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Lissmac Nextec Trencher DT60 Operating Manual

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EN
OPERATING MANUAL
MICRO-TRENCHING FLOOR SAW
Nextec Trencher DT 60
LISSMAC Maschinenbau GmbH
Lanzstrasse 4
88410 Bad Wurzach, Germany
Phone +49 (0) 7564 / 307-0
Fax +49 (0) 7564 / 307-500
lissmac@lissmac.com
www.lissmac.com
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Summary of Contents for Lissmac Nextec Trencher DT60

  • Page 1 OPERATING MANUAL MICRO-TRENCHING FLOOR SAW Nextec Trencher DT 60 LISSMAC Maschinenbau GmbH Lanzstrasse 4 88410 Bad Wurzach, Germany Phone +49 (0) 7564 / 307-0 Fax +49 (0) 7564 / 307-500 lissmac@lissmac.com www.lissmac.com 1/92...
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  • Page 3 Legal notice This operating manual is valid for: • Nextec Trencher DT60 Manufacturer: LISSMAC Maschinenbau GmbH Lanzstrasse 4 D - 88410 Bad Wurzach Phone: +49 (0) 7564 / 307 – 0 Fax: +49 (0) 7564 / 307 – 500 lissmac@lissmac.com www.lissmac.com...
  • Page 4  Instructions for the operator The warning notes contained are not exhaustive. Lissmac cannot foresee every potential hazard. Reasonable safety rules and precautions must be followed as with any other machine, in terms of working methodology and operation. 4/92...
  • Page 5 Warning and safety notes used: Read the operating manual Wear safety goggles Wear hearing protection Wear protective gloves Wear protective helmet Wear dust mask Wear work clothes and wash regularly. Sound power level of the machine Attachment point for crane transports Remove the ignition key before working on the unit Cutting hazard at the rotating tool Wait for all parts to stop...
  • Page 6 Warning of falling parts. Warning of hot surfaces. Warning of toxic fumes. Warning of potential injuries due to high pressure leaks. Warning of electric shock due to damaged power lines. Warning of batteries. Explosion hazard Do not use high pressure cleaners Use by unauthorised persons not permitted Do not enter the area Smoking prohibition...
  • Page 7 In addition to this operating manual, further documentations from the respective manufacturer of individual components of the machine are available:  Internal combustion engine operating manual For completeness regarding further documentation, LISSMAC does not assume responsibility or liability regarding their completeness. Changes and reservations We have taken every effort to ensure that this operating manual is correct and up to date.
  • Page 8 Notes: 8/92...

  • Page 9: Table Of Contents

    Table of contents 1. Features & Benefits ....................... 11 2. General safety notes ...................... 12 2.1. Principle of intended use ....................12 2.2. Organisational measures ....................13 2.3. Choice of personnel and - qualification; fundamental obligations ........14 2.4. Safety notes regarding the operating phases ..............14 2.4.1.
  • Page 10 7.9. Safe machine shutdown ....................52 7.10. Other adjustment options ..................... 52 8. Servicing......................... 53 8.1. Maintenance intervals ....................53 8.2. Air filter added ........................ 54 8.3. Cleaning the water pump set ..................55 8.4. Cleaning the distribution unit ..................55 8.5.

  • Page 11: Table Of Contents 1. Features & Benefits

     All settings can be made on the central display and all engine values can be read on the display  Easy access for common maintenance (air filters, oil and fuel filters)  The Nextec Trencher DT60 complies with the emission regulations of US EPA Tier 4/EU category IV...

  • Page 12: General Safety Notes

    Intended use The LISSMAC floor saw belongs to the floor cutting grinder and is designed exclusively for cutting joints in concrete or asphalt with the help of water. The cutting includes saw blades and may only be used for cutting on the ground.

