
Cut
27
�
5
235
230
139 Distance from �
line of cut
235
275
Possible�
dividing cut
Floor
Width of kerf
 Align upper �
rail support�
precisely,�
level and�
tighten
 Align lower�
rail support�
and tighten�
slightly�
Fastening to the base material
– The saw system can only be used efficiently and
safely when it is anchored rigidly and securely to the
base material. We recommend the use of Hilti
drilling machines and anchor systems.
– The rail supports and angular cutting plates must be
fastened using anchors suitable for the base materi-
al.
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 suita-
ble 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.
– For example, when using the Hilti HKD M12 metal
expansion anchor, a minimum edge distance of 18
cm must be observed. Generally speaking, the con-
crete dust should be blown out of the hole and the
anchors should be set > 5 mm below the concrete
surface.
– On masonry etc., for example, Hilti HIT adhesive
anchors or through rods may be used.
– On extremely uneven surfaces, suitable shims or
packing pieces must be positioned beneath the rail
supports and / or the rail support adjustment
screws adjusted accordingly.
– The most frequently used anchor on reinforced con-
crete:
HKD-D M12×50, d 16 The use of galvanised
HKD-E M12×50, d 15 screws is recommended.
7.1
approx. 5 mm
d�
mm
washer
M1240 screw
8.8 grade.
Positioning the rail supports for standard cuts
DS-TS22 main dimensions
Dimensions before beginning cut (mm)
Example: sawing out a door opening
7.2
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16
1
2
DS-RF�
rail support�
�
Clamping�
plate with�
M12 screw�
(19 mm AF)
Rail support with�
clamping plate
Attach the clamping piece
7. Setting up the saw system for various applications
Mounting the D-R..L rail, clamping piece and
rail extension
– D-R..L rails are available in 50, 100, 150, 200 and
230 cm lengths.
– Use the D-CP-M/L clamping piece when the rail is
mounted vertically. Attach the clamping piece to the
D-R..L rail and hook it into the upper, previously
aligned and levelled DS-RF rail support.
– Position the lower end of the rail in the lower rail
support (not yet fully tightened), slide up the clamp-
ing plate and tighten the M12 screw. Check the dis-
tance from the cutting line and alignment of the rail
before fully tightening the screw.
– When mounting the rails, always position the rail
support at right angles to the rail and then tighten
all rail fastening screws securely.
– All Hilti D-R..L rails can be extended to form a rigid
unit by making use of a tapered connector: D-CO-
ML double taper, eccentric 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.
– D-R..L rails are also used as the column in the
DD-750 HY hydraulic drilling system.
7.3
D-CO-ML
double taper D-EP-ML eccentric pin
D-CP-ML
clamping piece DS-ES-L end stop
Use a taper to extend rails for position a rail
support at the joint between the rails.
DS-ES-L
DS-RF
DS-RF
DS-ES-L
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17
7. Setting up the saw system for various applications
5
6
1
9
87
4
2
33
D-PRTFH1/4ʺpressure release valve
D-PRTPH5/8ʺpressure release valve
Mounting the DS-TS 22 saw head, hydraulic
hoses and saw blade
– The saw arm should be in the starting position
(vertically upwards). Press the black release buttons
➌ with the thumbs and bring the grips ➋ into the
open position by pivoting them towards the saw
arm until they engage in position. The eccentric
rollers ➍on the saw arm side are now in the open
position.
– Position the saw head on the rail (rail already fas-
tened securely), engage the carriage with the teeth
on the rack and close the eccentric rollers by press-
ing the lockbuttons with the thumbs and pivoting
the grips into the closed position.
– Connect the D-PH 58 hydraulic hose ➎ (5/8ʺpres-
sure hose for the motor) and the D-FH 4/14 hose set
➏ (1/4ʺcontrol hose) to the saw head.
– Bring the blade guard holder ➐ into a suitable posi-
tion on the saw arm. Use the hex. wrench (10 mm
AF) to tighten the hex. screw in the centre of the saw
arm securely before mounting the saw blade. The
holder and the blade guard then remain in the
desired position during the entire sawing procedure.
Mounting the saw blade
– Select the saw blade (diameter, type CS-M or
CM-M) depending on the concrete, the job to be
done and the cutting sequence using saw blades of
different diameters.
