Hilti D-LP 32 User manual

Operating instructions en
D-LP 32/
DS-T S 32
Printed: 08.07.2013 | Doc-Nr: PUB / 5069667 / 000 / 01

2
D-LP32/DS-TS32






Hydraulic unit
Remote control unit
Rail
Saw blade
Blade guard
Hydraulic hoses
End stop
Rail support

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Contents
1. General information 4
2. Description 5
3. System components, tools and 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
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1. General information
It is essential that the operating instructions are read
before the equipment is operated for the first time.
Always keep these operating instructions together
with the equipment.
Ensure that the operating instructions are with the
equipment when it is given to other persons.
Safety not ces and the r mean ng
1.1
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.
Explanation of the pictograms and
other information
1.2
eneral 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
protection.
Wear a hard hat.
Wear ear
protection.
Symbols
Return waste
material for recy-
cling Return waste
material for
recycling
Always fit the blade
guard
Always fit the rail
end stops
Read the operating
instructions before
use
A
Amps
V
Volts
kW
Kilowatts
Hz
Hertz
mm
Millimeters
/min
Revolutions
per minute
l/min
Liters per minute
rpm
Revolutions
per minute
bar
Bar
ii
Alternating current
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2. Description
Description 2.1 Areas of application 6
2.2 D-LP32/DS-TS 32 hydraulic saw system components 6
2.3 Parts and operating controls 8
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2. Description
Areas of application
The D-LP 32/DS-TS32 is a medium to heavy-duty high-
performance wall saw system for use with saw blades
of up to 1600 mm dia. It is capable of cutting to a depth
of 73 cm.
The D-LP32 hydraulic unit has a nominal power of
32 kW at 63 amps but can also be operated on 32 amp
mains supplies.
Its modular design permits rapid assembly and use for
many different applications. The DS-TS32 saw head for
example can be used to power the Hilti DS-WSS 30 high-
performance wire saw system.
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-LP32 hydraulic unit
D-RC-LP 32 remote control unit
DS-TS 32 saw head
D-R 200L rail
DS-C...H saw blade
DS-BG blade guard
D-PH/FH hydraulic hoses and water supply hose
DS-ES-L end stop (2 end stops supplied with each
D-R..L rail)
D-LP32/DS-TS 32 tool set
2.2
9
1
2
73
5
4
6
8
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2. Description
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 
800 - 1600 mm
DS-BGF 
800 - 1600 mm