  • Page 13: Organisational Measures

    2.2. Organisational measures This operating manual must be kept within easy reach for everyone at the place of use. Keep this manual for future reference. Supplements to the operating manual include general statutory and other binding regulations for preventing accidents and protecting the environment and must be obeyed. These duties may also relate, for example, to handling hazardous substances or wearing personal protective equipment or road traffic regulations.

  • Page 14: Choice Of Personnel And - Qualification; Fundamental Obligations

    2.3. Choice of personnel and - qualification; fundamental obligations Operators must be aged 18 or above and they must be mentally and physically capable of operating the floor saw. All persons must be instructed in the operation and be expressly assigned by the employer with the operation of the floor saw.

  • Page 15: Start-Up

    2.4.2. Start-up Check the direction of rotation when fitting the saw blade. The cutting process must always be counter rotational (up-cut); otherwise, the material will not be transported out of the kerf. When fitting the saw blade, protect your hands from sharp edges. Make sure the substrate that is used for cutting meets the load-bearing capacity.

  • Page 16: Relocating The Floor Saw

    2.4.4. Relocating the floor saw The floor saw may only be relocated when the saw blade is stationary. Before leaving the operating position on the floor saw, the internal combustion engine must be switched off and the saw blade must be stationary. There is a risk of injury from a rotating saw blade.

  • Page 17: Electrical Energy

    2.5.2. Electrical energy Only use original fuses with the prescribed amperage. The floor saw must be switched off immediately in the event of faults. Electrical work may only be carried out by certified and qualified technical personnel. The electrical equipment of a machine must be inspected/checked at regular intervals. Defects such as loose connections and damage cables must be rectified immediately.

  • Page 18: Packaging And Storage

    2.7. Packaging and storage In order to ensure sufficient protection during dispatch and transport, the machine and its components were packed carefully. The machine should be checked for damage upon receipt. The machine's packaging consists of recyclable materials. Please sort them into different materials and place them in the appropriate containers so that they can be recycled.

  • Page 19: Device Description

    3. DEVICE DESCRIPTION 3.1. Designation of machine parts Item 1 Driver's seat Item 12 Ejection channel Item 2 Joystick Item 13 Access to engine oil refill nozzle Item 3 Display Item 14 Diesel tank Item 4 Water tank Item 15 Water pump Item 5 Steering rod...

  • Page 20: Connections/Interfaces

    3.2. Connections/interfaces Power Item 1 Socket water pump 12V (15A) switchable Item 2 Socket 1 12V (10A) switchable Item 3 Socket 2 12V (10A) switchable Item 4 Socket 3 12V (10A) switchable Item 5 Socket 4 12V (10A) switchable Item 6 Socket 5 12V (10A) constant current Engine Item 7...

  • Page 21: Technical Specifications

    3.3. Technical specifications Nextec Trencher DT60 Max. cutting depth 380 mm Max. saw blade diameter 1000 mm Min./max. saw blade width 20 mm / 35 mm Saw blade arbor 35 mm (6 x M12 - TK120 mm) Drive unit Four-wheel-drive Drive speed Hydraulically stepless 0-60 m/min.

  • Page 22: Sound Power Level

    The emission sound power level at the operator's workplace L 89 dB(A) The guaranteed sound power level is: Nextec Trencher DT60 110 dB(A) The values are found by measuring the sound emissions. The test was carried out on the largest approved saw blade of the floor saw under load.

  • Page 23: Hand-Arm Vibration

    The specified value was determined with the maximum saw blade diameter of 1000 mm. The impact may be inversely proportional to the weight of the operator. Total vibration value: Nextec Trencher DT60 a below 2.5 m/s The following standards were applied for the measurements: EN ISO 5349, VD 2057 Part 2, 2002/42/EC Directive.

  • Page 24: Commisioning

    4. COMMISIONING 4.1. Connections and media Diesel (DSL) Use only diesel fuels according to EN 590 / ASTM D 975 No. 2D with a sulphur content <15 mg/kg (so-called ULSD (Ultra Low Sulphur Diesel)). When using other fuels, the emission levels change and the warranty expires.

