Lissmac DTS 901-H User manual

Operation Manual
Diamond cut-off saw DTS 901-V
Diamond cut-off saw DTS 901-H
Make this operation manual accessible to your operation staff in order to ensure that the
machine wi!! always be utilised correctly and remains in easy to handle condition!
Maschinenbau u. Diamantwerkzeuge GmbH
LanzstraP..e 4 - D-88410 Bad Wurzach
Tel. [phone] -Fax [phone]
State: 2006106
1

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,
appropriate 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
f' Maintenance (service, inspection, repair) and/or
f) 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 of machine
7.
Maintenance
8.
Malfunctions and obstructions
10. Guarantee
2

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.
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.
1.1.2 Explanation of the symbols mentioned on the machine
n
V
201606
"Read the operating manual!" "Wear
the ear protection!" "stacker loading points"
"Electrical danger" "Indication arrow
on the
saw hood"
"Limit stop for crane hook"
1.1.3 Saw blades
- It has to be used only diamond saw blades.
-Cutting with toothed saw blades is prohibited.
-The saw blades require a statement of the sense of rotation.
-Saw blade diameter, -revolutions and -bore hole must match to the machine (see 2.3).
-Damaged saw blades has not to be used.
3

1.2 Principle of intended use
&. Danger!
1.2.1 The diamond cut-off saw is exclusively designed for the wet cutting
of building bricks of mineral material. Cutting of wood, plastic, metal
or other materials is prohibited!
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.
i .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 diamond cut-off saw is guaranteed only when using saw blades which are
suitable for this machine.
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 accidents and environmental protection and make sure
hat these will be instructed!
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
on the machine must thoroughly have read this operation manual, particularly
the chapter "safety information" and all warnings described therein, which will
Ai,
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.
I CautioV 135
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!
(see i .1.2)
Ii\
~ Danger! 1.3.7
Do not remove safety information and warnings on the machine and
keep them in always legible, complete condition. (see 1.1.2)
4

& 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 person / 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!
,if\~.
Danger! 1.3.10 Only use original spare parts from the producer!
If
Danger! 1.3.11 Thoroughly observe servicing terms as prescribed or indicated
in this
.c.....:-
operation manual. An annual expert inspection is obligatory. (see 7)1
1.3.12 Carefully clean the machine before inspection.
/,.
)\
\, Danger! 1.3.13 Pull mains plug before performing any repair works or service outines
/f CI
.~ ._-
1.4 Choice of personnel and qualification; basic obligations
Danger! 1.4.i Only personnel having completed the
18
th
year of their life may
operate this machine who have been made familiar with it and
instructed accordingly.
Danger! 1.4.2 Unnecessary stay of unauthorised persons within the operation area
of the machine is prohibited!
& Danger! 1.4.3 Operation personnel must take care with all movements performed
with the machine that no third persons may get endangered.
1.4.4 Any works on the electrical equipment of the machine may be
&,Danger! performed and effected
by a specialist expert only or by instructed
personnel under supervision and guidance of an expert electrician
according to electronic regulations 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
n it if under constant supervision!
5

1.5 Safety information on particular stages of operation
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
modifications that have been detected (including operative behaviour)1 The case
given, immediately stop, lock and secure the machinel
i~·,·
Danger! 1.5.1 A
In case of functional troubles immediately stop, lock and secure the
til
~-
machine!
Danger! 1.5.1.5 The diamond cut-off saw has exclusively been designed for the wet
/'1\
cutting of bricks. Cutting of wood or metal prohibited!
Ii'
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
replaced -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).
1.5.1.11 Under no circumstances it is allowed to touch the running saw blade.
6

1.5.2 Special works
to be performed with the machine under normal operation, service
routines and trouble-shooting during operation; elimination
1.5.2.1 Thoroughly observe adjustment, maintenance and inspection routines at the
terms scheduled including information regarding exchange of parts/
equipment parts! These works may be performed by specialist experts only.
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 (remove
J"(\
the current conduction).
Information i .5.2.4 Before cleaning the machine with water or with some other cleaning agents
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!
1.5.2.6 Tighten screw connections loosened for performing servicing and
repair works.
J1\, Danger!
&
Danger! 1.5.2.7
In case disassembly of safety devices becomes necessary when performing
set-up, maintenance or repair works, said 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 kind 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
respectively must be eliminated immediately.
1.6.2 Dust
1.6.2.1 During the separation of the mineral material you produce a dust which is breathable and can
enter in the lung. Therefore you have to work always with a water sprinkling.
1.6.2.2 When you operate the machine in narrow rooms, always observe relevant national rules.
1.6.3 Noise value (see 2.4)
7

