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Lissmac MULTICUT 905 DT90 Operating Manual

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EN
OPERATING MANUAL
MULTICUT 905 DT90
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
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Summary of Contents for Lissmac MULTICUT 905 DT90

  • Page 1 OPERATING MANUAL MULTICUT 905 DT90 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 1/105...
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  • Page 3 Legal notice The operating manual is valid for: LISSMAC Floor Saw  MULTICUT 905 DT90 Headquarters: LISSMAC Maschinenbau GmbH Lanzstrasse 4 D - 88410 Bad Wurzach Tel: +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 predict every possible hazard. The suitable safety rules and precautions are to be followed as with any other machine, in regards to the working method and operation.
  • Page 5 The following warning and safety instructions are used: Read the operating manual Hot surfaces. Contact can cause burns Wear hearing protection Danger of suffocation due to toxic gases Wear eye protection Danger due to battery acid Wear gloves Explosion hazard Wear protective helmet Danger of drawing in due to open belt drive Risk of cutting injuries due to rotating cutting...
  • Page 6 Further documentation of the corresponding manufacturer of the individual components of the machine is available to complete this operating manual:  Internal combustion engine operating manual LISSMAC does not accept any responsibility or liability for the completeness of the additional documentation. Changes and reservations We have taken every effort to ensure that this operating manual is correct and up to date.
  • Page 7 Table of contents 1. Features & benefits ......................9 2. General safety notes ...................... 10 2.1. Principle of intended use ....................10 2.2. Organisational Measures ....................11 2.3. Choice of personnel and qualification; fundamental obligations ........12 2.4. Safety information relating to the phases of use ............12 2.5.
  • Page 8 12. Appendix A: Error code list HATZ ................74 8/105...
  • Page 9 1. FEATURES & BENEFITS The requirements arising from practice were taken into account in the development of these versatile power packs. The diesel floor saws, proven and tested by professionals, are convincing thanks to their excellent price-performance ratio, robust technology and simple operation. ...
  • Page 10 Intended 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. Cutting requires a tool in the form of a diamond saw blade.
  • Page 11 2.2. Organisational 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. Such regulations may also deal with, for example, the handling of hazardous substances, the wearing of personal protective equipment and with road traffic regulations.
  • Page 12 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 13 2.4.2. Commissioning 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. 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.
  • Page 14 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. A rotating saw blade poses a high risk of injury.
  • Page 15 2.5.2. Electrical Power 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. Regularly inspect and test the electrical equipment of the machinery. Defects such as loose connections or damaged cables must be remedied immediately.
  • Page 16 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 packing of the device consists of recyclable materials. Place them into the containers provided for recycling so that they can be recycled.
  • Page 17 3. DEVICE DESCRIPTION 3.1. Names Of The Machine Parts Pos. 1 Outrigger for mirror Pos. 9 Water tank Pos. 2 Attachment point for the crane Pos. 10 Pointer rear Pos. 3 Depth indicator Pos. 11 Deflector for ejector Pos. 4 Lashing aid Pos.
  • Page 18 Pos. 16 Rotating beacon (accessory) Pos. 21 Lubrication point for cutting shaft Pos. 17 Lifting cylinder for blade guard Pos. 22 Water supply flange Pos. 18 Crane eye for blade guard assembly Pos. 23 Selector lever for gear shift Pos. 19 Access for checking the V-belt tension Pos.
  • Page 19 Pos. 25 Water tank Gearbox and spray function Pos. 36 Clutch for travel drive Pos. 26 Water return from gearbox Pos. 37 Control lever for feed Pos. 27 Diesel tank Pos. 38 Lever for lifting Pos. 28 Clamping part for dipstick cable Pos.
  • Page 20 3.2. Technical data MULTICUT 905 DT90 Max. cutting depth 350 mm Max. saw blade 900 mm Saw blade holder 35 mm (6x M12 –TK 120 mm) Saw blade flange Ø 150 mm Rated speed 1000 1/min Drive motor HATZ 4-cylinder...
  • Page 21 The emission sound pressure at the workplace L 91.4 dB(A) The guaranteed sound power level LWA is: Multicut 905 DT90 96 dB(A) The values have been determined by sound emission measurement. The test was carried out on the largest approved saw blade of the floor saw under load.