D-FH14/14-10
D-LP15
D-PH58-10 (2x)
D-PH34-10 (2x)
D-FH4/14-10
3/4" - 5/8"
(2x)
D-RC-LP 32
DS-TS 30
DS-ES-L
D-LP32/DS-TS 32
Wall saws
2x DS-WS-SPP
7
DS-WSWS
6
2x DS-WSRF
5
DS-WSRP
4
DS-WSWD
3
DS-WSTA
2
DS-WSW500
1
DS-W11
7
6
5
74
123
D-LP 32/DD-750 HY/DS-PS 30
Hydraulic core drilling rig
Plunge saw
D-LP32/DS-TS32/DS-WSS 30
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-BA 6/DD-BA 3-70
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-LP 32
DD-FH
DS-B O600 - 1200
DS-BG 12-PS
PH
FH
D-R 100-L
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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-LP32 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-LP32 remote control unit
 On / off control switch
 Cap / oil filler neck
 230 V socket overload reset button
 Front support
 Hinged transport handle locking mechanism
28171 7 68 12
10 1521 16 14 11
13
9 820 319
184 5
22
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2. Description
Guidelines for use (sticker on D-LP32 hydraulic unit)
2.3.2
®Guideline • Richtlinie • Guide
D-LP 32 /DS-TS 32
356749
D-LP 32 /DS-TS 32 /WSS 30
45-50 Ampere
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
3263
45
100
1600
1200
1000
900
800
mm
D-RC-LP 32
Start
Ampere
II
I
32 63
45
100
1600
1200
1000
900
800
mm
220 kg
D-RC-LP 32
Start
Ampere
II
I
32 63
45
100
1600
1200
1000
900
800
mm
60
40
80
60
40
80
60
40
80
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2. Description
D-RC-LP32 remote control
Remote control unit casing
Grips / control panel protection bars
Display and operating controls
Attachment point for belt fastener
Shoulder belt with fastener
Rear side of remote control unit: Sawing guidelines
Emergency OFF switch
2.3.3
Sawing guidelines
See sticker on the rear of the D-RC-LP 32 remote con-
trol unit.
Cutting depth for soft concrete / masonry
Cutting depth for hard concrete
Optimum 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
56
3 2
l. ll. lll.
lll.
ll.
l.
15 15 15
l. ll. lll. ....
cm
Hard
Guide
cm
Tmax
33cm
800 mm
1. Tmax
43cm
1000 mm
2. Tmax
53cm
1200 mm
3. Tmax
73cm
1600 mm
356751/8
4.
800 100
1000 95
1200 85
1600 80
(mm) l/min
Soft 5
410 10 10
310 3 5413 32
69 7 89 9
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D-RC-LP 32
Start
Ampere
II
I
32 63
45
100
1600
1200
1000
900
800
mm
80
60
40
11
2. Description
Display, symbols and warning lamps on the
D-RC-LP 32
Hydraulic unit starting switch (OFF/ON/Start)
Oil flow rate (blade drive speed) 30–100 l/min.
(green spot lights up)
Direction of blade plunge movement (right / left)
Direction of advance (left / right or up / down)
Speed control for and 
Power control (amps) depending on mains supply
Emergency OFF switch
Oil flow rate indicator
Position of green spot corresponding to saw blade
diameter
 Temperature indicator 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 pressure (bar)
 Operating range for sawing
Operating range for wire sawing
 Operating range for core drilling
2.3.5
18A
Warnings
 Warnings
 General warning
 Always fit the blade guard
 Always fit the rail end stops
2.3.6
3 4 19 7 18 9 8 2
21
22
23
20 6 10 11 12 13 14 15 1 16 17 5
3 4 7
6 1 5
2
18A
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2. Description
DS-TS 32 saw head
Saw arm with built-in motor
Blade guard holder (moves with the saw arm)
Carriage with wear-resistant cam-action steel rollers 
Cam-action roller locking lever
Hydraulic coupling (PH 3/4˝) – pressure hose
Direction of oil flow
Hydraulic coupling (PH 3/4˝) – return hose
Hydraulic couplings (FH 1/4˝) – advance
Hydraulic couplings (FH 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 87
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
 Grease nipple for cam-action roller bearing
 Holder for blade guard rubber
 Special M12×25 / 10.9 screw
5A
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3. System components, tools and accessories
System components, 3.1 Hydraulic hoses and hydraulic hose 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-TS 32 tool set 16
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3. System components, tools and accessories
Hydraulic hoses and hydraulic hose set
3.1
DS-PH34-10 DS-FH4/14-10
hydraulic hose set hydraulic hose set (with water supply hose)
D-R50L rail
D-R100L rail
D-R150L rail
D-R200L rail
D-R230L rail
DS-ES-L end stop
D-R..L rails, DS-ES-L end stop, DS-RF rail support and
DS-RFP angular cutting plate
3.2
Accessories for securing and operating the saw
DS-BG / BGF blade guard
3.3
DS-ES-L DS-RFPDS-RF
Item no. Designation Use
238000 DS-BG65 blade guard Blade guard for blades up to 650 mm d a.
238002 DS-BG80 center sect on Blade guard for 600 to 900 mm d a. saw blades *
238003 DS-BG80 s de sect on Blade guard for 600 to 900 mm d a. saw blades
238004 DS-BG120 center sect on Blade guard for 1000 to 1200 mm d a. saw blades *
238005 DS-BG120 s de sect on Blade guard for 1000 to 1200 mm d a. saw blades
333883 DS-BG16 blade guard Blade guard for 1200 to 1600 mm d a. saw blades
Item no. Designation Use
238006 DS-BGF80 center sect on Blade guard for 600 to 900 mm d a. saw blades for flush cutt ng *
238007 DS-BGF80 s de sect on Blade guard for 600 to 900 mm d a. saw blades for flush cutt ng
238008 DS-BGF120 center sect on Blade guard for 1000 to 1200 mm d a. saw blades for flush cutt ng *
238009 DS-BGF120 s de sect on Blade guard for 1000 to 1200 mm d a. saw blades for flush cutt ng
256237 DS-BGF16 blade guard Blade guard for 1200 to 1600 mm d a. saw blades for flush cutt ng
* Only to be used with the corresponding side sections!
DS-BG DS-BGF
D-R..L
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3. System components, tools and accessories
Recommendations for use: Which specification for which material?
Diamond saw blades
We recommend Hilti CS-H CM-H or CH-H saw blades
for use with the D-LP32/DS-TS32. The saw blades can
be selected from the following table taking material
steel content and dimensions into account.
3.5
Important
■Sawing at a lower speed (reduced saw blade r.p.m.) is usually advantageous 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 Normal to high
CM-H / UP Well-balanced, good speed and life Hard aggregates Normal
CH-H / SP Fast-cutting and long life Soft to very hard aggregates Normal to high
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3. System components, tools and accessories
D-LP32 / DS-TS32 tool set
3.6
16
Ordering designation Qty. Use
D-LP32/DS-TS32 tool set 1LP32/TS32 hydr. saw system
comprising:
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
Safety goggles 1Operator
HSD-G M12 setting tool 1Setting anchors
BB blow out pump 1Anchor holes
Spirit level 1Assembling rails
Open-end / ring wrench, 19 mm 1Assembling rails
Open-end / ring wrench, 18 mm 1Assembling rails
Screwdriver 1Assembly
Hammer 11/2kg 1Setting anchors
Socket, 19 mm AF 1Assembling rails
Extension, 1/2˝square drive 1Assembling rails
Ratchet, 1/2˝square drive 1Assembling rails
D lever with 1/2˝square 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 8Fastening rail support
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 1/2˝eccentric pin 3Rail extension
D-CO-ML taper 1Rail extension
Rubber 2Blade guard holder
Grip nut 1Fastening blade guard
Hex. key, 4 mm 2Eccentric rollers / covers
Hex. key, 10 mm 1Fastening blade guard holder
DS hex. key with T-grip 1Eccentric 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 5Core bit extension
Special M10 countersunk-head srew (6 screws) 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
Additional accessories for the D-LP32/DS-TS32 (not included in the tool set)
Ordering designation Qty. Use
DS-ES-L end stop 2Securing carriage L
HKD-D M12×50 flush anchor 50 16 mm dia. hole
Water valve Y-piece 1Water supply
Water valve 1Water supply
Water connector for saw head 1Spare part for saw head
Hydraulic coupling, FH1/4˝(female) 1Spare part for FH1/4˝
Hydraulic coupling, FH1/4˝(male) 1Spare part for FH1/4˝
Hydraulic coupling, PH3/4˝(female) 1Spare part for PH3/4˝
Hydraulic coupling, PH3/4˝(male) 1Spare part for PH3/4˝
HVLP 46 hydraulic oil (25 litres) 1Hydraulic unit
Sharpening plate, 319 ×319 ×18 mm 1Saw blades, core bids
D-RC-Ext 10 extension cable, 10 m 1For remote control unit
CEE 63 A plug socket (female) 1Power extension cable
Shoulder belt with fastener RC-LP 32/TS 5-E 1 Spare part for remote control unit
Shoulder belt 1Spare part for 373243/5