1.7 Transport
& Danger! 1.7.1 Use a four ring suspension gear of sufficient carrying force
when
dislocating the machine.
Danger! 1.7.2 Determine
an expert to give the appropriate handling instructions for
41!\~,
the lifting procedure!
Danger! 1.7.3 Lift machine according to the instructions
as provided in the operation
;/'r\
~
manual (stop points for load carrying devices etc.) by means of the
lifting gear in a workmanlike manner!
1,\
' , Danger!
1.74 Use an appropriate transport vehicle with sufficient carrying force only.
•
!~
.'f
...
Dangerl 1.7.5 Lock and secure the load
in a reliable manner. Use appropriate stop
,I • \ points (pos.
12 and 14)!
I , Danger! 1.7.6 Consider the transport instructions (see 4)! Disconnect power supply
L:-.
even in case of minor dislocation of the machine! Connect machine to
the mains properly again before restarting of machine!
& Danger! 1.7.7 Proceed
as prescribed in the operation manual when restarting the
machine!
8

2. Description of machine
2.1 List of components
Pos. 1 - main switch
Pos. 2 - switch box
Pos. 3 - emergency switch
Pos. 4 - saw blade hood
Pos. 5 - hexagon nut for saw hood fixing
Pos. 6 - motor/gear
Pos. 7 - clamping lever for cutting height adjustment
Pos. 8 - connector plug
Pas. 9 - stand
Pas. 10 -locking of saw table
Pas. 11 -saw table
Pas. 12 -lim it stops
Pos. 13 -water tub
Pas. 14 -fork lift bars
Pos. 15 -parking brake
Pos. 16 -clamping lever for feed unit (only DTS 901 V)
Pas. 17 -feed crank (only DTS 901 V)
Pos. 18 -locking for saw arm
2.2 Protection devices
Pas. 4 - saw blade hood
Pos. 3 - emergency switch
9

2.3 Technical data
DTS 901-H DTS 901-V
Motor output 7.5 KW/400V 7.5 KW/400V
Current consumption 16.6 A 16.6 A
System of protection
IP 54
IP 54
Revolutions of saw blade shaft 910 r.p.m 910 r.p.m
Saw blade diameter
900mm
900 mm
Saw blade fixer/securer
60 mm 60 mm
Cut depth 370mm
370 mm
Cut length 660
mm 660 mm
Table width 745 mm 745 mm
Heiqht 1500
mm 1500 mm
Width 1030
mm 1030 mm
Net weiqht 310 kq 330 kq
Max. operation weight
340 kg
370 kq
Lenqth in transport position 1800 mm 1920 mm
Feed of table by hand by
crank'
Max. dimensions of the material
which can
be cut
L
W
H
660
660
370
660
600
370
Technical changes reservedI
16.03 ?O::.'k1
10

2.4 Noise emission values
The measurements were carried out in corresponding to the norms EN ISO 3744, EN ISO 11201 and
EN 12418. Therefore, a not noise reduced standard saw blade, type KS-4 0 900 mm, was used.
Without loading Aerated concrete Sand lime stone Vertically perforated
With highest
revolutions cutting depth
9,5cm
cutting depth
9,5 cm
brick
cutting depth 9,5
Permanent intensity levei at
84 dB (A) 87 dB (A) 94 dB (A) 91 dB (A)
the working place LpA
Sound power level
LwA [in dBl
99 dB (A) 100
dB (A) 107 dB (A)
I
106 dB (A)
i
I
3. Mounting and first operation preparation
3.1 Mounting tools with tool holder
• Fork wrench size 13 (for saw blade exchange)
• Fork wrench size 46 (for saw blade exchange)
3.2 Mounting
• Place the saw on a clean even ground
• Push parking brake (Pos. 15)
• At the working place has to be sufficient light
3.3 Fitting of the saw blade (or control of mounting)
• Tighten the height adjustment (Pos. 7).
• Water hose coupling is open.
• Loosen hexagon bolt (Pos. 5) (SW 13).
• Tilt saw blade hood ahead on the table.
• Remove the flange nut (left handed thread) and the pressure disk.
ATTENTION! The following must be observed when fitting the saw blade.
• All fixing surfaces must be clean.
Inform?tion! • Arrows indicating the sense of rotation
on the saw blade and on the hood must
conform.
• Use diamond saw blades provided by the manufacturer only.
• Mount pressure disk and flange nut (fork wrench SW 46).
• Tilt saw hood back.
• Fix saw hood with the hexagon bolt (Pos. 5).
• Close the water hose coupling.
3.4 Preparing for cut-off operation
• Fill water in the tub until the pump stands under water.
• Open water tap.
• Plug the mains supply cable (400V, 32A) into the socket (Pos. 8).
• Check the protection equipment (see 2.2).
11

3.5 Test sense of rotation of the saw blade
• Shortly position star-delta switch (Pos. 1) to "star".
• Verify sense of rotation of saw blade.
* Sense of rotation seem from left side in clockwise direction (indication arrow on the saw hood).
3.6 Change of sense of rotation
• Turn mains switch (Pos. 1) off.
• Remove supply cable from plug (Pos. 8).
• Turn phases of plug (Pos. 8) using a screw driver
* Press white disk inwards and turn it.
12