  • Page 22 The specified value was determined with a saw blade diameter of 1000 mm. The impact may be inversely proportional to the weight of the operator. Vibration total value: Multicut 905 DT90 below 2.5 m/s The following regulations were followed when taking the measurements: EN ISO 5349, VD 2057 Part 2, 2002/42/EC Directive.
  • Page 23 4. COMMISSIONING 4.1. Operating materials Diesel Only low-sulphur diesel fuels according to EN 590 / ASTM D 975-09a 1-D S15 or 2-D S15 with a sulphur content <15 mg/kg (so-called ULSD). When using other fuels, the emission levels change and the warranty expires. S≤15 mg/kg Engine oil Only use engine oil approved by HATZ in quality class ACEA E6.
  • Page 24 4.2. Tools (saw blade) NOTICE Selection of the tool No rotating tool, whose maximum speed is lower than the rated speed of the machine, must be used. Defective or broken tools must be replaced immediately. Selection of the saw See chapter 9 Tools blade Tool storage The tools used must be protected from moisture.
  • Page 25 4.3. Water pump (option) The removable water pump is suspended at the machine and supplies the saw blade with water. The water connection is via GEKA couplings. Power supply via 12V plug. The pump has a strainer insert with a transparent cover for daily visual inspection and cleaning.
  • Page 26 4.4. Refuelling WARNING Extremely flammable fuel vapours Danger of burns or severe injuries from fire or explosion. Smoking is strictly forbidden during the process.  Remove all inflammatory sources.  Do not overfill tank or spill fuel.  NOTICE Fuel storage Fuel must only be stored in approved containers.
  • Page 27 4.5. Saw blade installation/change (tool) WARNING Cutting and crushing injuries due to 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. ...
  • Page 28 Sequence: 1. Move the blade guard all the way up. 2. Shut down the motor. 3. Release / unhook the 5 retaining clips. 4. Remove the blade guard upwards using the handles 5. Remove the flange screws (Pos. 3) with the on- board tool and remove the pressure disc (Pos.
  • Page 29 4.7. Water supply NOTICE Gearbox must be cooled with water Dry operation leads to severe damage to the gearbox after a short time! Connection diagram Distributor The distributor fulfils several functions. All inserts are interchangeable if required. The flow rate is displayed for each nozzle. The water is finely filtered to protect the nozzles.
  • Page 30 4.8. Checking the drive belt tension WARNING Cutting and crushing injuries due to rotating belts Body parts and clothing can be retracted on contact with the belt drive. Danger of cutting and crushing injuries up to the severity of amputations. ...
  • Page 31 4.9. Changing / retightening the V-belt WARNING Cutting and crushing injuries due to rotating belts Body parts and clothing can be retracted on contact with the belt drive. Danger of cutting and crushing injuries up to the severity of amputations. Removing or opening the belt cover or engaging in the rotating belt drive is prohibited ...
  • Page 32 retensioning, the drive Dismantle the water supply connection belts Loosen screws (Pos. 2) (left and right) Evenly slacken the V-belt using screw Pos. 3 (left and right) Remove nuts (Pos. 4) and fold down clamps (Pos. 5) Remove the V-belt (Pos. 6) Install the saw blade shaft in reverse order 32/105...
  • Page 33 5. TRANSPORT 5.1. Transport position WARNING Danger of crushing due to unsecured machine Injuries due to the unintentional change of the position of the machine or the falling of parts.  Only transport the floor saw in transport position.  Secure the floor saw using lashing points NOTICE Machine transport Significant inclines must be avoided when transporting the floor saw.
  • Page 34 5.2. Relocating using a crane WARNING Suspended loads Danger of injury due to falling parts. Do not stay under hoisted machines or parts.  Only use undamaged hoisting devices with the sufficient load bearing capacity and length.  The machine must only be moved in the transport position. ...
  • Page 35 5.3. Securing the machine for transport WARNING Risk of crushing due to the machine slipping or tipping over People can be crushed by accidental position changes of the machine. Only ever transport the machine in transport position.  Secure the machine at the suitable attachment points. ...
