Lissmac DTS 120 User manual

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Operation Manual
Masonry Saw
DTS 120 and DTS 120 - G
Make this operation manual accessible to your operation staff in order to
ensure that the machine will always be utilised correctly and remains in easy
to handle condition!
Maschinenbau GmbH
Lanzstraße 4 - D-88410 Bad Wurzach
Telefon [phone] - Fax + 49 (0) 75 64/3 07-5 00
[email protected] -www.lissmac.com
State: 10/2009
Translation of the original operating manual

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Preface
This operation manual has been established to make it easier to become familiar with the machine and
to utilise its intended application options.
This operation manual contains important information on how to operate the machine in a safe, appro-
priate and economic manner. Observation of present operation manual contributes to avoid dangers,
repair costs and down times and to increase the reliability and lifetime of the machine.
This operation manual is subject to supplementation by existing national regulations for prevention of
accidents and for environmental protection.
Present operation manual must always be at hand at site and place of operation.
It must be read thoroughly and be applied by each person charged with performing works using this
machine, such as
•Operations including set-up routines, trouble-shooting during operation processes, elimination of
wastes from machining operation, care, elimination of process materials
•Maintenance (service, inspection, repair) and/or
•Transport
Apart from the provisions and instructions specified in this operation manual and the regulations valid
and in force in the land and at the place of operation for prevention of accident also the acknowledged
technical rules about the performance safety and technical works must be observed.
Table of contents
1. Basic safety information
2. Description of machine
3. Mounting and first operation preparations
4. Transport
5. Operation
6. Dismounting
7. Maintenance
8. Malfunctions
9. Guarantee

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1. Basic safety information
1.1 Warnings and safety symbols used in this manual
Danger! Indicates that non-observance may cause heavy or even deadly injuries to the
operator.
Caution! Indicates that non-observance may probably cause physical injuries.
Information! Indicates that non-observance may cause damages to the device or to other
material or physical assets.
1.2 Principle of intended use
Danger! 1.2.1 The masonry saw is exclusively designed for the wet cutting of
building bricks of mineral material. Cutting of wood or metal prohibited!
The sawing table must be removed when transporting the saw. Mounting and
dismounting of the saw must be performed by two persons.
The supplier/manufacturer does not assume any liabilities for any use not in
accordance with the intended use.
Observation of present operation manual as well as of the inspection and
servicing conditions under present manual are considered part of the intended
use.
1.2.2 Only use and operate this machine in perfect technical condition as well as in accordance with
regulations and be always aware of safety requirements and dangers and along the provisions
as set forth in this operation manual! Always eliminate all malfunctions and obstructions apt to
affect safety immediately (or let them have eliminated)!
1.2.3 The safety of this masonry saw is guaranteed only when using original Lissmac saw blades.
1.3 Organisational measures
1.3.1 This operation manual must always be kept and stored ready at hand near the place of
operation.
Danger! 1.3.2 Always observe any amendments to present operation manual as well as
general legal and other regulations valid and in force for the prevention of ac-
cidents and environmental protection and make sure that these will be in-
structed!
Any such obligations may also apply to the handling of hazardous materials or
to personal safety and protection equipment that is subject to wear or to road
traffic law regulations.
Danger! 1.3.3 Before starting to operate, personnel charged with performing any works

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on the machine must thoroughly have read this operation manual, particularly
the chapter "safety information" and all warnings described therein, which will
be too late to do during operation of the machine. This applies in particular for
any personnel performing occasional routines on the machine only, such as
set-ups, servicing etc.
1.3.4. At least check occasionally if the personal charged with performing any such
works observes the provisions specified in this operation manual and
performs works in full awareness of safety requirements and dangers.
Caution! 1.3.5 As far as necessary or required by prescriptions, always use personal safety
equipment.
Danger! 1.3.6. Observe all safety and danger information indicated on the machine!
Danger! 1.3.7 Do not remove safety information and warnings on the machine and keep
them in always legible, complete condition.
Danger! 1.3.8 In case of safety relevant modifications detected on the machine or if a
changed operational behaviour is detected, please immediately notify the per-
son / authority responsible thereof.
Danger! 1.3.9 Do not perform any modifications of or make extensions to the machine
whatsoever without the supplier's previous consent!
Danger! 1.3.10 Only use original spare parts from the producer!
Danger! 1.3.11 Thoroughly observe servicing terms as prescribed or indicated in this
operation manual. An annual expert inspection is obligatory.
1.3.12 Carefully clean the machine before inspection.
Danger! 1.3.13 Pull mains plug before performing any repair works or service routines.
1.4 Choice of personnel and qualification; basic obligations
Danger! 1.4.1 Only personnel having completed the 18th year of their life may operate this
machine who have been made familiar with it and instructed accordingly.
Danger! 1.4.2 Unnecessary stay within the operation area of the machine prohibited!
Danger! 1.4.3 Operation personnel must take care with all movements performed with the
machine that no third persons may get endangered.
Danger! 1.4.4 Any works on the electrical equipment of the machine may be performed
and effected by a specialist expert only or by instructed personnel under su-
pervision and guidance of an expert electrician according to electronic regu-
lations valid and in force at that time.
Danger! 1.4.5 Personnel under training, instruction or on completion of transfer-training may
only operate the machine or perform works or services on it if under constant
supervision!
1.5 Safety information on particular stages of operation