3.7 Trial run
-The position of the user during the operation is by the crank handle (Pos. 17) or in front of the
pushing handle (DTS 901-H).
• Place a brick on the cut-off saw.
. Danger! Avoid any touching with the running saw blade!
';.,
/' . • Position brick to limit stop.
• Position switch (Pos. 1) to "star".
~. Wait till motor has achieved a constant r.p.m. (constant noise).
e Turn switch (Pos. 1) to position "triangle".
Is there enough cooling water for the saw blade?
" Dry cuts prohibited.
" An insufficient quantity of cooling water results in premature wear or defect of the
saw blade.
e Wear tight clothes
e Start advance movement via crank handle (Pos. 17) (or sliding handle DTS 901-H).
* 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. 7) is fixed.
• Position saw table back wall and bolt it (Pos. 10).
• Loosen clamping lever (Pos. 16).
• Turn feed unit to the back.
• Draw the clamping lever (Pos. 16) tight.
4.2 Dislocation via building crane
Caution! The locking for the saw arm (Pos. 18) must be in vertical position!
• Hang up the three suspenion gear with sufficient carrying force into the eyelets provided for this
purpose at the limit stops (Pos. 12).
• Always watch the saw when dislocating.
4.3 Transport on a lorry
• Arrest the wheels with the brakes (Pos. 15).
• Fasten saw additionally at the limit stops (Pos. 12) by means of tension belts.
4.4 Transport by a fork lift
• Put saw offat the fork lift bars (Pos. 14).
13

16.Q3.20o-1
5. Operation
5.1 Placing of the saw
• Place the saw on clean and solid, stable ground.
• All three wheels must have contact
to the ground.
• Push the brakes (Pos. 16).
5.2 Preparing of cut-off operations (see 3.4)
5.3
Check sense of rotation of saw blade (see 3.5)
5.4
Change sense of rotation (see 3.6)
5.5
Cutting (see 3.7)
5.6
Cutting quality of the saw blade
Should the saw blade loose ist cutting quality after a longer operation term, some cuts into lime clay
bricks or some similar material will "regrind" the blade.
14

5.7 Change of cooling water
Strongly polluted water reduces the lifetime of 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.
5.8 Height adjustment
Height adjustment is needed:
e to cut bricks with a height of more than 370 mm by means of reversing cuts.
Handling of height adjustment.
Attention! Saw arm locking (Pas. 18) must be in horizontal position!
e· Motor ist switched off.
e Loosen the clamping lever (Pos. 7).
• Adjust saw head to the desired height.
e Tighten the clamping lever (Pos 7).
5.9 Replacement of saw blade (see 3.3)
6. Dismounting
• Turn mains switch (Pos. 1) back.
• Remove connection cable.
• In danger of frost you should 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
7.1. Maintenance works
• Thoroughly clean the saw once a week (in off circuit condition).
• Daily check the saw blade
7.2 Following operations has to be made in off cicuit condition
• Repair at the motor my only be repaired
by a qualified electrician
• Repair of switches may only
be repaired by a qualified electrician
• Repair on cables may only be repaired by a qualified electrician
• Saw blade change
• Repair at the saw blade cover
7.3 Checking of the electric according to UVV (only valid in Germany)
BGV A2 (VBG4)
15

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
Wrong sense
of rotation of saw
blade • Motor poled wrong • Change poles of phase shift
plug (Pos. 8) (see 3.6)
Motor stops while cutting
operation, can
be re-started after
a short break time
.. Advance to high
• Saw blade 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 • Pump does not work
• Tubing system clogged
• Must
be checked by an expert
electrician
e Clean the tubing system
16

c
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 defineable 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
c> 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
e 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
e energy accumulation
17

ILISSMAC Maschinenbau u. Diamantwerkzeuge GmbH
EEC Declaration of conformity for
Diamond cut-off saw DTS 901 ~V
Producer
Description of
machine
Relevant EC-
directives
Authorized person
Legally responsible:
DrS 901·H
L1SSMAC Maschinenbau u. Diamantwerkzeuge GmbH
Lanzstrar-.e 4
0-88410 Bad Wurzach
-Circular brick saw
-Cut depth = 370 mm
V= Advance by crank
H= Advance by hand
EC Machine Directive (Council Directive 98/37/EEC)
Low Voltage Directive (LVD), (Council Directive 73/23 EEC) ,
EC Electromagnetic Compatibility Directive (Council Directives
89/336/EEC, EN 12100, EN 294, EN 349, EN 12418, EN 50081-1,
EN 55014, EN 50082-1, EN 60204, EN 60204-1, EN 418, EN 953)
Noise Directives 2000/14/EEC
Josef Weiland
Technical Director
18

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ERSATZTEIL-LISTE
Spare Parts List
Liste des Pieces detachees
Lista di parti di ricambio
Diamanttrennsage
DTS 901-V
DTS 901-H
Maschinenbau und Diamantwerkzeuge GmbH
D~8841 0 Bad Wurzach • LanzstraBe 4
Tel. [phone] -Fax + 49 (0) 75 64/3
07 -5 00
[email protected] • www.lissmac.com
Stand 2006109 1