– Select the correct gear (slow speed – 1st gear / fast
speed – 2nd gear).
– Position the saw blade in the correct direction of
rotation on the drive hub of the saw arm.
– Fit the special blade flange ➑ and the special screw
➒ 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 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-
necting. Turn the securing ring on the coupling after
the click is heard.
– To ensure reliable operation and extend the life of
the entire system, it is important that all hydraulic
couplings are cleaned daily.
7.5
7.4 – Do not leave hydraulic couplings Iying in the dirt
and do not knock them against concrete surfaces.
Avoid dragging hydraulic hoses over sharp edges.
– After transporting all modules to the workplace, the
hydraulic unit should be positioned correctly and
the hydraulic hoses connected to the unit immedi-
ately. In this way, no pressure can build up in the
hoses even when directly exposed to the heat of the
sun.
– If the hydraulic hoses cannot be connected, try to
relieve pressure in the system by operating all
valves (controls). Alternatively, the D-PRT pressure
release valve can be used to release the pressure.
The small quantity of oil which escapes should be
caught in a cloth.
– Before disconnecting couplings, first turn the lock-
ing sleeve until it engages in position with the ball.
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18
Flush cutting using the
innovative DS-FCA-110
flush-cutting flange
– As for standard sawing applica-
tions, the blade can be fitted
after the saw has been mounted
on the rail. (Old method: The saw and the fitted saw
blade had to be lifted together onto the rail and the
saw blade guided into the kerf).
– The 2-piece DS-FCA-110 flush-cutting flange will
permit more rapid progress and help prevent back
injuries caused by lifting heavy loads.
– The Hilti saw system can be preassembled and
positioned extremely precisely.
– The control system permits the saw arm to be piv-
oted effortlessly into position in the saw blade.
– Spindle speeds and the sawing procedure are as for
standard applications.
7.8
7. Setting up the saw system for various applications
Blade guard
– Always ensure that the
DS-BG blade guard is in
place when the saw is in
operation.
– The blade guard is in two
sections to permit cutting
into corners.
– Thanks to its symmetrical design, the blade guard
can simply be turned to permit cutting into a corner
to the left or right (or upwards and downwards)
without removing the blade from the kerf.
– Use the hex. wrench 10 mm AF to tighten the blade
guard. The blade guard than always stays in the
same position.
– Use the DS-BGF blade guard (open on one side) for
flush cutting.
Using the DS-RFP angular cutting plate
– The angular cutting plate is used for sawing on
stairs, in tunnels and for producing cuts at an angle
of up to 45°.
– Align the equipment by using a protractor to mea-
sure the angle at the blade mounted on the saw.
– Due to the angle of the blade, cutting depth is
reduced. The blade is also subjected to additional
bending loads. Please refer to the following table for
setting-up dimensions and cutting depths.
IMPORTANT: When making angular cuts, make a
shallow guide cut and begin cutting gently!
Angle of cut 10° 20° 30° 40° 45°
∅900 900 900 900 900
C30241883
A 24262934 38
7.7
7.6
A
C
1
2
3
4
DS-BGF
5 mm
183 mm
274 mm
177
243
363
94
5
DS-BG
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19
7. Setting up the saw system for various applications






Ordering designation Qty. Use
LP15-TS-HY tool set 1D-LP15/DS-TS 22/ DD-750 HY
comprising: Hydraulic sawing and coring
Hilti plastic toolbox with insert 1Operator
Accessories, list of contents and their use 1Operator
Folding rule, 2 m 1Operator
STOF cleaning cloth 1Operator
Flat brush 1Operator
Hilti spray 1Operator
Hilti grease dispenser 1Operator
Ear protectors 1Operator
BB blow out pump 1Blowing out anchor holes