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1.5.1 Normal operation
1.5.1.1. Refrain from performing any operations critical in regard to safety!
Danger! 1.5.1.2 Take precautions that the machine will only be operated in safe and operative
condition!
1.5.1.3 Check the machine for damages and defects visible from outside at least once per
shift! Immediately inform the person / authority responsible of any changes or modifi-
cations that have been detected (including operative behaviour)! The case given, im-
mediately stop, lock and secure the machine!
Danger! 1.5.1.4 In case of functional troubles immediately stop, lock and secure the
machine!
Danger! 1.5.1.5 The masonry saw has exclusively been designed for the wet cutting of
bricks. Cutting of wood or metal prohibited!
Danger! 1.5.1.6 It is interdicted to connect the machine to the mains supply without residual
current operated device (FI) fitted in the supply cable.
Danger! 1.5.1.7 Before starting any cutting operations, daily check machine for:
•Condition of the diamond saw blade (cracked saw blades must be re-
placed – the case given, be checked by a specialist)
•Operative condition of the protective devices
•Sufficient cooling water supply – dry cuts prohibited!
Danger! 1.5.1.8 Do not tilt the saw blade.
Danger! 1.5.1.9 Mains plug must not be pulled if machine is under power supply load.
Information! 1.5.1.10 Take water pump off the tub when there is danger of freezing (do not switch
on pumps that are already frozen – they must be thawed out slowly).
1.5.2 Special works to be performed with the machine under normal operation, service rou-
tines and trouble-shooting during operation; elimination
Caution! 1.5.2.1 Thoroughly observe adjustment, maintenance and inspection routines at the
terms scheduled including information regarding exchange of parts / equip-
ment parts! These works may be performed by specialist experts only.
Caution! 1.5.2.2 Always inform operators before starting to perform special works and
servicing routines on the machine! Name a supervisor!
Danger! 1.5.2.3 If the machine is completely off circuit when performing servicing and repair
works, make sure that it is protected against unintentional restart, too.
Information 1.5.2.4 Before cleaning the machine with water or with some other cleaning agents

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always close or cover all machine openings and apertures using a scotch tape
or other means, into which no water/steam/cleaning agent may penetrate due
to safety or functional reasons. Electric motor, switch and plug connections are
particularly endangered. Cleaning by means of a water jet prohibited.
Information 1.5.2.5 Completely remove covers / scotch taped covers after cleaning!
Danger! 1.5.2.6 Tighten screw connections loosened for performing servicing and repair
works.
Danger! 1.5.2.7 In case dismounting of safety devices becomes necessary when performing
set-up, maintenance or repair works, that safety devices must be re-assem-
bled immediately after and checked accordingly.
1.5.2.8 Take care that process materials and exchange parts will be eliminated in a
manner that is friendly to the environment!
1.6. Information about special kinds of dangers
1.6.1 Electric energy
Danger! 1.6.1.1 Use original fuses apt for the prescribed current intensity rate only! Switch off
machine immediately in case troubles with the electric power supply to the
machine occur!
Danger! 1.6.1.2 Only perform maintenance and repair works if the machine is off circuit.
Danger! 1.6.1.4 The electric equipment of the machine must be controlled / inspected
regularly. Any defects such as loose connections or damaged cables respec-
tively must be eliminated immediately.
1.6.2 Dust
1.6.2.1 When operating the machine in narrow rooms, always observe relevant national rules
and regulations valid and in force, if existing!
1.7 Transport
Danger! 1.7.1 Machine must not be dislocated by means of a building crane.
Danger! 1.7.2 Use an appropriate transport vehicle with sufficient carrying force only.
Danger! 1.7.3 Reliably secure and protect the load on the vehicle. Use the appropriate stop
points provided for this purpose.
Danger! 1.7.4 Disconnect power supply even in case of minor dislocation of the machine!
Connect machine to the mains properly before restarting it!
Danger! 1.7.5 Only proceed as prescribed in the operation manual when restarting the
machine!