  • Page 25: Water Supply

    4.3. Water supply The removable water pump is suspended at the machine and supplies the saw blade with water. The 200l tank enables standalone operation of the machine. The water connection is via GEKA couplings. The pump has a sieve insert for daily visual inspection and cleaning.

  • Page 26: Refuelling

    4.4. Refuelling WARNING Extremely flammable fuel vapours Risk of serious injury from fire or explosion. Smoking is prohibited during the refuelling process.  Remove all sources of ignition  Do not overfill tank or spill fuel.  NOTICE Store fuel safely Fuel must only be stored in approved containers.

  • Page 27: Saw Blade Installation/Change (Tool)

    4.5. Saw blade installation/change (tool) WARNING Risk of injury from rotating parts Rotating saw blade or flange can catch and sever clothes or body parts. Switch off the engine and remove the ignition key.   Before working on the machine, all parts must be stationary. Secure the machine against accidental restart ...

  • Page 28: Control Desk

    5. CONTROL DESK NOTICE Handling the control desk/machine Before you start the floor saw, you must first familiarise yourself with the operation. The personnel assigned with activities at the machine must have read the operating manual  before starting work, and here particularly the chapter safety notes. The operator requires a release by the seat switch to start driving functions.

  • Page 29: Joystick

    5.1.1. Joystick Joystick position when starting the machine! If the joystick is not in the neutral position when starting, it must first be set to neutral position to be able to move the machine. Joystick movement Forward (invert with pre-selection page 1 (item 4)) Neutral position Right Left...

  • Page 30: Hmi Control Unit

    5.2. HMI control unit The control unit is ideally suited for rough outdoor use. It is vibration-resistant up to 5g, has the protection class IP 65, can be operated at ambient temperatures of -25 to + 65 °C. It has a high-contrast display that displays the information legibly both during the day and at night.

  • Page 31: Dashboard

    5.2.1. Dashboard The dashboard provides the user with the most important information at a glance. 1,2° 100% Item 1 Display of steering mode 1 / steering mode 2 Item 2 Factor 10 for setting the values Activation/release of SCR regeneration "Standstill" (see section 8.10) Item 3 Button for switching the small analogue display (C) Engine speed / water temperature / battery voltage / oil pressure / toe in...

  • Page 32: Pre-Selection

    5.2.2. Pre-selection page 1 Displays and settings for cutting mode. 100% Settings for cutting The pre-selection is made via the rotary push-button. operation (current selection box is marked with a red border) Press to activate the highlighted selection box. Activated symbols are white, while inactive symbols are greyed out. Item 1 Button for switching to pre-selection page 2 Item 2...

  • Page 33: Pre-Selection

    5.2.3. Pre-selection page 2 Displays and default settings for display and features. Settings of joystick The pre-selection is made via the rotary push-button. (current selection box is marked with a red border) buttons Press to activate the highlighted selection box. Activated symbols are white, while inactive symbols are greyed out.

  • Page 34: Fault Memory

    Item 3 Pending fault message SPN (Suspect Parameter Number) DEUTZ SPN/PIN Yellow = warning PIN fault code LISSMAC Red = fault Item 4 List of detected faults FMI (Failure Mode Identifier) fault code 1 = GND short circuit 2 = UB short circuit...

  • Page 35: Overview

    5.2.5. Overview Summary of important system information The "Overview page" menu can be accessed at any time using the Overview button (item 2). Page 1 Page 2 Item 1 Rotary push-button Item 9 Next page/previous page Displays Item 2 Overview direct selection button Item 10 Charge air filter pressure Item 3...

  • Page 36: Display Settings

    5.2.6. Display settings The display settings menu allows the operator to adjust the backlight brightness of the display and buttons. Item 1 Rotary push-button control Displays Item 2 Display settings direct selection button Item 3 Display brightness Item 4 Button brightness Setting the brightness ...

