Lissmac DTS 901-H User manual

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CONSTRUCTION TECHNOLOGY
OPERATING MANUAL
MASONRY SAW DTS
DTS 901-H
DTS 901-V
LISSMAC Maschinenbau GmbH
Lanzstrasse 4
D-88410 Bad Wurzach
Telephone [phone] / 307 - 0
Fax [phone] / 307 - 500
[email protected]
www.lissmac.com

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The operating manual is valid for:
LISSMAC Masonry Saw
DTS 901-H
DTS 901-V
Imprint
Company headquarters:
LISSMAC Maschinenbau GmbH
Lanzstraße 4
D - 88410 Bad Wurzach
Tel: [phone] / 307 – 0
Fax: [phone] / 307 – 500
[email protected]
www.lissmac.com
Translation of the original operating manual
Version: 07-2013
The dissemination or duplication of this operating manual in any form, or the reuse of contents is
forbidden unless permitted in writing.
Non-compliance is subject to compensation for damages. All rights reserved for the purpose of
patent, utility model, or design patent registration.

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BASIC SAFETY INSTRUCTIONS
Warning notices and symbols in this operating manual
Danger! Indicates that failure to comply could lead to severe injury or even death.
Caution! Indicates that failure to comply could sometimes lead to injuries.
Note Indicates that failure to comply leads to damage to the machine or other property.
Handling information for operators
The defined sequence of the handling steps makes proper and safe handling of the machine easier.
Handling instructions for the operator
The following warning and safety symbols were attached on the machine.
Observe the operating manual
Wear hearing protection
Wear safety glasses.
Noise power level
Noise level of the machine
Risk of shearing from moving parts
Rotating sawblade
Forklift transport
Warning of dangerous electrical voltage
Remove power plug before
transport or service
Open water tap when sawblade
is running
Do not remove power plug when
sawblade is running
Running direction of sawblade

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OPERATING MANUAL
This operating manual should make it easier to get to know the machine and make use of
its intended applications.
The operating manual contains important information on how to operate the machine
safely, properly and economically. Your close attention helps avoid risk, repair costs and
downtime, and increase the reliability and lifetime of the machine.
The operating manual is to be supplemented by directives for accident prevention and
environmental protection, according to applicable national requirements.
The operating manual is to be kept permanently available at the machine location.
The operating manual must be read and used by each person assigned to work with the
machine, e.g.: .
Operating, including tooling, troubleshooting during operating, correction of
production rejects, service, disposal of operating and auxiliary materials
Maintenance (service, inspection, repair) and/or
Transport
Preface
Along with the operating manual and the valid legal regulations for accident prevention in
the country of use and the place of use, also recognised technical regulations for safety
and proper work are to be observed.
Required tool In order for the masonry saw to be operated, a tool - in the form of a saw blade - is
required. These tools can be purchased from the manufacturer.
Changes and reservations We attempt for this operating manual to be correct and up-to-date. To maintain our
technological lead, it can be necessary to change the product without advance notice and
to perform their operation. We accept no liability for malfunctions, breakdowns and
damage caused by this.

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Notes:

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Table of Contents 1. Description of performance.................................................................................................. 8
1.1. Selection of the tool.............................................................................................................9
1.2. Basics of intended use.........................................................................................................9
1.3. Organisational measures ................................................................................................... 10
1.4. Personnel choice and personnel qualification; basic responsibilities..............................10
1.5. Safety instructions for operation phases ..........................................................................11
1.5.1. Danger for the operator by the machine ..................................................................11
1.5.2. Transport, assembly and installation .......................................................................11
1.5.3. Commissioning..........................................................................................................12
1.5.4. Operation................................................................................................................... 12
1.5.5. Moving the masonry saw..........................................................................................13
1.5.6. Special work while using the machine..................................................................... 13
1.6. Safety instructions for special types of dangers............................................................... 14
1.6.1. Electric power ...........................................................................................................14
1.6.2. Dust ...........................................................................................................................14
1.6.3. Noise .........................................................................................................................14
1.7. Transport ............................................................................................................................15
1.8. Packaging and Storage ......................................................................................................15
1.9. Environmental protection...................................................................................................15
1.10. Disposal............................................................................................................................15
2. Description of the device.....................................................................................................16
2.1. Name of machine parts......................................................................................................16
2.2. Safety guards .....................................................................................................................16
2.3. Technical data.................................................................................................................... 17
2.4. Scope of delivery ............................................................................................................17
2.5. Noise power level ..............................................................................................................18
2.6. Hand arm vibration.............................................................................................................18
3. Commissioning ......................................................................................................................19
3.1. Connections and operating materials................................................................................19
3.2. Function and adjustable parts............................................................................................19
3.3. Setting up the masonry saw .............................................................................................. 19
3.4. Water tank and pump ........................................................................................................20
3.5. Parking brake......................................................................................................................20
3.6. Tools (saw blade) ...............................................................................................................20
3.7. Clamping lever for cutting height adjustment...................................................................20
3.8. Direction of rotation of the tool.........................................................................................21
3.9. Install saw blade................................................................................................................22
4. Transport................................................................................................................................23
4.1. Transport position .............................................................................................................. 23
4.2. Move with the construction crane..................................................................................... 23
4.3. Move with the forklift ........................................................................................................24
5. Operation................................................................................................................................25
5.1. Setting up the masonry saw .............................................................................................. 25
5.2. Saw preparation.................................................................................................................25
5.3. Sawing with the masonry saw ..........................................................................................25
5.4. Resharpening the tool........................................................................................................ 26
5.5. Changing the cooling and lubricating agent......................................................................26
6. Maintenance..........................................................................................................................27
6.1. Service................................................................................................................................27
6.2. Troubleshooting table ........................................................................................................28
6.3. Torque of screw connections............................................................................................. 28
6.4. Maintenance plan ..............................................................................................................29
7. Conditional connections ......................................................................................................30
8. Tools........................................................................................................................................30
9. Warranty ................................................................................................................................31
10. Spare parts list ....................................................................................................................33

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1. DESCRIPTION OF PERFORMANCE
The masonry saw DTS 901 belongs to the equipment class masonry machines and is used to cut
components from mineral material in the wet cutting method.
The ideal combination of modern technology and a well thought out user-oriented design make the
LISSMAC DTS diamond cut-off saws the jack-of-all-trades on the construction site.
The innovative sawing technology and precise saw head guidance guarantee exact cutting, low saw
blade wear and high stability of the saw head.
Construction site appropriate and low maintenance design
High stability of value and operating safety
Easy to service and maintain due to modular design
Exact table support for precise stone cuts
Firm, torsion-free seat through three-point support
Stable and strong frame
Galvanised sawing table with imprinted scale
Table guidance profile and rollers made of durable, high-strength steel
Low tool costs due to precise table guiding
Perfect saw blade cooling and immediate removal of sawing debris with the LISSMAC water
feed system
User friendly through free loading and front-side operating controls
Easy removal of the water pump (e.g. for cleaning or to avoid freezing)
Water tank extends toward the rear
Simple and secure transport position of the saw head
Easier transport due to front swivel castor, forklift brackets and crane eyes
Inclusive LISSMAC diamond cutting disc Ø 900 mm for Poroton/ sand-lime brick
Saw blade drive via a high performance chain in a totally enclosed low maintenance gearbox
– no V-belts – no wear