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2. Description of machine
2.1 List of components
Pos. 1 - Frame
Pos. 2 – Saw head
Pos. 3 - Switch
Pos. 4 – Saw hood
Pos. 5 - Motor
Pos. 6 – Cut depth adjustment
Pos. 7 – Cool water supply
Pos. 8 – Water pump
Pos. 9 – Splash guard
Pos. 10 – Saw blade
Pos. 11 – Saw table
Pos. 12 – Feet
Pos. 13 – Screws for mitre cut adjustment
2.2 Protective devices
Pos. 4 – Blade guard
Pos. 9 – Splash guard
2.3 Technical data
DTS 120 DTS 120-G
Operation voltage
Motor output
230V
2.2 kW S6 - 40%
230V
Number of revolutions 2800 r.p.m
Saw blade diameter 380 mm (for mitre cut only350 mm)
Cut depth 120 mm 120 mm
Cut length 600 mm 600 mm
Saw blade securer/
fixer (bore hole)
25.4 mm 25.4 mm
Weight 80 kg 83 kg
Dimension L/W/H 1200/700/1240 mm 1200/700/1240 mm
Technical changes reserved!
2.2 kW S6 - 40%
2800 r.p.m
380 mm

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8
10
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1
12
6
4
7
2
9

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3
5
13
2
9
4

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2.4 Noise emission values
Concrete block
Granite
Poroton
Noise emission level
LwA [in dB]
110
111
109
Work place related noise emission value LpA [in dB(A)]: 85
The work place related noise emission value refers to an 8 hour working shift and reduces corre-
spondingly at lower working terms.
ATTENTION! Ear protection must be worn when exceeding noise levels of 85 dB(A).
3. Mounting and first operation preparations
3.1 Mounting tools
•Fork wrench size 30 (for sawing blade exchange)
•Fork wrench size 10 (for sawing blade exchange)
3.2 Mounting and assembly
•Mounting may only be effected by two persons.
•Place legs in the prepared mounting device.
•Turn the ring bolts tight.
•Check if the saw is standing stable, if necessary place s.th. underneath.
•Put the sawing table on.
3.3 Fitting of the saw blade (or control of fitting)
Note! The stop plate of the saw head height adjustment (Pos. 6) is prepared for a saw blade with 350 mm
diameter.
•Remove cap nuts using a fork wrench.
•Take the blade guard side panel off.
•Remove flange nut (left hand thread) and pressure disk.
CAUTION! When fitting the saw blade the following must be observed:
•All surfaces must be clean.
•Arrows indicating sense of rotation on saw blade and on the hood must conform.
•Use diamond saw blade types as provided by the manufacturer only.
•Install pressure disk and flange nut.
•Screw the wing screw until it holds fast.
•Mount the blade guard side panel.
•Check the seat of all water hoses.
3.4. Preparation for cut-off operation
•Fill water into the tub till the pump is completely covered with water.
•Open the water tap.
•Plug the mains supply cable into the socket of the switch (Pos. 3).
•Check and control safety devices (see 2.2).

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3.5 Trial run
•Place a brick on the saw.
•Slide brick to limit stop.
•Push mains switch (Pos. 3).
ATTENTION! Is there enough cooling water for the saw blade?
CAUTION! •Dry cuts prohibited.
Information! •An insufficient quantity of cooling water results in premature wear or defect of the saw blade.
•Start advance movement at the saw table.
∗First cut at low advance speed.
∗Adjust advance speed to advance force.
4. Transport
4.1 Transport preparations
•Disconnect saw from the supply cable.
•Remove water from the tub.
•Height adjustment (Pos. 6) is fixed.
Danger! •Take the saw table off.
Danger! •Dislocation via building crane prohibited!
4.2 Two persons needed for carrying the saw.
Danger! •Take the saw table off.
5. Operation
5.1 Placing of the saw
•Place the saw on clean, stable ground.
•Check if the saw is standing stable.
5.2 Cutting preparation (see 3.4)
5.3 Cutting (see 3.5)
5.4 Cutting quality of the saw blade
Should the saw blade loose its cutting quality after a longer operation term, some cuts into lime clay
bricks or some similar material will „regrind“ the blade.
5.5 Cooling water
Strongly polluted water reduces the lifetime of the pump and saw blade.
•When used frequently, replace water daily and remove the sawing mud, too..
•Clean the suction sieve of the pump each time when replacing the water.