  • Page 37: Service Menu

    5.2.7. Service menu This menu is primarily for service technicians. The menu is password-protected. The operator does not need this menu in daily use. Item 1 Rotary push-button control Displays Item 2 Service direct selection button Item 3 Level selection 1- 4 Item 4 Input field 7-digit service code / password Item 5...

  • Page 38: Transport

    6. TRANSPORT 6.1. Transport position Conditions  Engine is turned off.  Saw blade guard is dismantled.  Saw blade is removed.  Seat with water pump and footboard removed.  Cable and hoses are lashed or separated.  Water tank is drained. WARNING Injuries due to slipping or tilting of the machine Unintentional changes in the position of the machine can crush people.

  • Page 39: Procedure In Cutting Or Rapid Traverse Mode

    6.2. Procedure in cutting or rapid traverse mode WARNING Risk of injury due to rotating saw blade By touching the rotating saw blade clothes can become entangled and limbs severed. Any movement of the machine outside the area where cutting work is to be performed must be ...
  • Page 40 Controls Down Forward (invert with pre-selection page 1 (item 4)) Neutral position Right Left Backward (invert with pre-selection page 1 (item 4)) Traversing in the cutting  Move the saw blade over the thumbwheel A to the uppermost position. mode ...

  • Page 41: Relocating Using A Crane

    6.3. Relocating using a crane WARNING Suspended loads Risk of injury due to falling parts. Do not stay under raised machinery or parts.  Only use undamaged lifting gear and loading equipment with sufficient load-bearing capacity and  length. Sequence ...

  • Page 42: Securing The Machine For Transport

    6.4. Securing the machine for transport WARNING Injuries due to slipping or tilting of the machine Unintentional changes in the position of the machine can crush people. Only transport the machine in transport position.  Secure the machine over the attachment points. ...

  • Page 43: Operation

    7. OPERATION 7.1. Safety • The floor saw may only be operated by one person. General rules Direct other people out of the work area or build a barrier. • The operator must not leave his workplace while the engine is running and the saw blade is turning.
  • Page 44 Always check first, then cut! Check cutting progress according to the latest wiring diagram.  Consider tolerance ranges.   Consider height differences in the course. Pay attention to unrecorded local changes.  Mark the cutting area clearly.   Do not cut within the tolerance range.

  • Page 45: Preparing The Floor Saw

    7.2. Preparing the floor saw 7.2.1. Setting up the saw blade NOTICE Alignment of the saw blade The saw blade flange must be aligned to be exactly parallel to the frame. Any misalignment damages both the blade and the machine. The blade flange is aligned ex factory. Except for accidents, no corrections are required, regular checks are recommended though.

  • Page 46: Setting Up The Laying Unit

    7.2.2. Setting up the Laying unit NOTICE Alignment of the Laying unit The Laying unit must be perfectly aligned with the saw blade in the cutting kerf. Any misalignment will damage the Laying unit and machine and affect their function. The blade may never be narrower than the Laying unit (20mm).
  • Page 47 Using the set screws, the Laying unit can be adjusted exactly for alignment, inclination and distance to the saw blade. Alignment: +/- 0,5 mm Distance Laying unit to blade: 0 - 3 mm Inclination plow to horizontal plane: + 3mm Adjustment range: Min 5mm Deviation:...

  • Page 48: Relocating Or Positioning The Floor Saw

    7.3. Relocating or positioning the floor saw WARNING Risk of injury due to rotating saw blade By touching the rotating saw blade clothes can be pulled in and limbs severed. Any movement of the machine outside the area where cutting work is to be performed must be ...

  • Page 49: Initiating The Cutting Process

    7.5. Initiating the cutting process Approach  Put the floor saw in position.  Fold the steering rod down.  Move the joystick to the neutral position  Set the engine speed rotary knob to the lowest possible position.  Start the engine using the ignition key. Set RPM to 100% via potentiometer Set pressure to 250 - 280 bar ...

