Lissmac MULTICUT 905 SG Operating Manual
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Lissmac MULTICUT 905 SG Operating Manual

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EN
OPERATING MANUAL
FLOOR SAW
MULTICUT 905 SG / SGH
LISSMAC Maschinenbau GmbH
Lanzstrasse 4
D-88410 Bad Wurzach
Telefon +49 (0) 7564 / 307 - 0
Telefax +49 (0) 7564 / 307 - 500
lissmac@lissmac.com
www.lissmac.com
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  • Page 1 OPERATING MANUAL FLOOR SAW MULTICUT 905 SG / SGH LISSMAC Maschinenbau GmbH Lanzstrasse 4 D-88410 Bad Wurzach Telefon +49 (0) 7564 / 307 - 0 Telefax +49 (0) 7564 / 307 - 500 lissmac@lissmac.com www.lissmac.com 1/112...
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  • Page 3 Legal notice This operating manual is valid for: LISSMAC Floor saw  MULTICUT 905 SG / SGH 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...
  • 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. 4/112...
  • Page 5 The following warning signs and safety notes are used: Read the operating manual Wear hearing protection Wear safety goggles Wear work gloves Wear protective helmet Wear dust mask Wear suitable work clothes and wash regularly Attachment point for crane transports Remove the ignition key before working on the unit Engage or release parking break only at standstill Cut hazard at the rotating tool...
  • Page 6 Burn hazard Suffocation hazard from of toxic exhaust fumes Battery acid hazard Explosion hazard Entanglement hazard at belt drive Cut hazard at rotating tool Crush hazard Electrocution hazard from buried power lines Do not use high pressure cleaners Use by unauthorized persons not permitted No smoking Hazardous material: fine silica dust Do not work on machine while the tool is spinning...
  • 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 LISSMAC does not assume responsibility or liability regarding correctness and completeness of third- party documentation. Changes and reservations We have taken every effort to ensure that this operating manual is correct and up to date.
  • Page 8 Notes: 8/112...

  • 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. Organizational measures ....................13 2.3. Choice of personnel and - qualification; fundamental obligations ........14 2.4. Safety notes regarding the operating phases ..............14 2.5.
  • Page 10 8.8. Regeneration of the Diesel particulate filter ..............69 8.9. Troubleshooting .......................71 8.10. Torque values for screw connections ................72 8.11. Maintenance plan......................73 9. Tools ..........................74 10. Warranty ........................75 11. Circuit diagram ......................77 12. Appendix A: Error code List HATZ ................81 10/112...

  • Page 11: Features & Benefits

    1. FEATURES & BENEFITS The practical requirements of professional use were incorporated in the design of this powerhouse. This professional heavy duty Diesel-powered machine impresses witch outstanding price-performance ratio, rugged design and easy operation.  Optimum power transmission by high-performance v-belt drive ...

  • Page 12: General Safety Notes

    Intended use The LISSMAC floor saw is defined as a floor cutting-off machine and is designed exclusively for wet- cutting joints in concrete or asphalt. The cutting requires a tool in form of a diamond saw blade. The floor saw may only be operated by one person.

  • Page 13: Organizational Measures

    2.2. Organizational measures This operating manual must be kept within easy reach for everyone at the place of use. 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 at least 18 years of age and 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 2.4.2. Commissioning When fitting the saw blade, protect your hands from sharp edges. Make sure the aggregate surface has the required load-bearing capacity. All obstacles must be removed from the cutting area and good lighting must be provided. Visual check of the entire floor saw for any damage and defects. Separate check of the protective devices.

  • Page 16: Note Relating To Special Types Of Danger

    2.4.4. Maneuvering the floor saw The floor saw may only be relocated when the saw blade is standing still. Before leaving the operating position on the floor saw, the internal combustion engine must be switched off and the saw blade must be standing still. A rotating saw blade poses a serious cut hazard.

  • Page 17: Transport

    2.5.2. Electrical Energy Only use original fuses with the prescribed rating. 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: Packing And Storage

    2.7. Packing and storage In order to ensure sufficient protection during dispatch and transport, the machine and its components were carefully packed. The machine should be checked for damage upon receipt. The machine's packaging consists of recyclable materials. Please separately collect the different materials and place them in the appropriate containers for recycling.