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1.1. Selection of the tool
Only diamond saw blades should be used
Cutting with toothed saw blade is prohibited
The saw blade requires input of direction of rotation and must be specified for the intended
use in this machine. Saw blade diameter, speed and adapter must fit the machine
Damaged saw blades must not be used.
Note In the LISSMAC sales booklet DIAMOND TOOLS, the tools can be determined.
This sales booklet can be obtained from the manufacturer at any time.
1.2. Basics of intended use
1.1.1 The warranty obligation of the manufacturer and supplier is voided for improper or non-intended
use. Any change to the machine which is not carried out by the manufacturer is prohibited.
Changes, removal or addition of parts to the masonry saw only with the written approval of the
manufacturer.
1.1.2 The machine is constructed according to the state of the art and recognised technical safety rules.
However, danger to life and limb of the user or third parties, and/or damage to the machine or other
property may still arise from its use.
1.1.3 Only use the machine in technically faultless condition and for intended use, aware of safety and
danger complying with the operating manual. You should particularly handle malfunctions which
can compromise safety immediately, or have them addressed by experts.
1.1.4 The LISSMAC masonry saw is made exclusively for sawing mineral material, in the wet cutting
method. Sawing of wood, plastic or metal and other materials is not intended use. The masonry
saw may only be operated by one person. The operation is limited through the intended position of
the operator directly on the feed crank (Pos. 17) or directly in front of the push handle by the saw
table (Pos. 11). Any other use or use above and beyond is not considered intended use. The safety of
this machine is only guaranteed when correct saw blades for this machine are used.
Intended use also includes compliance with the operating manual and observance of inspection and
maintenance manual.
1.1.5 Foreseeable misuse / non-intended use:
Sawing without saw hood
Sawing without water
Sawing of wood, plastic or metal
Any constructional changes, which change the safety or the type of design

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1.3. Organisational measures
1.3.1 The operating manual must be easily accessible for each person at the location of the masonry saw.
1.3.2 All additions to the operating manual, all generally valid legal and otherwise binding regulations for
accident prevention and environmental protection are to be followed and instructed!
Such obligations may also apply, for example, to the handling of hazardous materials or the wearing
of personal protective gear or traffic regulations.
1.3.3 Personnel assigned to activities on the masonry saw must have read and understood the operating
manual, particularly the Safety Instructions chapter, before starting work. In the middle of work it is
too late. This particularly applies to personnel only occasionally engaged with the crane, such as
those involved in tooling and maintenance.
1.3.4 At least occasionally, perform checks for safe and hazard awareness work by operators while
following the operating manual!
1.3.5 Use personal protection equipment if necessary or required by regulations!
1.3.6 Observe all safety instructions and danger warnings on the masonry saw and keep them complete
and in legible condition! Replace safety and danger instructions that are damaged or non-readable
any more.
1.3.7 For safety-related changes to the machine or its running behaviour, stop the machine immediately
and mark it accordingly. Report the problem to the responsible post/person!
1.3.8 No changes, removal or addition of parts without the written approval of the manufacturer! The
instructions of the tool maker must be followed.
1.3.9 Only use tested original replacement parts from the manufacturer!
1.3.10 Observe required or prescribed deadlines given in the operating manual for inspection.
1.3.11 Before the test, the machine must be thoroughly cleaned and the power plug must be pulled for all
service and repair work.
1.3.12 Workshop equipment suitable for the work is absolutely necessary for performing maintenance
actions.
1.4. Personnel choice and personnel qualification; basic responsibilities
1.4.1 Only qualified personnel 18 years of age or older may operate the masonry saw independently. All
personnel must be trained in the operation and be explicitly, in writing, authorized by the company
to operate the machine.
1.4.2 Establish responsibilities of the personnel for operating, changeover, servicing, and repairing the
machine!
1.4.3 Make sure that only authorized personnel works at the machine.
1.4.4 The operator must wear personal safety equipment according to the safety regulations, such as
safety shoes, safety gloves and safety glasses.

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1.4.5 Remaining in the working area of the machine unnecessarily is prohibited! Direct unauthorised
personnel, who are not working on the machine, away from the work area. Block off the working
area, if necessary
1.4.6 During all movements, operating personnel must ensure that they and other people are not
endangered. All obstacles which may hinder the operation or implementation of the machine at the
location of use must be moved out of the way.
1.4.7 Work on the electrical equipment of the machine may only be carried out by qualified electricians or
trained personnel under the management and supervision of a qualified electrician, and in
accordance with the rules of electronics.
1.4.8 Any personnel training, learning, being instructed, or currently involved in general education may
only work with the machine under the continual supervision of an experienced person!
1.5. Safety instructions for operation phases
1.5.1. Danger for the operator by the machine
1.5.1.1 Before leaving the operating position, the machine must be shut down and the saw blade must no
longer rotate. There is a danger of injury by a rotating saw blade.
1.5.1.2 Working on the masonry saw and moving with rotating saw blade is prohibited.
1.5.1.3 The motor must only be put in operation for intended use cutting.
1.5.2. Transport, assembly and installation
1.5.2.1 Transport, assembly and installation may only be carried out in transport position. The masonry
saw must be secured against rolling away using the parking brake.
1.5.2.2 Transport the masonry saw in compliance with the maximum operating weight, this should be
exclusively done by crane.
1.5.2.3 Transport may only be done, as long as all machine parts are tightened on the machine and
individual parts cannot fall.