  • Page 50: Comfort Mode

    7.7. Comfort Mode The comfort mode combines related command strings to reduce the operating effort. The comfort status and settings are not stored. They have to be reactivated after each restart. Deactivating of the comfort mode automatically deactivates the related function to the default off setting. Activation Comfort mode is selected via the soft key on the pre-selection page 2.

  • Page 51: Setting Toe In

    7.8. Setting toe in The saw blade for deep cuts tends to pull the machine to one side. This is completely normal and can easily be corrected via the toe-in adjustment to ensure a straight cut. The dashboard page can be accessed at any time using the "Dashboard" button (item 2). -0.6°...

  • Page 52: Safe Machine Shutdown

    7.9. Safe machine shutdown Sequence  Raise Laying unit, blade guard and saw blade  Place floor saw in parking position on firm ground.  Move the joystick to the neutral position  Stop the machine and remove the ignition key. ...

  • Page 53: Servicing

    8. SERVICING 8.1. Maintenance intervals Before each Daily Weekly Monthly  Conduct a visual inspection for obvious damage and defects.  Thoroughly clean the floor saw (depending on the application).  Check engine oil. Every 500 operating hours Diesel engine maintenance For details, see separate instructions by DEUTZ.

  • Page 54: Air Filter Added

    8.2. Air filter added Floor saws always work in more or less dusty environments. As a result, dust settles at different rates on the air filter. To maintain full engine performance, the air filter must be kept clean. The engine therefore has a dirt sensor that continuously monitors the filter condition, and prompts the operator in good time to clean the air filter as needed.

  • Page 55: Cleaning The Water Pump Set

    8.3. Cleaning the water pump set Check sieve daily before starting work. Do not operate the pump without a sieve insert. Unscrew cover and remove sieve. Clean sieve insert using water and soft brush. Caution! Do not apply pressure to the fabric. Insert sieve and screw the cap.

  • Page 56: Fuses

    10 A NOx sensor 15 A Microtrenching Spare LED lighting 10 A Spare Socket 2 10 A Spare Spare Socket 1 10 A Electronics (LISSMAC) 5 A Spare Socket 15 A Control desk Fuel pump 20 A Water pump 56/92...
  • Page 57 Exhaust gas post-treatment 30 A Water pump socket 40 A DEUTZ control unit 30 A Sockets 1,2 Sockets 3,4,5 40 A LISSMAC control unit 30 A Control desk 30 A Fuel pump 40 A LED lighting Laying unit, four wheel Electronics...

  • Page 58: Lube Points

    8.6. Lube points WARNING Risk of injury from rotating objects By touching the rotating saw blade clothes can be pulled in and limbs severed. Maintenance and repairs may only be carried out with the machine switched off and the ignition ...

  • Page 59: Troubleshooting

    8.7. Troubleshooting The internal combustion engine must be turned off before starting any maintenance or repair work. Secure against accidental restart. Maintenance and service work may only be carried out by qualified technical personnel. NOTICE In case of cutting problems, check the following points: ...

  • Page 60: Support And Training

    8.8. Support and training If you have a problem with the machine, need spare parts, accessories or would like to receive training, do not hesitate to contact your support distributor or our service. 8.9. Torque values of screw connections Strength class: 10.9 12.9 Dimension...

  • Page 61: Regeneration Of The Scr System "Standstill

    8.10. Regeneration of the SCR system "standstill" SCR function In normal mode, the soot particles spontaneously burn above a certain exhaust gas temperature. maintenance However, soot particles are deposited on the catalyst in the course of time. This requires burning of the catalyst to remove the soot.
  • Page 62 CAUTION Danger of burns on the exhaust system During regeneration, temperatures of up to 600 °C (1120 °F) occur at the tailpipe. Avoid contact.  Keep flammable substances away.  1. Switch off the water pump using the button 2 on the joystick. Preparation 2.