  • Page 19: Device Description

    3. DEVICE DESCRIPTION 3.1. Designation of machine parts Pos. 1 Steering wheel Pos. 9 Pointer Pos. 2 Control desk Pos. 10 Blade guard Pos. 3 Diesel Tank Pos. 11 Drive axis (Hydrostatic) Pos. 4 Air filter Pos. 12 Rail for water pump (Option) Pos.

  • Page 20: Technical Specifications

    3.2. Technical specifications MULTICUT 905 SG MULTICUT 905 SGH Max. cutting depth 515 mm (20.1 in) Max. saw blade diameter 1200 mm (47.2 in) Saw blade arbor 25,4 or 35 mm (6x M12 –TK 120 mm) Blade flange Ø Ø 150 mm (5.9 in) Nominal speed 1.

  • Page 21: Sound Power Level

    The emission sound power level at the operator's workplace L 91,4 dB(A) The guaranteed sound power level is: Multicut 905 SG / SGH 96 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 22: Hand-Arm Vibration

    The stated value was measured using a saw blade with 1000 mm in diameter. The effective values may be inversely proportional to the weight of the operator. Vibration total value: Multicut 905 SG / SGH a below 2,5 m/s The measurement were taken in accordance with the following standards: EN ISO 5349, VD 2057 Part 2, 2002/42/EC Directive.

  • Page 23: Comissioning

    4. COMISSIONING 4.1. Consumables Diesel Only use Diesel fuel according to EN 590 / ASTM D 975-09a 1-D S15 or 2-D S15 with a Sulfur content of <15 mg/kg. So-called Ultra Low Sulfur Diesel (ULSD). When using other fuels, the emission levels change and the warranty expires. S≤15 mg/kg Engine Oil Only use HATZ-approved engine oil.

  • Page 24: Tools (Saw Blade)

    4.2. Tools (saw blade) NOTICE Tool selection Never use a rotating tool, with a maximum speed rating lower than the rated speed of the machine. Defective or broken tools must be replaced immediately. Selecting a saw blade See section 9 Tools Storing tools The tools used must be protected from moisture.

  • Page 25: Water Pump (Option)

    4.3. Water pump (option) The removable water pump is suspended at the machine and supplies the saw blade with water. The water connection via GEKA couplings. Power supply is a switchable 12V outlet on the control panel. The pump has a sieve insert and a transparent plastic cover for daily inspection and cleaning.

  • Page 26: Refueling

    4.4. Refueling WARNING Extremely flammable fuel vapors Risk of serious injury from fire or explosion. Smoking is prohibited during the 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 Cut and crush hazard from rotating parts Rotating saw blade or flange can pull in 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. ...
  • Page 28 Sequence  Loosen clamping bolt (Pos. 1) on the inside of the blade guard (Pos. 2).  Remove blade guard by pulling up on the handle.  Remove flange screws (Pos. 3) with supplied tools and remove pressure disc (Pos. 4). NOTICE Saw blade installation Ensure flange surfaces to be clean before installing the diamond blade.

  • Page 29: Checking V-Belt Tension

    Clamping range and use of spacer (Pos.6) 4.6. Checking v-belt tension WARNING Cut and crush hazard from rotating v-belt drive When touching the rotating v-belt, hands and clothing can become entangled and pulled in, resulting in cut and crush injuries including dismemberment. ...

  • Page 30: Replacing And Tensioning V-Belts

    4.7. Replacing and tensioning v-belts WARNING Cut and crush hazard from rotating v-belt drive When touching the rotating v-belt, hands and clothing can become entangled and pulled in, resulting in cut, and crush injuries including dismemberment. Do not open or remove the belt guard or touch the v-belt while it rotates. ...
  • Page 31  Loosen bolt (Pos. 5) and open clmap (Pos. 6)  Remove worn belts, check sheaves for damage and wear and install new belts Approved belts 14 pc. XPA 1732 antistatic Installation or  Close clamp. Orient the notch on shaft with making (Pos. 8) and tighten bolt (Pos. 5) replacement of belts ...

  • Page 32: Transport

    5. TRANSPORT 5.1. Transport position WARNING Crush hazard from unsecured machine Injuries through unintentional position change of the machine or falling of parts. Only transport the floor saws in the transport position   Secure the floor saw via the attachment point NOTICE Transport of the machine Large inclined positions must be avoided during the transport of the floor saw.