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5.6 Height adjustment
Height adjustment is needed:
•to cut higher bricks by means of reversing cut
Handling of height adjustment.
•Motor is switched off.
•Loosen clamping lever (Pos. 6).
•Adjust saw head to the desired height.
•Tighten the clamping lever (Pos. 6).
5.7 Replacement of saw blade (see 3.3)
5.8 Adjustments for mitre cut (only DTS 120-G)
Attention! You can only adjust a mitre joint of 45° and 90°. The saw table will get damaged for all other
degrees.
•Loosen the screws (Pos. 13)
•Turn the saw head to 45° or 90°
•Tighten the screws (Pos. 13)
6. Dismounting
•Turn off mains switch (Pos. 3).
•Remove supply cable.
•If there is danger of frost take the water pump out of the water and let the water drain off..
ATTENTION! Pumps that are already frozen must be thawed out before starting them.
•Transport (see 4)
7. Maintenance
•Thoroughly clean the saw once a week (in off circuit condition).

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8. Malfunctions
Trouble
Possible reason
Remedy
Motor does not work
•Supply cable defect
•Motor defect
•Switch defect
•New supply cable
•May be remedied by an expert
electrician only
Motor stops while cutting
operation continuous, can
neverheless be re-started after a
short break time
•Advance too high
•Saw blade is blunt
•Saw blade worn
(coating < 2 mm)
•Cut with lower advance
•Regrind saw blade by cutting
10-15 times into lime clay brick
•Replace the saw blade
No water at the saw blade
•Tubing system clogged
•Pump does not work
•Clean the tubing system
•May be remedied by an expert
electrician only

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10. Guarantee
The guarantee time is 12 months. The following wearing parts you will get only
in guarantee, when the wearing is not due to working conditions.
Wearing parts are parts, which will be worn out in working conditions due to intended use of
a machine. The time of wearing is not definable in an uniform way, it depends on their
application intensity. The wearing parts for each specific machine has to be attended,
adjusted and if necessary exchanged in accordance to the user’s manual of the producer.
For wearing due to working conditions there is no guarantee.
•Advance- and driving elements as toothed racks, toothed wheels, pinions, spindles,
spindle nuts, spindle bearings, ropes, chains, chain wheels, belts
•Washers, cables, hoses, collars, plugs, clutches and switches for pneumatic, hydraulic,
water, elektricity, fuel
•guidance elements as guiding joints, guiding bushes, guiding rails, rolls, bearing,
antislipping devices
•flushing head seal
•sliding- and rolling bearing, which are not running in an oil-bath
•rotary shaft seal and sealing elements
•friction- and overload clutches, brake gears
•graphite brush, collectors
•potentiometer control and manual control elements
•fuses and lamps
•process materials
•fixing materials as plugs, anchor and screws
•bowden wires
•lamellars
•membranes
•spark plugs, glow plugs
•parts of reversing starter as start by rope, start by handle, start by roll, start by spring
•sealing brush, packing rubber, splash guard rags
•filter all types
•driving-, deflection roller and roller lining
•protection elements for rope lays
•running- and driving wheels
•water pumps
•transport roller for cutting material
•drilling-, parting-off- and cutting tools
•conveyor belt
•rubber stripes
•needled felt protection

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LISSMAC Maschinenbau GmbH
EC Declaration of conformity for
Table – Saw DTS 120 / DTS 120-G
•Producer: LISSMAC Maschinenbau GmbH
Lanzstr. 4
D-88410 Bad Wurzach
•Storage of the technical documents by:
Andreas Buschle (Technical editor)
LISSMAC Maschinenbau GmbH
Lanzstr. 4
D-88410 Bad Wurzach
•Description of machine:
Masonry saw
Cutting depth 120mm
Cutting length 600 mm
Electrical motor 2,2 kW / 230V
Serial numbers: D17, D18
•Applied procedure of conformity evaluation:
Internal control of production
(RL 2000/14/EG Annex V)
•Measured sound power level : 88 dB
•Guaranteed sound power level : 89 dB
•Applied standards and regulations:
EC Machine guidline 2006/42/EG,
Sound emission 2000/14/EG,
Low voltage directive 2006/95/EG,
Electromagnetic Compatibility 2004/108/EG,
EN 55014-1: 2006
EN 55014-2: 1997 + A1: 2001 + A2: 2008
EN 61000-3-2: 2006
EN 61000-3-3: 1995 + A1:2011 + A2: 2005
Directive for vibration protection 2002/44/EG
•Authorized person legally responsible:
LISSMAC Maschinenbau GmbH
Gewerbepark West – Lanstrasse 4
88410 Bad Wurzach
Tel.: [phone], Fax: [phone]
Mail: [e-mail] – www.lissmac.com
Bad Wurzach 01.06.2011
_____________________________________
Marcel Hofstetter by proxy
(Head of Development Construction Technology)

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