  • Page 36 6. CONTROL PANEL ON THE FLOOR SAW NOTICE Operation of the machine Before you start the floor saw, you must familiarise yourself with the operation first. The personnel assigned with activities at the machine must have read the operating manual ...
  • Page 37 6.1. Multifunction display NOTICE Illumination of the indicator lights As a function check, the six indicator lights around the multifunction indicator must light up briefly when the machine is started. The battery charge indicator and the engine oil pressure indicator light remain lit until the machine is started.
  • Page 38 6.2. Warning lights NOTICE Always observe fault signals The warning lights notify you of an fault in the system. The indicated fault must be resolved immediately to prevent damage to the machine. Oil level warning light Lights red when the ignition is switched on. Turns off following successful start up. If the warning light shines red when the motor is running, the oil level is too low.
  • Page 39 7. OPERATION 7.1. Safety • The floor saw may only be operated by one person. General rules Ensure that other people vacate the work area, or set up a barrier. • The operator must not leave the machine while the engine is running. •...
  • Page 40 WARNING Danger due to rotating saw blade Serious cuts due to rotating saw blade or ejected parts. Only cut with the blade guard in closed position.  Keep a safe distance.  Never touch the rotating saw blade.  Wear personal protective equipment. ...
  • Page 41 7.2. Parking lock WARNING Danger of crushing Injuries due to the machine rolling away unintentionally. To secure the floor saw against unintentional rolling away, the parking lock must be used as soon  as the machine is not in use. NOTICE The parking lock is used exclusively to secure the machine against unintentional rolling away.
  • Page 42 7.3. Start-up preparations NOTICE Cutting without obstacles Damage to objects in the cutting area or to the saw blade.  All obstacles must be removed from the cutting area  Provide good lighting for the work area The cutting process can be marked with a marking spray for orientation of the cutting process. Initial preparation In order to use the floor saw safely and properly, the following conditions must be met: ...
  • Page 43 7.5. Setting the lowering speed The valve should first be closed completely. Then open slowly step by step and try to find the suitable position for a suitable lowering speed. Fast lowering Slow lowering 7.6. Converting the feed lever Sequence: Remove the rear cover.
  • Page 44 7.7. Starting and stopping the motor Start Turn the ignition key to the ignition position. Wait until the multifunction display is raised and „0“ appears in the transmission speed and engine speed. (3- 4 seconds) Only then start the engine. NOTICE Error message when attempting to start the engine without completing the boot process...
  • Page 45 7.8. Cutting with the floor saw WARNING Risk of injury from ejected parts The saw blade can be damaged if it is lowered too fast. Segments can break out and parts can be ejected. Slowly lower the saw blade into the cutting surface. ...
  • Page 46 Cutting 1. Engage feed lever (Pos. 37) in neutral start position. 2. Start the diesel engine using the key in the ignition lock (Pos. 39). 3. Release the brake (Pos. 35). 4. Engage clutch for travel drive (Pos. 36). 5. Position the floor saw above the cutting line. 6.
  • Page 47 7.9. Repositioning 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 48 7.10. Switching off the floor saw WARNING Risk of crushing due to the machine rolling away Unintentional changes in the position of the machine can crush people. Activate the parking lock before leaving the machine  Switching off the floor ...
  • Page 49 7.11. Engine compartment Pos. 1 Hydrostat-gear oil reservoir (20W50) Pos. 2 Equalising reservoir for hydraulic unit for saw blade lift (HV68) The correct hydraulic oil level can only be checked when the machine is completely lowered. Pos. 3 Starter battery Pos.
  • Page 50 7.12. Fuses MC 905 Standard motor vehicle blade fuses are used, type C according to ISO 8820-3 (ATO, blade-type). Always replace fuses with ones of the same type only. Fuses Rated current: Function Mount 35 A Main fuse 15 A Water pump socket 10 A Socket...
  • Page 51 7.13. Battery 12V 62Ah - 540A starting current (replacement only by same type) If the battery voltage drops below 6V at a time, the controller will be disabled. Check battery voltage regularly. Charge a weak battery or replace the old battery. WARNING Risk of explosion and chemical burns Explosive oxyhydrogen gas is produced when charging the battery.
  • Page 52 7.15. Drain cooling water NOTICE Drain water if there is a risk of frost! If there is a risk of frost, the cooling water must be drained from the gearbox via the tap. Sequence:  Switch off the engine at the ignition lock. ...