  • Page 33: Relocating By Crane

    5.2. Relocating by crane WARNING Suspended loads Crush hazard from falling parts. Do not step under raised machines or parts  Only use undamaged lifting devices with sufficient load capacity and length  The machine may only be moved in the transport position ...

  • Page 34: Tie Down For Transport

    5.3. Tie down for transport WARNING Crush hazard due to slipping or tilting of the machine Unintentional changes in the position of the machine can crush people. Only transport the floor saw in transport position.  Secure the floor saw over the attachment points. ...

  • Page 35: Control Desk

    6. CONTROL DESK NOTICE Machine handling Before you start the floor saw, you must first familiarize 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. Pos.

  • Page 36: Multifunction Display

    6.1. Multifunction display NOTICE Heed monitor warning lights As a functional control, all six warning lights around the LCD display must light up with active ignition. The alternator and oil level warning light remain lit until the engine is running. Warning lights Pos.
  • Page 37 6.2. Warning lights NOTICE Heed dashboard warning lights Warning signals indicate a fault in the engine. To avoid damage to the machine the indicated fault must be corrected as soon as possible. Oil level warning lamp Lights up red with ignition. Goes out a soon as the engine is running. If signal lights up during operation, the oil level is too low.

  • Page 38: Operation

    7. OPERATION 7.1. Safety General principles • The floor saw may only be operated by one person. Direct other people out of the work area or build a barrier. • The operator may not leave the machine while the engine is running. •...
  • Page 39 WARNING Cut hazard form rotating saw blade Severe cut injuries from to rotating saw blade or ejected parts. Only cut with the blade guard in closed position.  Keep safety distance.  Never touch the rotating blade.  Wear personal protective equipment. ...

  • Page 40: Parking Lock

    7.2. Parking lock WARNING Crush hazard Crush hazard from unintended rolling of the machine. To prevent the machine from rolling, the parking lock has to be activated whenever the machine is  not in use. NOTICE The parking lock serves exclusively to immobilize the machine. Due to its cog-style design it may ONLY be activated at standstill.

  • Page 41: Start Preparations

    7.3. Start preparations NOTICE Cutting without obstacles Damage of articles located in the cutting area or the saw blade.  Remove all obstacles from the cutting area and  Provide good lighting of the work area. The cutting sequence can be marked by a marking spray for the orientation of the cutting sequence. Start preparation The following conditions must be fulfilled in order to use the floor saw safely and as intended: ...

  • Page 42: Adjusting Lowering Speed Of Saw Arm

    7.5. Adjusting lowering speed of saw arm The throttle valve should be fully closed first. Then gradually open the throttle as you perform test runs to set the right lowering speed. lower faster lower slower 7.6. Adjusting the operating position NOTICE Handle steering wheel carefully The steering wheel is a high-pressure hydraulic component.

  • Page 43: Gear Selection

    7.7. Gear selection NOTICE Change gears only at standstill The three gears allow the tool’s speed setting to be adjusted to each saw blade diameter and aggregate to be cut. Severe damage to the gearbox if operated incorrectly.  Only change gears with the engine stopped. ...

  • Page 44: Drive Lever Conversion

    7.8. Drive lever conversion Sequence Remove rear cover. Disconnect plug and extract through hole in side panel. Loosen bolt and remove drive lever unit from arbor. Fasten drive lever unit on opposite side. The handle can be adjusted in height and orientation according to the personal preferences oft eh individual operator.

  • Page 45: Switching From Up-Cut To Down-Cut

    7.9. Switching from up-cut to down-cut NOTICE Invert the running direction at standstill only Inverting the running direction, allows up-cutting or down-cutting operations as required. Severe damage to the gearbox if operated incorrectly.  Only change gears with the engine stopped. ...

  • Page 46: Engine Starting And Stopping

    7.10. Engine starting and stopping Starting set the ignition key to ignition wait until the multifunction display has been raised and the "0" appears in the speed display for the gearbox and engine speed. (3-4 seconds) then start the engine. NOTICE Error message when trying to start without completing the boot process If an attempt is made to start the engine without starting the multifunction device, the following permanent...

  • Page 47: Cutting Operation

    7.11. Cutting operation WARNING Ejected parts hazard If the saw blade is not supplied with a sufficient amount of cooling water, the blade can overheat and cutting segments may break off and be ejected. Grinding dust is not bound effectively. Always ensure a sufficient supply of cooling water for the diamond blade ...
  • Page 48 Cutting 1. Place drive lever (Pos. 11) in neutral start positon 2. Start engine with ignition key (Pos. 13). (SGH Functional check  Hydraulic radiator fan must spin) 3. Lower pointer with rope (Pos. 16) and maneuver flor saw into position 4.