Spirit level 1Assembling rails
Open-end / ring wrench, 19 mm 1Assembling rails
Open-end / ring wrench, 13/18 mm 1Assembling rails/Eccentric rollers
Screwdriver, 6 mm 1Assembly
Hammer 11/2kg 1Setting anchors
Socket, 19 mm AF 1Assembling rails
Extension, 1/2ʺsquare drive 1Assembling rails
Ratchet, 1/2ʺsquare drive 1Assembling rails
D lever with 1/2ʺsquare drive 1Assembling rails
D-CP-ML rail clamp 1Mounting rails
Hex. screw, M12×40/8.8 8Fastening rail support
Hex. screw, M12×70/8.8 8Fastening rail support
Washer A13 8Fastening rail support
DS-RF clamping piece 1Spare part rail support
Washer, 12×18×13Spare part rail support
Spring, 1×12×25 3Spare part rail support
M12 nut with collar 8Angular cutting plate
D-EP-ML 1/2ʺeccentric pin 3Rail extension
D-CO-ML taper 1Rail extension
Rubber 2Blade guard holder
Grip nut 1Fastening blade guard
Hex. key, 4 mm 2Covers
Hex. key, 10 mm 1Fastening blade guard holder
DS hex. key with T-grip 1Saw head gear change
Oil change sticker 1D-LP15 hydraulic unit
D-LP15 plug contact 1D-LP15 spare part
T4A / 250 V fuse 10 D-LP15 transformer spare fuse
D-PRT pressure release valve FH1/4ʺ1Pressure release FH1/4ʺ
D-PRT pressure release valve PH5/8ʺ1Pressure release PH5/8ʺ
D-steel wedge 130×70×20 6Securing concrete block
Copper ring 5Core bit extension
Special M10 countersunk-head srew (set of 6) 1Spare part, DS-FCA flange
Set of 3 seals 1Spare part, DS-FCA flange
Special hex. screw, M12×25/10.9 2Spare part, mounting saw blade
Hose coupling, 15–24 mm 2Attaching water hose
Tool set for the D-LP 15/DS-TS 22/DD-750 HY
The items in the tool set are required for correct, safe operation of the wall saw system.
7.9
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20
7. Setting up the saw system for various applications




Additional accessories for the D-LP 15/DS-TS 22/DD-750 HY
The following items are not included in the tool set:
Ordering designation Qty. Use
DS-ES-L end stop 2End stop for L rail
Water valve Y-piece 1Water supply
Water valve 1Water supply
Water connector for saw head 1Spare part for saw head
DD 750-HY water hose 1Spare part for DD-750 HY
Hydraulic coupling, FH1/4ʺ(female) 1Spare part for FH1/4ʺ
Hydraulic coupling, FH1/4ʺ(male) 1Spare part for FH1/4ʺ
Hydraulic coupling, PH5/8ʺ(female) 1Spare part for PH 5/8ʺ
Hydraulic coupling, PH5/8ʺ(male) 1Spare part for PH 5/8ʺ
HVLP 46 hydraulic oil (25 litres) 1Hydraulic unit
Sharpening plate, 319 ×319 ×18 mm 1Saw blades, core bids
CEE 32 A plug socket (female) 1Power extension cable
Open-end wench, 36 mm AF, DIN 894 1Core bits / extension / fitting
Open-end wench, 41/46 mm AF, DIN 895 1Core bits / extension / fitting
Using other hydraulic units to power the DS-TS 22 saw heads
– This is permitted only when the hydraulic unit fulfils the following conditions:
■Maximum oil flow rate 45 l/min.
■Maximum operating pressure 190 bar.
■Modifications to the DS-TS22 hydraulic couplings are NOT permitted. In particular, the directions of
advance and return (marked with an arrow) must be observed.
– The user carries the responsibility for ensuring that the control system employed functions correctly. It is of
advantage to make use of the D-RC22 with the DS-TS 22.
– Damage to the DS-TS 22 resulting from use of a hydraulic unit other than the D-LP 15 to power the system is
not covered by the warranty provided by the Hilti corporation.
– If the D-LP32(30) hydraulic unit is used, power setting 5 should not be exceeded, i.e. max. oil flow rate 45
l/min.
7.10
Connecting and operating the DS-TS 22 with
the D-RC22
– The DS-TS22 must be controlled by the D-RC22
remote control unit.
– The D-RC22 remote control unit can be mounted
conveniently on the hydraulic unit.
– If desired, the D-RC22 may be mounted on a sepa-
rate stand.
7.11
;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;
1x DS-FH 4/14-10
2x D-PH 58-10
D-RC22
2x D-PH 58-1
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