  • Page 53 7.17. Checking the oil level Check the oil level daily before starting work. Sequence:  Check the oil level with the oil dipstick (1).  If necessary, open the flap (Pos. 2) and top up with SAE 10W-40 oil via the opening below. Do not spill any oil.
  • Page 54 8. MAINTENANCE 8.1. Maintenance WARNING Crushing and cutting injuries due to rotating parts Serious injury from rotating saw blade or belt drive. Maintenance and repairs must only ever be carried out when the machine is switched off.  Maintenance and repairs may only be carried out by qualified personnel. ...
  • Page 55 8.2. Retensioning the drive chain NOTICE Tensioning the drive chains The correct tension is crucial for the function and longevity of the drive. Excessive chain tension can cause damage to the drive unit.  The sag in loose side must not exceed 10 mm. ...
  • Page 56 8.3. Draining the motor oil NOTICE Dispose of motor oil safely Avoid environmental pollution and observe country-specific regulations. A collecting vessel must be placed underneath when draining the motor oil.  Dispose of used engine oil properly and in an environmentally friendly manner with your waste ...
  • Page 57 8.4. Where To Lubricate The internal combustion engine must be turned off before starting any maintenance or repair work. Secure the machine against being accidentally switched on again. Maintenance and service work must only be carried out by qualified technical personnel. Secure the machine with a crane.
  • Page 58 8.5. Hydrostat oil change Intervals First after 80, then every 400 operating hours. Required material Oil: 20W50 approx. 2.3 litre oil filter: # 1054655 Preparation  Park the floor saw on a level surface and activate the parking lock.  Raise the cutting shaft until the frame is tilted slightly backwards. ...
  • Page 59 Oil change sequence 1. Loosen the cap of the expansion tank. (Pos 1) 2. Unscrew the adapter strip (A). 3. Unscrew holder for support (B). 4. Unscrew the cover plate (C). 5. Place the collection container underneath. 6. Open the oil drain plug and drain the oil. 7.
  • Page 60 Bleeding sequence  Jack up the floor saws securely and prevent them from rolling away. Drive wheels must be able to run freely.  Open bypass valve (= disengage clutch)  Start the motor.  Release the parking lock  Slowly move the feed selector lever 6-8 times alternately to 100% forwards and 100% backwards (wheels do not turn) ...
  • Page 61 8.6. Regeneration of the diesel particulate filter DPF 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 Preparation Place floor saw in open ground away from flammable objects. The coolant temperature must be at least 75 °C (167 °F). Set the engine speed (Pos. 6) to the lowest position (idling). Start Feed lever (Pos. 12) in neutral position Disengage the drive (Pos.
  • Page 63 8.7. Troubleshooting table The internal combustion engine must be turned off before starting any maintenance or repair work. Secure the machine against being accidentally switched on again. Maintenance and service work must only be carried out by qualified technical personnel. NOTICE In the event of cutting problems, check the following points: ...
  • Page 64 8.8. 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 64/105...
  • Page 65 8.9. Maintenance Schedule This section is to serve as evidence for the maintenance and service book already supplied. All maintenance and service work must be registered as evidence. Machine/type: Serial number/year of manufacture: Date Maintenance or service work carried out Date/signature 65/105...
  • Page 66 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 found in the LISSMAC sales booklet. This sales booklet can be obtained at any time from the manufacturer.
  • Page 67 10. WARRANTY The warranty for this machine is 12 months. Warranty is only provided for the wear parts listed below if the wear is not due to operation. Wear parts are parts which undergo operation-dependent wear during the intended use of the machine. These parts have varying service lives, depending on the intensity with which they are used.
  • Page 68 This EC Declaration of Conformity according to Annex II, A of Directive 2006/42/EC is valid for the following machine: LISSMAC Floor saws MULTICUT 905 DT90. This declaration only refers to the machine in the condition in which it was sold; parts retrofitted by the end user and / or retrospective intervention is not covered by this declaration.
  • Page 69 11. CIRCUIT DIAGRAM 69/105...
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  • Page 74 12. APPENDIX A: ERROR CODE LIST HATZ 74/105...
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