  • Page 49: Maneuvering The Floor Saw

    7.12. Maneuvering the floor saw WARNING Cut hazard from 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 done using a non-rotating tool.

  • Page 50: Floor Saw Shut-Down

    7.13. Floor saw shut-down WARNING Crush hazard from unintended movement Personal and material damage from accidentally rolling machine.  Always activate the parking lock before leaving the machine Shutdown  Open clutch with lever (Pos. 9)  Set drive lever (Pos. 11) to neutral position. ...

  • Page 51: Conversion From Left- To Right-Cutting

    7.14. Conversion from left- to right-cutting WARNING Cut and entanglement hazard When touching the rotating v-belt, hands and clothing can become entangled and pulled in, resulting in cut and crush injuries including dismemberment. Do not open or remove the blade guard or touch the saw blade while it rotates. ...

  • Page 52: Service Compartment

    7.15. Service compartment Pos. 1 Reservoir for Hydrostatic-transmission oil (20W50) Pos. 2 Reservoir for cutting shaft lifting unit (HV68) Hydraulic oil fill level can only be checked correctly when the machine is lowered completely. Pos. 3 Battery Pos. 4 Hydrostatic drive unit Pos.

  • Page 53: Hydraulic Unit (Option Sgh)

    7.16. Hydraulic unit (Option SGH) The hydraulic unit can drive auxiliary equipment like a slurry extraction unit. NOTICE Overheating of hydraulic oil If no auxiliary equipment is connected, the ball valve at the hydraulic interface must be set to the closed O position. Otherwise, the hydraulic oil will overheat. Check oil level before each use at sight glass.
  • Page 54 7.17. Fuses MC 905 The machine uses standard automotive ATO blade Type C fuses (ISO 8820-3). Replace only with same type and current rating. Fuse Rating Function Holder 35 A Main fuse 15 A Socket for Water pump 10 A Socket 10 A Socket...
  • Page 55 7.18. Battery 12V 62Ah - 540A cold cranking amps (replace with same type only) If battery tension drops below 6V at any point, the control unit will deactivate. Check battery tension regularly in the control menu section. Recharge or replace weak batteries. WARNING Explosion and corrosion hazard When charging batteries, explosive oxyhydrogen gas is produced.

  • Page 56: Draining Gearbox Cooling Water

    7.20. Draining gearbox cooling water HINWEIS Drain water if there is risk of frost If there is risk of frost, the cooling water must be drained from the gearbox via the ball valve. Sequence  Stop engine.  Wait for all parts to stand still. ...

  • Page 57: Checking Engine Oil

    7.22. Checking engine oil Check engine oil level daily before use. Sequence  Check oil level with dipstick (Pos. 1)  Replenish SAE 10W-40 as required via previously cleaned filler neck (Pos. 2). Do not spill. Do not overfill. 57/112...

  • Page 58: Cutting With Open Blade Guard

    7.23. Cutting with open blade guard WARNING Ejected parts and cut hazard Serious personal injury from contact with running blade or ejected parts when cutting with open blade guard. Cordon off cut area  Never touch the rotating blade  Wear hard hat, goggles and safety boots ...

  • Page 59: Installing Seat Conversion Option (Accessory)

    7.24. Installing seat conversion option (accessory) Sequence Remove path indicator and use five bolts (Pos. 1) to attach the three spacer plates to the frame. The threaded plate for the spacer bolts (Pos. 2) goes on the outside. (Distance between spacer plate to hex bolt head approx. 5 cm / 2“) 59/112...
  • Page 60 Insert bolts (Pos. 3) and set the hex nuts to the same distance as the spacer bolts. Insert articulated front assembly (Pos. 4) in central tube. The front face shall protrude about 10 cm (4“). Both locking screws need to have grip. Remove bolt from front wheel hub and attach front assembly (Pos.

  • Page 61: Maintenance

    8. MAINTENANCE 8.1. Service WARNING Cut and crush hazard from rotating objects Rotating objects can cut, crush or sever limbs on contact.  Maintenance and repair may only be performed with the machine switched off Maintenance and repair may only be performed by trained personnel ...