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4. Technical data
Technical data 4.1 Power 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
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4. Technical data
Power supply
Electric power supply
Mains voltage: 400 V 3-phase 50 Hz
Fuse rating: At least 32 amps
63 amps recommended
Generator: 60 kVA recommended
The generator must be earthed when in operation
Water supply for hydraulic unit, saw head and saw
blades
Cooling water: 7 l/min. at 4–6 bar; temp. 20°
Dimensions and weights
D-LP 32 hydraulic unit
L×B×H 790×540×1090 mm
Weight with oil 220 kg
remote control unit D-RC-LP 32
L×B×H 390×180×120 mm
Weight 2.2 kg
DS-TS 32 saw head
L×B×H 510×380×400 mm
Weight 36 kg
IP protection code
D-LP 32 hydraulic unit: IP 44
D-RC-LP 32 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-LP 32 /DS-TS32 hydraulic saw system are applic-
able at ambient temperatures within the –15°C to
+45°C range (hydraulic unit warmed up in advance
at temperatures below zero).
■When dry the units can be stored at temperatures
between –15°C and +50°C.
4.4
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4. Technical data
Technical data
D-LP 32 hydraulic unit
Rated power input at 63 A 43 kW
Rated output 32 kW
Rated voltatge 400 V / ~ 50 Hz 3P+N+PE or 3P+PE
Ground fault circuit breaker (PRCD) 30 mA in mains supply on site
Max. operating pressure 210 bar
Oil flow rate 30–100l/min.
Dimensions (L×B×H) 790×540×1090 mm
Weight 220 kg
IP protection code IP 44
Cooling Water cooling with 7 l/min. at max. 6 bar
and water temperature 20°C
D-RC-LP 32 remote control unit
Control voltage 24 V (DC)
Dimensions (L×B×H) 390×180×120 mm
Weight 2.2 kg
IP protection code IP 65
Cable length 10 m
Cable length with extension 20 m
DS-TS 32 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-LP 32 digital electronic remote control
Saw blade diameter range 800–1600 mm dia.
Wire sawing 500 dia. drive wheel
Weight 36 kg
Noise information
Equipment: D-LP 32/DS-TS 32 hydraulic saw system
Typical A-weighted noise level of the equipment:
Emission sound pressure level (at a distance of 3 m)
as per ISO 11203 90 dB(A)
Sound power level as per ISO 3743-1 103 dB(A)
Noise protection measures are necessary.
Wear ear protection!
4.5
4.6
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4. Technical data
Rating plates
4.7
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