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1.5.3. Commissioning
1.5.5.1 The commissioning of the machine may only be carried out in transport position.
1.5.3.2 When inserting the saw blade, observe the running direction.
1.5.3.3 When inserting the saw blade, protect against sharp edges.
1.5.3.4 Ensure that the floor on which cuts are to be made fulfils load carrying capacities.. All obstacles
must be cleared away from the cutting area and make sure there is sufficient lighting.
1.5.3.5 At least once per shift check the machine for externally recognisable damage and deficiencies!
Any changes which occur (including operating behaviour) must be reported immediately to the
responsible post/person! If necessary, immediately stop the machine and secure it against restart!
Before starting cutting operation each day, you must check:
check condition of the saw blade
Check safety equipment for proper function
1.5.3.6 No rotating tools which have a maximum rotation speed smaller than the nominal speed of the
machine can be used.
Defective or broken tools must immediately be replaced.
1.5.4. Operation
1.5.4.1 Refrain from working in any manner that is questionable in regard to safety!
1.5.4.2 Take measures to ensure that the masonry saw is operated only in a safe, functional condition!
1.5.4.3 At least once per shift check the machine for externally recognisable damage and deficiencies!
Any changes which occur (including operating behaviour) must be reported immediately to the
responsible post/person! If necessary, immediately stop the machine and secure it against restart!
1.5.4.4 Immediately stop and secure the machine in case of malfunctions! Immediately correct
malfunctions! Electrical work may only be carried out by qualified electricians.
1.5.4.5 Only suitable and tested tools must be used.
1.5.4.6 The masonry saw is made exclusively for sawing mineral material, in the wet cutting method.
Sawing of wood, plastic or metal and other materials is not intended use.
1.5.4.7 It is forbidden to connect the machine to the power mains without GCFI protection in the mains
supply line or the junction box.
1.5.4.8 For protection before acceleration, the cutting process must be initiated into the material slowly
and in steps. Avoid any contact with the running tool.
1.5.4.9 It is prohibited to cut without the saw hood (Pos. 4). The operator must be protected by turning
parts.

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1.5.4.10 Keep water sources handy for refilling the water tank. Water sources may not be connected
directly.
1.5.4.11 Do not pull the power plug when power is on.
1.5.4.12 Remove the water pump from the water tank if there is danger of frost. Already frozen water
pumps must be thawed out before turning on.
1.5.5. Moving the masonry saw
1.5.5.1 The masonry saw may only be moved when the saw blade is at a standstill.
1.5.5.2 Before leaving the operating position, the machine must be shut down and the saw blade must no
longer rotate. There is a danger of injury by a rotating saw blade.
1.5.5.3 The operator activates the parking brake directly after moving the machine.
The machine must be secured against rolling away.
1.5.6. Special work while using the machine
1.5.6.1 Follow all setup, maintenance, and inspection activities and schedules prescribed by the operating
manual, including all information about the replacement of parts / assemblies! These activities
may only be carried out by technical personnel.
1.5.6.2 Inform operating personnel before beginning special and maintenance work! Name a supervisor!
1.5.6.3 If the machine is turned off during maintenance and repair work, it must be secured against
unexpected application of power.
1.5.6.4 Before cleaning all openings in which no cleaning agent should penetrate due to safety and/or
functional reasons must be covered and glued. Electric motors, switches and plugs are especially
at risk. After cleaning, remove the covers/tape completely!
1.5.6.6 During service and repair work, always tighten loose bolt joints!
1.5.6.7 If dismantling is required for fitting, servicing and repair, the safety fittings must be remounted
and checked immediately following the service and repair work!
1.5.6.8 No rotating tools which have a maximum rotation speed smaller than the nominal speed of the
machine can be used.