  • Page 63: Scr Monitoring

    8.11. SCR monitoring The SCR system monitors emission-related parameters in accordance with EU/EPA guidelines: -AdBlue fill level -Catalyst function -AdBlue quality -Manipulation detection Engine protection function If a serious fault occurs, poor quality of the reducing agent or tampering is detected, or a fault condition is not resolved, the system automatically initiates a two-stage power reduction.

  • Page 64: Refuelling Adblue/Def

    8.12. Refuelling AdBlue/DEF NOTE: with the AdBlue (DEF) tank empty, the machine cannot be started! The blocking function can only be reset by a DEUTZ service technician on site. Always refuel in time! IMPORTANT: when the warning level is active, never top up to less than the minimum quantity of 5l (1.32 gallons) per tank step, specified by the engine manufacturer, so that refilling is detected by the system and, if necessary, an active power reduction is removed.
  • Page 65 Fill level When the DEF tank is nearly empty (<15%), the operator is warned by displays and prompted to refuel. Fill level AdBlue/DEF Symbol Behaviour Tank System response symbol display Colour Non-EU (EPA) ---- ---- >15% ---- ---- ---- ---- ---- ---- (Tank refill...

  • Page 66: Torques Of Screw Connections

    8.13. Torques of screw connections Strength class: 10.9 12.9 Dimension Max. tightening torque in Nm Max. tightening torque in Nm Max. tightening torque in Nm 11.2 11.3 16.5 19.3 27.3 40.1 46.9 1057 1136 1329 1176 1674 1959 1597 2274 2662 66/92...

  • Page 67: Maintenance Schedule

    8.14. Maintenance schedule This section is designed to keep a record of maintenance work already completed and as a service record. All maintenance and service work must be entered to create a full record. Machine/Type: Serial number/Year of manufacture: Date Completed maintenance or service work Date/Signature 67/92...

  • Page 68: Tools

    For the best results, the parameters must be correct. With this diagram, the optimum cutting performance can be determined. The prices of the tools can be determined in the LISSMAC sales booklet. This sales booklet can be obtained at any time from the manufacturer.

  • Page 69: Warranty

    10. WARRANTY The warranty period for this machine is 12 months. A warranty is only provided for the following wearing parts if the wear is not caused by normal operation. Wearing parts are parts which are designed to wear during operating when the machine is used for its intended purpose.
  • Page 70 LISSMAC Maschinenbau GmbH, D-88410 Bad Wurzach Machine description The LISSMAC floor saw belongs to the floor cutting grinder and is designed exclusively for cutting joints with the help of water in concrete or asphalt for laying pipes and lines. Nextec Trencher DT60...

  • Page 71: Circuit Diagram

    11. CIRCUIT DIAGRAM 71/92...
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  • Page 88: Hydraulic Diagram (Schematic)

    12. HYDRAULIC DIAGRAM (SCHEMATIC) The warranty for this machine is 12 months. A warranty is only provided for the following wearing parts if the wear is not caused by normal operation. Wearing parts are parts which are designed to wear during operating when the machine is used for its intended purpose.
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  • Page 90: Error Codes

    13. ERROR CODES PIN / Error Code Source of Error UC600 UC520 Systemdiagnose 32768 Fault CAN 1 32769 Supply voltage too high > 18 V 32770 Supply voltage too low < 9 V 32771 Fault supply voltage 5 V 32772 Fault supply voltage 10 V 32773 Fault start conditions...
  • Page 91 PIN / Error Code Source of Error UC600 UC520 Proportional solenoids Prop Steering left Prop Steering right Prop Drive forwards Prop Drive backwards Prop Saw forward rotation Prop Saw backward rotation Prop Blade guard lift Prop Saw blade lift Prop Saw blade lower Prop Suction unit Prop Blade guard lower Prop Cutting hydraulic motor...
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