  • Page 62: Tensioning The Drive Chain

    8.2. Tensioning the drive chain NOTICE Drive chain tension The correct chain tension is essential for the proper operation and longevity of the drive. Over-tensioning can cause damage to the drive unit.  Maximum slack on the return strand may not exceed 10mm (0,4 in). ...

  • Page 63: Changing Motor Oil

    8.3. Changing motor oil NOTICE Engine oil disposal Disopse of used engine oil an enviromentally friendly and in accordance with national environmental protection laws. Use a colletion tray when drainig the engine oil  Observe the engine manufacturer's operating instructions, enclosed with each machine. ...

  • Page 64: Drain Hydraulic Oil

    8.4. Drain hydraulic oil WARNING Danger of electric shock Serious injury from electric shock if tool comes into contact with starter motor pole. Always drain oil directly at the tank or siphon it off from above.  Disconnect the battery terminals before working in the area of the pump. ...

  • Page 65: Grease Points

    8.5. Grease points Before performing service or maintenance work, the engine has to be switched off. Secure machine against inadvertent activation. Service and maintenance work may only be carried out by qualified personnel. Secure machine with a crane when working underneath. On both sides 65/112...

  • Page 66: Transaxle Oil Change

    8.6. Transaxle oil change Interval Initially after 80, then every 400 operating hours. Required Material Oil: 20W50 ca. 2,3L (4 Quarts) Oil filter: #1054655 Preparation  Place flow saw on even ground and activate parking lock.  Lift blade shaft, until frame is slightly tilted towards the back. ...
  • Page 67 Oil change sequence 1. Loosen the cover of the expansion tank. (Pos. 1) 2. Unscrew the adapter strip (A). 3. Unscrew the holder for support (B). 4. Unscrew back plate (C). 5. Place the collection container underneath. 6. Open the oil drain plug and drain the oil. 7.

  • Page 68: Particular Maintenance

    Sequence Air purge  Hoist the floor saw drive wheels off the ground and secure the machine from rolling away. Drive wheels must be able rotate freely.  Open the bypass valve (= disengage)  Start the engine  Release parking lock ...

  • Page 69: Regeneration Of The Diesel Particulate Filter

    8.8. Regeneration of the Diesel particulate filter DPF regeneration During regular operation, the soot particles are automatically burned once a certain exhaust gas temperature is reached. However, over time, some ash and soot particles may still deposit in the particulate filter system. This may require a manually initiated pyrolytic cleaning process of the catalyst.
  • Page 70 Securely park floor saw in an open space with ample distance to flammable objects. Preparation The engine coolant temperature must be above 75°C (167°F). Set engine RPM (Pos.6) to idle. Initiate Set drive lever (Pos. 11) to neutral position Disengage drive clutch (Pos. 9) Engage parking block (Pos.

  • Page 71: Troubleshooting

    8.9. Troubleshooting Stop engine before carrying out any service or repair work. Secure machine against accidental startup. Maintenance and service work may only be carried out by qualified technical personnel. NOTICE The following points must be checked first with cutting problems: ...

  • Page 72: Torque Values For Screw Connections

    8.10. Torque values for screw connections Grade: 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 72/112...

  • Page 73: Maintenance Plan

    8.11. Maintenance plan This section shall serve as proof maintenance already performed and as service booklet. All maintenance and service work must be entered as proof. Machine/Type: Serial number/year of manufacture: Date Implemented maintenance or service work Date/signature 73/112...

  • Page 74: Tools

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

  • Page 75: Warranty

    10. WARRANTY The warranty for this machine is 12 months. For the wear parts listed in the following, warranty is only granted if the wear is not due to operation. Wear parts are those parts, which are subject to an operational wear with an intended use of the machines. The wear time cannot be defined in a uniform manner, it differs according to the usage intensity.
  • Page 76 Person authorized to compile the technical files: Head of Engineering / Technical Documentation Machine description: The LISSMAC Floor saw pertains to floor cutting-off machines and is exclusively intended for cutting joints in concrete or asphalt. MULTICUT 905 SG / SGH...

  • Page 77: Circuit Diagram

    11. CIRCUIT DIAGRAM 77/112...
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  • Page 81: Appendix A: Error Code List Hatz

    12. APPENDIX A: ERROR CODE LIST HATZ 81/112...
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