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1.6. Safety instructions for special types of dangers
1.6.1. Electric power
1.6.1.1 Use only original fuses with the specified current rating! In case of malfunctions, turn off the
machine immediately! Electrical work may only be carried out by technical and qualified
personnel.
1.6.1.2 Carry out maintenance or repair work only when the motor of the machine is turned off and the
saw blade is not running any more. Transport position requires special care.
1.6.1.3 The machine's electrical equipment must be inspected/checked regularly. Faults such as loose
connections or damaged cables must be corrected immediately. The machine must be labeled so
that it cannot be started by others.
1.6.2. Dust
1.5.2.1 When working in close quarters, follow any applicable national guidelines!
15.2.2 To prevent dust build-up during cutting, the saw blade must be cooled using water. Dry cutting is
prohibited and damages not only the saw blade.
1.6.3. Noise
1.5.3.1 see 2.5 Noise power level of the machine

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1.7. Transport
1.7.1 To implement using a crane, slinging equipment with sufficient load carrying capacity must be
used. Slinging equipment must be checked for damage before use.
1.7.2 Name expert instructors for the lifting process!
1.7.3 Lift the machine only according to the instructions in the operating manual and with proper lifting
accessories!
1.7.4 Only use suitable transport vehicle with sufficient load capacity!
1.7.5 Secure loads reliably according to the regulations. Use suitable attachment points!
1.7.6 Even when moving only for a short distance, the motor of the machine must be turned off. The saw
blade may not be rotating before a restart!
1.7.7 When recommissioning, follow the operating manual!
1.8. Packaging and Storage
To ensure sufficient protection during shipping and transport, the machine and its components are
carefully packaged. When receiving the machine, the machine should be checked for damage.
The packaging of the device consists of materials which can be recycled. Put these by type into the
relevant recycling containers, so that they can be recycled properly.
In the case of damage, the machine must not be put into operation. Even damaged cable and plugs
represent a safety risk and must not be used. In this case, please contact the manufacturer.
If the machine is not immediately put into operation after unpacking, it must be protected from
moisture and dirt.
1.9. Environmental protection
Packaging material, cleaning agents, used or residual operating materials, as well as removed
wear parts, such as drive belts or motor oils must be taken to recycling corresponding to the valid
regulations for environmental protection at the place of use.
1.10. Disposal
If the expiry date of the device has been reached, in particular if functional errors happen, make
the machine unusable.
Dispose of the device according to the valid regulations for environmental protection of your
country. Electrical waste may not be disposed of in household waste. Take the used device to a
central rubbish collection centre.

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2. DESCRIPTION OF THE DEVICE
2.1. Name of machine parts
Pos. 1 Main switch Pos. 10 Locking for saw table
Pos. 2 Switch box Pos. 11 Saw table
Pos. 3 Emergency stop switch Pos. 12 Crane eye
Pos. 4 Saw hood Pos. 13 Water tank with water pump
Pos. 5 Hexagon head screw for
fastening the saw hood
Pos. 14 Forklift supports
Pos. 6 Motor/ Gears Pos. 15 Steerable wheel with parking brake
Pos. 7 Clamping lever for cutting
height adjustment
Pos. 16 Clamping lever for feed unit
(only DTS 901-V)
Pos. 8 Power plug Pos. 17 Feed crank (only DTS 901-V)
Pos. 9 Frame Pos. 18 Locking for saw arm
2.2. Safety guards
Pos. 3 Emergency stop switch Pos. 4 Saw hood
4
5
12
11
10
9
8
18
(7)
6
1
2
3
17
13
16
15
14
14
7

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2.3. Technical data
DTS 901-H DTS 901-V
Motor output 7.5 KW/400V
Power consumption 15.1 A
Power supply (3PH+N+PE)
max. cutting depth 370 mm
max. cutting length 660 mm
max. saw blade diameter 900 mm
Saw blade holder 60 mm
Saw blade shaft speed 910 RPM
Table width 745 mm
Nominal weight 315 kg 338 kg
Max. operating weight 345 kg 378 kg
Dimensions L/W/H 1800 / 1050 / 1500 mm 2000 / 1050 / 1500 mm
Protection class IP 54
max. dimensions of the workpiece to be cut
Length 660 mm
Width 660 mm
Height 370 mm
2.4. Scope of delivery
1 pc.
1 pc.
1 pc.
1 pc.
Masonry saw DTS 901 with saw hood, water tank, saw table and water pump
Saw blade Ø 900 mm
Open ended spanner SW 13
Open ended spanner SW 46

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2.5. Noise power level
Danger! In an environment with a high noise level, for example when working near loud machinery,
wearing hearing protection in the workplace is prescribed for above 85 dB(A).
The details define volume of noise level, related to the operator workspace and the noise power
level of the masonry saw.
The measured noise level LwA 99 dB(A)
The emission noise pressure at the operator's place LpA 84 dB(A)
The guaranteed noise power level is 100 dB(A)
The values are determined by the noise emission measurement.
Testing is done without load with the largest permitted saw blade of Ø 900 mm.
Without load Porous concrete
cutting depth 95
mm
Sand-lime brick
cutting depth 95
mm
Perforated brick
cutting depth 95
mm
Continuous
sound power
level at
workplace LpA
84 dB(A) 87 dB(A) 94 dB(A) 91 dB(A)
Noise power
level LwA 99 dB(A) 100 dB(A) 107 dB(A) 106 dB(A)
Measurement tolerances:
2.5 dB for the A-value noise power level
4 dB for the A-valued emissions noise pressure level
Emission noise pressure is done in compliance with
EN ISO 3744, EN 12418 and guidelines 2000/14/EC.
2.6. Hand arm vibration
The given value was determined with a maximum saw blade diameter of 900 mm.
The total vibration value is under the action value of 2.5 m/s2.
In practice, these values are influenced by the following conditions:
- Quality of the saw blade
- Number of saw blades
- Weight of the operator
- Feed speed
- Condition of the machine
- Material properties and type

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3. COMMISSIONING
3.1. Connections and operating materials
Connection of electricity
Allowable power source with working voltage of 400V, 32A must be available.
Operating material drive oil
The motors are filled with drive oil by the manufacturer.
Operating material water
The water tank may only be filled with water. This water is used when sawing as a cooling and
lubricating agent and is conveyed with a water pump to the saw blade.
3.2. Function and adjustable parts
Main switch (pos. 1)
The main switch consists of a star delta connection and is
used to start larger 3-phase motors with squirrel cage rotors
having a power of 4 kW and up. This prevents the triggering
of fuses and possible voltage drops due to the high starting
current with direct starting.
Emergency stop switch (Pos. 3)
The machine is switched off by activation of the Emergency
Stop switch. The power mains to the drive elements is
finally disconnected.
Power plug (Pos. 8)
The power plug can be locked by hanging in the receptacle
with a padlock.
3.3. Setting up the masonry saw
Note Ensure that the floor on which the machine is used fulfils load carrying capacities. All obstacles
must be cleared away from the cutting area and make sure there is sufficient lighting.
Y
0 

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3.4. Water tank and pump
Note If there is danger of frost, the water pump must be taken out of the water tank (Pos. 13) and the
water circuit must be emptied. Already frozen pumps must be thawed out before turning on.
3.5. Parking brake
Danger! In order to secure the masonry saw against rolling away, the parking brake must be used.
The parking brake (Pos. 15) is engaged using the steerable wheel.
3.6. Tools (saw blade)
Selection of the saw blade
see 8 Tools
3.7. Clamping lever for cutting height adjustment
The saw head can be adjusted in height by releasing the clamping lever (Pos. 7).
Danger! The clamping lever (Pos. 7) may only be opened when the saw blade is stopped!
Danger! During sawing the clamping lever (Pos. 7) must be tightened so that the saw head is in a firm
position. During this the locking of the saw arm (Pos. 18) must be parallel to the frame of the
masonry saw.
The safety stop is in the pathway of the clamping lever (Pos. 7) and prevents the saw table from
being sawn into.